LEAN SIX SIGMA FINAL EXAM 2026 QUESTIONS AND
ANSWERS GRADED A+
✔✔Brainstorming - ✔✔1.Two Techs:
Rounds (go around in turns with one item per person until done)
Popcorn (anyone calls out ideas no order
2.Guidelines
start with think time, don't hold back, no criticism, build on ideas, post ideas,
more=better
✔✔Cause and Effect Diagrams (fishbone diagram) - ✔✔Ishikawa developed
1. Starts withn effect which usually a problem that seeks a cause
2. Tool for structure "brainstorming"
3. 5 Major Contributors to variation: (Materials, Methods, People, Enviro, Machines)
✔✔Poka-Yoke - ✔✔"Mistake-Proofing"
1. Identify possible errors that might occur
2. Determine a way to detect that an error or malfunction might occur
3. Identify and select the type of action to be taken to prevent error (control, shutdown,
warning)
✔✔Poka-Yoke Techniques - ✔✔Color-Shape coding
Symbols and Icons
Computerized checklists
Simple workflows
Visual Displays
✔✔What is lean? - ✔✔Unrelenting focus on eliminating waste
Philosophy of continuous, incremental improvement
Providing exactly what is needed at the right time
Keeping things moving; in a value added effective manner
Reducing variation
Respecting people
Taking a long term view
*CHANGE IN CULTURE*
✔✔Why lean? - ✔✔Traditional Thinking
Cost+Profit=Price
Lean Thinkning
Price-Cost=Profit
✔✔Lean Fundamentals - ✔✔Eliminate Waste
Focus on Business Processes
Mistake Proof of your Processes (Poka-Yoke)
Processes should be "pull" not "push"
, Defects are not made and/or passed along
Level & Balanced
✔✔8 Wastes - ✔✔1. Overproduction
2. Transportation
3. Inventory
4. Waiting
5. Extra Processing
6. Defects
7. Motion
8. Intellect
✔✔3 M's of Lean Waste - ✔✔Muda (waste)
Mura (unevenness)
Muri (overdoing)
✔✔5S - ✔✔Sort
-retain, return, rid
Set in Order/Simplify
-everything in its place
Sweep/Shine
Standardize
-repeat on a schedule
Sustain
-make it better
✔✔Value Stream Mapping - ✔✔Describes all activities that are performed and the
information required in a process to deliver a given product or service
Value-Added (add customer value to actual product)
Non-Value Add (waste)
Tools (VSM compares VA to NVA)
✔✔Value Stream Mapping Explanation - ✔✔The visual representation of the process
(work and info) required to meet customer demand
-includes VA and NVA activities
-current state map shows areas of waste
-future state map is roadmap to improvement that is immediate and longer term
✔✔Kaizen - ✔✔Continuous Improvement
Kaizen/Blitz Event
-short duration (days)
-focused team
-rapid action
-major improvements in a process in a week
ANSWERS GRADED A+
✔✔Brainstorming - ✔✔1.Two Techs:
Rounds (go around in turns with one item per person until done)
Popcorn (anyone calls out ideas no order
2.Guidelines
start with think time, don't hold back, no criticism, build on ideas, post ideas,
more=better
✔✔Cause and Effect Diagrams (fishbone diagram) - ✔✔Ishikawa developed
1. Starts withn effect which usually a problem that seeks a cause
2. Tool for structure "brainstorming"
3. 5 Major Contributors to variation: (Materials, Methods, People, Enviro, Machines)
✔✔Poka-Yoke - ✔✔"Mistake-Proofing"
1. Identify possible errors that might occur
2. Determine a way to detect that an error or malfunction might occur
3. Identify and select the type of action to be taken to prevent error (control, shutdown,
warning)
✔✔Poka-Yoke Techniques - ✔✔Color-Shape coding
Symbols and Icons
Computerized checklists
Simple workflows
Visual Displays
✔✔What is lean? - ✔✔Unrelenting focus on eliminating waste
Philosophy of continuous, incremental improvement
Providing exactly what is needed at the right time
Keeping things moving; in a value added effective manner
Reducing variation
Respecting people
Taking a long term view
*CHANGE IN CULTURE*
✔✔Why lean? - ✔✔Traditional Thinking
Cost+Profit=Price
Lean Thinkning
Price-Cost=Profit
✔✔Lean Fundamentals - ✔✔Eliminate Waste
Focus on Business Processes
Mistake Proof of your Processes (Poka-Yoke)
Processes should be "pull" not "push"
, Defects are not made and/or passed along
Level & Balanced
✔✔8 Wastes - ✔✔1. Overproduction
2. Transportation
3. Inventory
4. Waiting
5. Extra Processing
6. Defects
7. Motion
8. Intellect
✔✔3 M's of Lean Waste - ✔✔Muda (waste)
Mura (unevenness)
Muri (overdoing)
✔✔5S - ✔✔Sort
-retain, return, rid
Set in Order/Simplify
-everything in its place
Sweep/Shine
Standardize
-repeat on a schedule
Sustain
-make it better
✔✔Value Stream Mapping - ✔✔Describes all activities that are performed and the
information required in a process to deliver a given product or service
Value-Added (add customer value to actual product)
Non-Value Add (waste)
Tools (VSM compares VA to NVA)
✔✔Value Stream Mapping Explanation - ✔✔The visual representation of the process
(work and info) required to meet customer demand
-includes VA and NVA activities
-current state map shows areas of waste
-future state map is roadmap to improvement that is immediate and longer term
✔✔Kaizen - ✔✔Continuous Improvement
Kaizen/Blitz Event
-short duration (days)
-focused team
-rapid action
-major improvements in a process in a week
