Applied assessment — holding the gain

4 of 5 needed to pass

1. 1. A team is monitoring daily percent-defective on a finishing line where the sample size varies each day (not constant). Which control chart is appropriate?

   Choose one answer.

   X-bar and R chart, since it is the most commonly used chartp-chart, since it tracks a proportion defective and can handle varying subgroup sizesc-chart, since defects are being countedI-MR chart, since it works for any type of data
2. 2. A p-chart shows the last 8 consecutive points above the centerline (though all still inside the control limits). What does this pattern indicate and what should the team do?

   Choose one answer.

   A run of 8 points on one side of the centerline is a non-random pattern (common Western Electric-type rule) suggesting a process shift; it should be investigated even though no point breached the limitsThe control limits must be recalculated immediately because they are clearly wrongThis pattern only matters on variable control charts, not attribute chartsNothing — points inside the control limits are always considered normal, random variation
3. 3. After implementing a fix, capability is recalculated: Cpk rose from 0.75 to 1.42 over a 4-week verification window using the same measurement system validated in Measure. What is the appropriate conclusion for the Control tollgate?

   Choose one answer.

   Cpk of 1.42 means the process is now perfect and no further monitoring is neededSince Cpk more than doubled, the data must be an error and should be re-collectedCpk cannot be compared across phases, so no conclusion can be drawnThe improvement appears real and capability-confirmed, provided the 4-week window reflects normal operating conditions and the gage is still trustworthy; a control plan should now be put in place to sustain it
4. 4. A control plan lists a reaction plan of 'investigate and adjust' for out-of-control signals, but does not specify who is responsible, what adjustment is permitted, or how it should be logged. What is the main risk at handover?

   Choose one answer.

   This level of detail belongs in the SOP, not the control plan, and should be deletedNone; a general instruction is sufficient because operators will use common senseWithout a specific owner, permitted adjustment, and logging method, out-of-control signals are likely to be handled inconsistently or ignored after the Black Belt leaves, eroding the gainThe control plan should instead remove the reaction plan section entirely
5. 5. At project closure, the financial controller has not yet independently verified the claimed savings, and the receiving supervisor has not been trained on the new SOP or control chart. The Black Belt wants to close the project this week to meet a deadline. What should happen?

   Choose one answer.

   Close the project on schedule regardless, since the technical work is finishedDelay formal closure until savings are independently verified and the process owner is trained and equipped to sustain the control plan, even if that means missing the target dateClose the project but let finance verify savings whenever convenient, with no fixed timelineSkip supervisor training since the control chart is self-explanatory