Model answers for Green Belt Questions

Q1 Marks: 5

What do the letters in SIPOC stand for?

Briefly (one or two bullet points) explain the value of a SIPOC.
The purchasing department of CS&F has initiated an improvement project to look at
improving the supply chain for the acquisition of sugar. Identify TWO customers who should
be listed on the SIPOC.

Suppliers, Inputs, Process, Outputs and Customers (1 mark)

Value
The SIPOC can be used at the be beginning of a change project to gain a clear
understanding of the scope of the project (2 marks)

Customers
Goods Inwards, Manufacturing (2 marks)

(Only two asked several other choices such as compliance, R&D etc.)

Q2 Marks: 4

Briefly (2 – 3 bullet points) explain what a process is in the context of Lean 6 Sigma. Provide
an example of a process conducted by CS&F (Uncle Jim's).

Process:
 Transforms a number of inputs into a number of outputs
 Everything can be considered a process (2 marks)

Example: Processing an order for sweets from the Internet (2 marks)

1
Q3 Marks: 8

Q4 Marks: 3

Answer: B - Measure

2
Q5 Marks: 3

Answer: D
Lean Management focuses on autonomous, self-directed cells motivated by the HP
Challenge. The Manager lets the team get on with the work adapting to situational changes
(as indicated by Visual Factory). The team need to demonstrate to the Manager that they are
in control of the work – Daily Stand-ups are one way that they can demonstrate this.
SMED is all about minimising changeover times. This is often an important technique for the
team to practice but it does not form the basis of Lean Management in the TKA Body of
Knowledge.
The key word in the question is “Management”.

Q6 Marks: 2

No it is not capable as there are several plots outside of a Specification Limit.

Q7 Marks:2

Yes it is – none of the JQT rules appear to be broken.

Q8 Marks: 2

(a)

Yes: they change over during production runs and this means stopping the production line.
This is waste which needs to be minimised.

(b) Alternative answers

Yes: I manage a Call Centre team and each operator handles between 100-200 calls in a
shift. Reducing the time from changing between calls will have a big impact on our efficiency.

No: We perform drainage consultancy for large construction projects. The work is unique and
a typical job runs over months with teams being dedicated to the work full time. Change over
time is not as key to us in terms of efficiency and waste removal as other techniques.

Q9 Marks: 2

Q9 Answers – NOTE: only ONE answer needed. Here are examples for both techniques.

Poka Yoke: This procedure will prevent mistakes happening which is a core aim of Poka
Yoke.

SMED: Because there are no or fewer interruptions the staff member can change from one
prescription to another more rapidly. The fact that they do not have to remember where they
were in the process when interrupted also helps. From the perspective of the drug round
SMED will be improved as a focussed staff member will have “tidied up” as they have gone
along and will not have to spend time looking for misplaced items before turning to their next
duty.

Q10 Marks: 3

Answer: D