Six Sigma Black Belt Certified Practice Exam

What lean tool is exemplified by a system that prevents incorrect orders from reaching production scheduling?

1. Standard work

2. Kanban

3. Poka-yoke

4. Visual factory

The correct answer is: Poka-yoke

The correct answer is Poka-yoke, which refers to a quality assurance method aimed at avoiding errors in processes by preventing mistakes or identifying errors before they can affect the output. In the context of a system that prevents incorrect orders from reaching production scheduling, Poka-yoke would use mechanisms or techniques to ensure that only correct and complete information progresses through the workflow. For instance, using checklists, automated systems, or specific guidelines that validate information can help catch errors upfront and prevent them from reaching the production phase. The focus of Poka-yoke is on mistake-proofing processes to enhance quality and efficiency, thereby minimizing the chance of defects or errors. In this situation, it ensures that the correct orders are accurately recognized and processed before they enter production scheduling, thus protecting the integrity of the production process. Contextually, standard work refers more to the documentation of best practices for performing a task consistently, Kanban deals with the visual signaling methods for controlling the flow of materials in a lean production system, and the visual factory concept emphasizes using visual cues to improve communication and clarity in the workplace. While these tools are valuable in lean thinking, they do not specifically address the prevention of incorrect orders like Poka-yoke does.