LSS Black Belt · PeopleCert · Control · Bank updated 2026-07-03
LSS Black Belt practice questions: Control
5 free questions from 30 on this area · answer and explanation for each · no sign-up
These 5 questions come from the Control section of our LSS Black Belt bank (30 questions on this area, which carries 20% of the real exam). Every question is original, with the correct answer explained and linked to the source it is drawn from.
1/5 · Control · easy
In the 5S methodology used to sustain a Lean workplace, which activity corresponds specifically to the fifth S, Sustain (Shitsuke)?
AAssigning a fixed, labeled location for every remaining tool and material.
BCleaning the work area and simultaneously inspecting equipment for early signs of wear.
CEstablishing standardized audit schedules, visual controls, and accountability so the first four S's are maintained without ongoing special effort.
DSorting through items at the workstation and removing anything not needed for the current task.
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2/5 · Control
A Black Belt is preparing to formally close a project and hand ownership of the improved process to the process owner. Which set of actions BEST reflects the Control-phase requirement for sustaining the gains after project closure?
ATransfer the completed control plan, updated standard work, response plan, and a training/audit schedule to the process owner, who formally accepts responsibility for ongoing monitoring.
BSchedule a single follow-up review six months after closure and treat it as the sole mechanism for sustaining the improvement.
CArchive the project charter and DMAIC storyboard in the quality department's files; no further documentation is required once results are validated.
DKeep the Black Belt as the informal owner of the control chart data indefinitely so the improvement is not lost after the project team disbands.
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3/5 · Control · hard
A Black Belt designs a full factorial DOE with 4 factors, each at 2 levels, and adds 3 center points to check for curvature. If the entire design is run only once, with no additional replication of the corner points, how many total experimental runs are required?
A12 runs, because a 2^4 full factorial only requires 2 times 4 = 8 corner runs plus 4 additional center points.
B19 runs: 2^4 = 16 corner points plus 3 center points.
C32 runs, because a 2^4 design with center points must always be replicated twice.
D16 runs, because center points are not counted as separate runs in a 2^k design.
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4/5 · Control · hard
A CUSUM chart monitors a process with target T = 100, reference value K = 1, and decision interval H = 5. The upper cumulative sum is calculated after each sample as C+_i = max(0, C+_{i-1} + (x_i − T − K)), starting from C+_0 = 0. Three consecutive sample values are observed: x1 = 102, x2 = 103, x3 = 104. What is C+ after the third sample, and does the chart signal an out-of-control condition?
AC+ = 6 after the third sample, but this does not signal because CUSUM charts, like Shewhart charts under Western Electric zone rules, require two consecutive violations before declaring out-of-control.
BC+ = 6 after the third sample, which signals out-of-control because 6 exceeds the decision interval H = 5.
CC+ = 3 after the third sample, which does not signal because 3 is less than the decision interval H = 5.
DC+ = 9 after the third sample, which signals out-of-control because 9 exceeds the decision interval H = 5.
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B is correct. The CUSUM statistic accumulates deviations from the target beyond a slack value K, resetting to zero whenever the running sum would go negative. Applying the formula sequentially gives C+1 = 1, C+2 = 3, C+3 = 6, and because 6 exceeds the decision interval H = 5, the chart signals a sustained upward shift after the third sample — a single exceedance of H is sufficient, unlike the multi-point zone rules used with Shewhart charts.
↗ the IASSC Lean Six Sigma Black Belt Body of Knowledge (ILSSBOK BB, PeopleCert syllabus v1.0) — Control
5/5 · Control · hard
After a control chart shows a filling process to be in statistical control for several weeks, a plant manager states: 'Since the process is in control, all output must be meeting the customer's fill-weight specifications.' What is the flaw in this statement?
AIt confuses control (statistical predictability from the process's own control limits) with capability (meeting specification limits); a stable process can still produce out-of-spec output.
BThe statement is correct only if the control limits were calculated directly from the customer's specification limits rather than from sample statistics.
CThe statement is correct, because being 'in control' by definition means every point falls inside the specification limits set by engineering.
DThe statement is wrong because control charts apply only to attribute data, so a continuous measurement like fill weight cannot legitimately be charted at all.
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A is correct. A frequent misconception is equating 'in control' with 'meeting specifications.' Control limits are statistically derived from the process's own natural variation and describe predictability, whereas specification limits are externally imposed customer requirements describing acceptability. A process can be stable (in control) while still centered or spread such that some output falls outside spec — that is a capability problem, addressed separately (e.g., Cp/Cpk), not a control-chart signal.
↗ the IASSC Lean Six Sigma Black Belt Body of Knowledge — Control
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