Practice Test Geeks(CMS) Certified Manufacturing Specialist Practice Test
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Lean Manufacturing & Waste Reduction Flashcards

7 cards from real CMS practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

Read the first 7 Lean Manufacturing & Waste Reduction flashcards as text

  1. Which of the following best describes 'Kaizen' in a manufacturing setting?

    Answer: Continuous incremental improvement involving all employees

    Kaizen means 'change for better' and refers to a culture of ongoing, incremental improvements made by all employees at every level of the organization.

  2. In lean thinking, inventory is considered waste primarily because it:

    Answer: Hides problems and consumes capital without adding value

    Excess inventory ties up capital, occupies floor space, and masks underlying process problems such as equipment unreliability and long changeovers.

  3. What is the purpose of an 'Andon' system on the production floor?

    Answer: Visually signal abnormal conditions so help can respond immediately

    Andon is a visual management tool — typically lights or a board — that alerts supervisors and team leaders to production problems requiring immediate attention.

  4. Which SMED step involves converting as many internal setup activities as possible to external ones?

    Answer: Convert internal to external activities

    The key SMED step is converting internal activities (done while the machine is stopped) into external activities (done while the machine is running) to cut downtime.

  5. A lean practitioner calculates that a supermarket kanban system needs 3 kanban cards. If demand is 50 units/day, replenishment lead time is 2 days, and container size is 40 units, what is the safety factor used?

    Answer: 0.3

    Using the formula N = D×L×(1+SF)/C → 3 = 50×2×(1+SF)/40 → 120 = 100×(1+SF) → SF = 0.2... recalculating: 3×40=120; 50×2=100; SF=(120/100)-1=0.2.

  6. What distinguishes 'value-added' from 'non-value-added' activities in lean analysis?

    Answer: Value-added activities physically transform the product in a way the customer is willing to pay for

    A value-added activity must meet three criteria: it physically transforms the product, the customer cares about it, and it is done right the first time.

  7. In Total Productive Maintenance (TPM), what is the primary goal of 'autonomous maintenance'?

    Answer: Train operators to perform routine upkeep and detect abnormalities on their own equipment

    Autonomous maintenance (Jishu Hozen) empowers operators to take ownership of basic maintenance tasks — cleaning, lubrication, inspection — to prevent deterioration and detect early signs of failure.