CMS Lean Manufacturing & Waste Reduction 2

Question 1

Which lean concept describes the ideal state where every process step adds value with zero waste?

Accepted Answer

Perfection (the fifth lean principle)

Answer

Perfection is the fifth lean principle, representing the ideal end-state where all waste is eliminated and every step adds customer value.

Question 2

A factory produces 500 units/day with a net available time of 27,000 seconds/day. What is the takt time?

Accepted Answer

54 seconds

Answer

Takt time = available time ÷ customer demand = 27,000 ÷ 500 = 54 seconds per unit.

Question 3

What is the primary purpose of a Heijunka box in lean production?

Accepted Answer

Level production volume and mix over time

Answer

A Heijunka box is a visual scheduling tool that levels production by distributing orders evenly across a time period to smooth demand fluctuations.

Question 4

In the context of the 7 wastes (Muda), which category does a worker walking across the plant floor to retrieve a tool represent?

Accepted Answer

Motion

Answer

Unnecessary movement of people is classified as Motion waste, whereas Transportation refers to unnecessary movement of materials or products.

Question 5

What does OEE measure in a lean manufacturing environment?

Accepted Answer

Overall Equipment Effectiveness combining availability, performance, and quality

Answer

OEE (Overall Equipment Effectiveness) is the product of Availability × Performance × Quality and benchmarks how effectively equipment is utilized.

(CMS) Certified Manufacturing Specialist Practice Test