CMS Lean Manufacturing & Waste Reduction 4

Question 1

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

Accepted Answer

Continuous incremental improvement involving all employees

Answer

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

Question 2

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

Accepted Answer

Hides problems and consumes capital without adding value

Answer

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

Question 3

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

Accepted Answer

Visually signal abnormal conditions so help can respond immediately

Answer

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

Question 4

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

Accepted Answer

Convert internal to external activities

Answer

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.

Question 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?

Accepted Answer

0.3

Answer

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.

(CMS) Certified Manufacturing Specialist Practice Test

(CMS) Certified Manufacturing Specialist Practice Test

CMS Lean Manufacturing & Waste Reduction 4