CPIM Operations Execution & Continuous Improvement 4 — Questions and Answers
Question 1: A quality engineer calculates that a process has a Cpk of 0.85. What does this indicate?
- The process is centered and capable of meeting specifications
- The process is not capable and is producing some defects outside specification (Correct answer)
- The process has too little variation relative to the specification width
- Cpk cannot be used without knowing the Cp value first
Correct answer: The process is not capable and is producing some defects outside specification
A Cpk below 1.0 indicates the process does not reliably meet specifications and is producing out-of-spec output.
Question 2: In lean manufacturing, poka-yoke devices are designed primarily to:
- Detect defects after they have been produced and quarantine them
- Prevent errors from occurring or make errors immediately detectable (Correct answer)
- Track defect rates over time using statistical methods
- Reduce the number of inspection steps required by quality auditors
Correct answer: Prevent errors from occurring or make errors immediately detectable
Poka-yoke (mistake-proofing) devices are designed to prevent errors at the source or make them instantly visible.
Question 3: A CPIM candidate reviews a value stream map. Which symbol typically represents a push arrow between processes on a VSM?
- A straight push arrow (→) indicating batch transfer without a pull signal (Correct answer)
- A lightning bolt indicating electronic data flow
- A kanban card icon indicating replenishment authorization
- A circular pull icon indicating demand-driven flow
Correct answer: A straight push arrow (→) indicating batch transfer without a pull signal
On a VSM, a straight push arrow between processes indicates that material is pushed regardless of downstream demand.
Question 4: A manufacturer reduces batch sizes from 500 to 50 units. The MOST likely impact on lead time is:
- Lead time increases because more setups are required per period
- Lead time decreases because work-in-process inventory levels fall (Correct answer)
- Lead time remains the same since processing time per unit is unchanged
- Lead time increases due to higher transportation frequency between stations
Correct answer: Lead time decreases because work-in-process inventory levels fall
Smaller batches reduce WIP queues and wait time between operations, significantly cutting total lead time.
Question 5: An operations team is using the Plan-Do-Check-Act (PDCA) cycle. In which phase would they pilot a solution on a small scale before full implementation?
- Plan
- Do (Correct answer)
- Check
- Act
Correct answer: Do
The 'Do' phase involves executing the planned change, typically as a small-scale pilot or trial.
Question 6: Which of the following is a key difference between a push and a pull production system?
- Push systems are always manual; pull systems are always automated
- Push systems produce to a forecast; pull systems produce in response to actual demand (Correct answer)
- Pull systems always use kanban cards; push systems never do
- Push systems are used only in make-to-order environments
Correct answer: Push systems produce to a forecast; pull systems produce in response to actual demand
Push systems schedule production based on forecasts, while pull systems authorize production only when downstream demand signals are received.
Question 7: A supervisor uses the '5 Whys' technique after a machine breakdown. The PRIMARY goal of this technique is to:
- Quantify the financial cost of a quality failure
- Identify the root cause of a problem by repeatedly asking why (Correct answer)
- Prioritize defect types using a Pareto chart
- Assign accountability to specific operators or departments
Correct answer: Identify the root cause of a problem by repeatedly asking why
The 5 Whys iteratively drills past symptoms to uncover the root cause of a problem, enabling permanent corrective action.
CPIM Operations Execution & Continuous Improvement 4
A quality engineer calculates that a process has a Cpk of 0.85.
What does this indicate?