CPM CPM Lean Manufacturing & Waste Reduction 2

Question 1

What does Overall Equipment Effectiveness (OEE) measure in a lean plant?

Accepted Answer

Combined impact of availability, performance, and quality losses

Answer

OEE = Availability × Performance × Quality, providing a single metric that captures all major equipment loss categories.

Question 2

In lean manufacturing, a 'supermarket' refers to:

Accepted Answer

A controlled inventory location that replenishes downstream processes via pull signals

Answer

A lean supermarket is a strategically located inventory buffer that is replenished by upstream processes only when downstream processes withdraw items.

Question 3

Which of the following best describes 'heijunka' in a lean production system?

Accepted Answer

Production leveling that smooths volume and mix over time

Answer

Heijunka levels production by distributing orders evenly over a shift or day to reduce variability and prevent overburden (muri).

Question 4

A plant manager wants to identify non-value-added activities in a process. Which lean waste category covers unnecessary movement of workers within a workstation?

Accepted Answer

Motion

Answer

Motion waste refers to unnecessary physical movement by operators (bending, reaching, walking) within their work area, distinct from transportation of materials.

Question 5

When implementing a pull system, what is the function of a kanban card?

Accepted Answer

Authorize the production or movement of a specific quantity of material

Answer

A kanban card is a visual signal that authorizes upstream processes to produce or supply a defined quantity only when downstream consumption creates a need.

(CPM) Certified Plant Manager Practice Test

(CPM) Certified Plant Manager Practice Test

CPM CPM Lean Manufacturing & Waste Reduction 2