CPM CPM Lean Manufacturing & Waste Reduction

Question 1

Which of the eight wastes in lean manufacturing refers to overproduction causing excess inventory buildup?

Accepted Answer

Overproduction

Answer

Defects

Answer

Waiting

Answer

Motion

Question 2

In a Value Stream Map (VSM), what does the 'push' arrow symbol indicate?

Accepted Answer

Material or information pushed regardless of downstream need

Answer

Pull-based replenishment triggered by downstream demand

Answer

Supermarket-managed inventory flow

Answer

Electronic kanban signal

Question 3

What is the primary purpose of a 5S workplace organization program in a plant environment?

Accepted Answer

Create a safe, organized, and standardized work environment

Answer

Reduce labor headcount

Answer

Eliminate defects through statistical control

Answer

Implement single-minute die exchange

Question 4

A plant manager implements Kaizen events. What is the typical duration and focus of a Kaizen event?

Accepted Answer

3–5 day rapid improvement workshop focused on a specific process problem

Answer

6-month project targeting capital investment decisions

Answer

Annual strategic planning session for the entire plant

Answer

Daily stand-up meeting to review KPIs

Question 5

Takt time is calculated as:

Accepted Answer

Available production time divided by customer demand rate

Answer

Total production time divided by number of operators

Answer

Customer demand rate divided by cycle time

Answer

Total units produced divided by total defects

Question 6

Which lean tool is specifically designed to reduce changeover/setup time between production runs to less than 10 minutes?

Accepted Answer

SMED (Single-Minute Exchange of Die)

Answer

Poka-yoke

Answer

Heijunka

Answer

Andon