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

Overproduction is considered the worst lean waste because it generates excess inventory that ties up capital and hides other problems.

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

A push arrow in VSM indicates that material is moved forward based on a schedule or forecast rather than actual downstream demand.

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

5S (Sort, Set in Order, Shine, Standardize, Sustain) establishes a disciplined, visual workplace that supports safety and efficiency.

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

Kaizen events (or blitzes) are intensive 3–5 day workshops where a cross-functional team rapidly improves a targeted process area.

Question 5

Takt time is calculated as:

Accepted Answer

Available production time divided by customer demand rate

Answer

Takt time = Available production time ÷ Customer demand, setting the pace at which products must be produced to meet demand.

(CPM) Certified Plant Manager Practice Test