CPT Lean Manufacturing Principles 3

Question 1

A manufacturer groups similar machines together in one area of the plant. From a lean perspective, this layout is most likely to cause which type of waste?

Accepted Answer

Overproduction and excess inventory

Answer

Functional (departmental) layouts often lead to large batch production and work-in-progress inventory building up between departments.

Question 2

What is the primary goal of implementing cellular manufacturing in a lean environment?

Accepted Answer

Reducing lead time by co-locating equipment for product families

Answer

Cellular manufacturing arranges equipment and workstations into a U-shaped or linear cell dedicated to a product family, minimizing transport and wait time.

Question 3

During a kaizen event, a team discovers that operators walk 300 feet to retrieve components. Which waste category does this fall under?

Accepted Answer

Motion

Answer

Motion waste refers to unnecessary movement of people, such as walking long distances to retrieve parts, tools, or materials.

Question 4

What does 'heijunka' mean in lean production?

Accepted Answer

Production leveling to smooth out volume and mix over time

Answer

Heijunka is the practice of leveling the production schedule by quantity and variety to reduce unevenness (mura) and overburden (muri).

Question 5

Which metric measures the percentage of time a process is available, performing, and producing quality output?

Accepted Answer

Overall Equipment Effectiveness (OEE)

Answer

OEE combines Availability, Performance, and Quality rates into one metric to identify how effectively manufacturing equipment is being used.

(CPT) Certified Production Technician Practice Test

(CPT) Certified Production Technician Practice Test

CPT Lean Manufacturing Principles 3