CWLP Lean Operations 2 — Questions and Answers
Question 1: Which lean tool uses a visual card system to signal replenishment and control work-in-progress inventory?
- Andon
- Kanban (Correct answer)
- Poka-yoke
- Heijunka
Correct answer: Kanban
Kanban uses physical or digital cards to authorize production or movement of materials, pulling inventory only when needed.
Question 2: In lean warehousing, 'heijunka' refers to:
- Eliminating defects at the source
- Leveling production volume and mix over time (Correct answer)
- Mapping the current state value stream
- Standardizing operator work sequences
Correct answer: Leveling production volume and mix over time
Heijunka is the practice of leveling the type and quantity of production over a fixed period to reduce unevenness (mura).
Question 3: A warehouse notices workers walking long distances to retrieve tools. Which of the 8 wastes does this represent?
- Overproduction
- Waiting
- Motion (Correct answer)
- Transportation
Correct answer: Motion
Unnecessary motion of people—such as excessive walking or reaching—is classified as the motion waste in lean thinking.
Question 4: What is the primary purpose of a 'gemba walk' in a lean warehouse?
- Conducting employee performance reviews
- Observing actual work conditions at the point of activity (Correct answer)
- Calculating takt time for each workstation
- Training new employees on standard procedures
Correct answer: Observing actual work conditions at the point of activity
A gemba walk involves leaders going to the actual workplace to observe processes, identify waste, and engage with frontline workers.
Question 5: Which metric measures the ratio of value-added time to total lead time in a process?
- Overall Equipment Effectiveness (OEE)
- Process Cycle Efficiency (PCE) (Correct answer)
- Dock-to-Stock Time
- Perfect Order Rate
Correct answer: Process Cycle Efficiency (PCE)
Process Cycle Efficiency equals value-added time divided by total lead time, revealing how much time is truly productive.
Question 6: In lean operations, 'jidoka' (autonomation) means:
- Producing only what is needed, when needed
- Machines detect abnormalities and stop automatically (Correct answer)
- Reducing setup time to under ten minutes
- Assigning one operator to multiple machines
Correct answer: Machines detect abnormalities and stop automatically
Jidoka empowers machines and workers to stop production immediately upon detecting a defect, preventing defects from passing downstream.
Question 7: A 'milk run' delivery system in lean logistics is best described as:
- Delivering full truckloads to minimize transportation cost per unit
- A fixed-route, fixed-schedule vehicle collecting from multiple suppliers (Correct answer)
- Storing safety stock at each supplier location
- Using refrigerated trucks for perishable goods only
Correct answer: A fixed-route, fixed-schedule vehicle collecting from multiple suppliers
A milk run uses a scheduled route to pick up small, frequent deliveries from multiple suppliers, reducing inventory and improving flow.
CWLP Lean Operations 2
Which lean tool uses a visual card system to signal replenishment and control work-in-progress inventory?