CWLP Lean Operations 3 — Questions and Answers
Question 1: Which lean principle states that products should flow through processes without interruption, backflow, or waiting?
- Pull
- Continuous flow (Correct answer)
- Perfection
- Value identification
Correct answer: Continuous flow
Continuous flow (one-piece flow) eliminates batching and queues so each item moves directly from one process step to the next.
Question 2: When applying SMED (Single-Minute Exchange of Die) in a warehouse context, the primary goal is to:
- Eliminate all setup activities permanently
- Convert internal setup tasks to external tasks to reduce downtime (Correct answer)
- Standardize the number of SKUs per picking zone
- Automate all changeover activities using robotics
Correct answer: Convert internal setup tasks to external tasks to reduce downtime
SMED focuses on converting setup steps done while equipment is stopped (internal) to steps done while it runs (external), cutting changeover time below 10 minutes.
Question 3: In a lean value stream, a 'push' system is characterized by:
- Producing based on actual customer demand signals
- Manufacturing or picking goods based on forecasts or schedules regardless of downstream need (Correct answer)
- Using kanban cards to authorize each replenishment
- Pulling inventory from the last process step backward
Correct answer: Manufacturing or picking goods based on forecasts or schedules regardless of downstream need
A push system produces or moves inventory based on planned schedules, often creating overproduction and excess inventory when forecasts are inaccurate.
Question 4: Which type of waste involves storing more inventory than is immediately needed to fulfill customer demand?
- Defects
- Overprocessing
- Overproduction
- Inventory (Correct answer)
Correct answer: Inventory
Inventory waste occurs when excess raw materials, work-in-process, or finished goods are held beyond what current demand requires, tying up capital and space.
Question 5: What does 'takt time' represent in lean warehouse operations?
- The time required to complete one full picking cycle
- The available production time divided by customer demand rate (Correct answer)
- The average lead time from order receipt to shipment
- The time allocated for daily team meetings
Correct answer: The available production time divided by customer demand rate
Takt time is the pace at which work must be completed to match customer demand, calculated as available work time divided by units required.
Question 6: A 'supermarket' in lean warehouse design refers to:
- A retail-style picking area open to the public
- A controlled buffer stock location that replenishes downstream processes on demand (Correct answer)
- A zone dedicated exclusively to high-velocity SKUs
- A cross-docking area for inbound freight consolidation
Correct answer: A controlled buffer stock location that replenishes downstream processes on demand
A lean supermarket is a strategic inventory buffer that holds a defined quantity of items and triggers replenishment when a kanban signal is received.
Question 7: Which lean concept involves each worker being responsible for the quality of their own output before passing it to the next step?
- Kaizen
- Andon
- Built-in quality (jidoka) (Correct answer)
- Error-proofing (poka-yoke)
Correct answer: Built-in quality (jidoka)
Built-in quality through jidoka means workers are empowered and responsible for inspecting their work and stopping the line if a defect is found.
CWLP Lean Operations 3
Which lean principle states that products should flow through processes without interruption, backflow, or waiting?