CWLP Lean Operations 4 — Questions and Answers
Question 1: In lean, 'mura' refers to:
- Waste generated by unnecessary process steps
- Unevenness or variability in workflow and demand (Correct answer)
- The physical burden placed on workers by poor ergonomics
- Overproduction caused by large batch processing
Correct answer: Unevenness or variability in workflow and demand
Mura is one of the three 'M's in lean (muda, mura, muri) and describes inconsistency or unevenness in production that leads to waste and strain.
Question 2: Which tool is used in lean to visually represent the sequence of value-added and non-value-added steps a product follows from supplier to customer?
- Fishbone diagram
- Value Stream Map (VSM) (Correct answer)
- Spaghetti diagram
- SIPOC chart
Correct answer: Value Stream Map (VSM)
A Value Stream Map depicts all process steps, information flows, and inventory queues, distinguishing value-added from non-value-added activities.
Question 3: A warehouse implements daily 5-minute team meetings at the start of each shift to review key metrics and issues. This is an example of:
- A3 problem solving
- Daily stand-up or Tier 1 meeting (visual management) (Correct answer)
- Value stream mapping session
- Root cause analysis using 5 Whys
Correct answer: Daily stand-up or Tier 1 meeting (visual management)
Short, frequent Tier 1 stand-up meetings are a lean visual management practice that keeps teams aligned, surfaces problems quickly, and drives continuous improvement.
Question 4: In lean operations, 'overprocessing' waste occurs when:
- More units are produced than customer orders require
- Workers perform unnecessary steps or use higher-precision methods than the customer requires (Correct answer)
- Defective products must be reworked or scrapped
- Inventory levels exceed the minimum reorder point
Correct answer: Workers perform unnecessary steps or use higher-precision methods than the customer requires
Overprocessing means doing more work, adding more features, or using more precise methods than the customer values or the specification requires.
Question 5: The 'future state' Value Stream Map is used to:
- Document current performance metrics for auditing purposes
- Design the ideal lean process flow after waste is eliminated (Correct answer)
- Identify which products to discontinue based on demand
- Calculate the return on investment for automation equipment
Correct answer: Design the ideal lean process flow after waste is eliminated
The future state VSM depicts the target process after applying lean improvements, serving as a blueprint for the improvement roadmap.
Question 6: Which lean concept describes the idea that small, incremental improvements made continuously by all employees are more sustainable than occasional large projects?
- Kaikaku
- Kaizen (Correct answer)
- Yokoten
- Nemawashi
Correct answer: Kaizen
Kaizen means 'continuous improvement' and relies on everyone contributing small, frequent enhancements rather than sporadic major overhauls.
Question 7: A picker in a warehouse must wait 8 minutes for a forklift to move a pallet before continuing their route. This is an example of which waste?
- Transportation
- Motion
- Waiting (Correct answer)
- Inventory
Correct answer: Waiting
Waiting waste occurs any time a worker is idle because a process upstream has not delivered what is needed to continue work.
CWLP Lean Operations 4
In lean, 'mura' refers to: