CWLP Lean Operations 5 â Questions and Answers
Question 1: In lean logistics, 'cross-docking' reduces which waste most directly?
- Defects
- Overprocessing
- Inventory and transportation (Correct answer)
- Motion
Correct answer: Inventory and transportation
Cross-docking eliminates storage time and reduces handling by transferring inbound shipments directly to outbound vehicles, cutting inventory holding and unnecessary transportation legs.
Question 2: Which lean problem-solving method uses a structured one-page document to define, analyze, and plan countermeasures for a problem?
- PDCA cycle
- A3 report (Correct answer)
- DMAIC framework
- 8D report
Correct answer: A3 report
The A3 report, named for its paper size, is a lean tool that structures the entire problem-solving storyâfrom background to follow-upâon a single page.
Question 3: What does 'yokoten' mean in lean practice?
- Stopping the production line when a defect is detected
- Horizontally deploying successful improvements across all applicable areas (Correct answer)
- Conducting a waste walk with the entire team
- Applying 5S to new warehouse zones
Correct answer: Horizontally deploying successful improvements across all applicable areas
Yokoten is the lean practice of sharing and replicating proven improvements across other departments or facilities to multiply the benefit.
Question 4: In a lean warehouse, 'standard work' documentation should include all of the following EXCEPT:
- Takt time for the operation
- Sequence of work steps
- Required inventory investment for the entire facility (Correct answer)
- Minimum stock-on-hand at each workstation
Correct answer: Required inventory investment for the entire facility
Standard work documents takt time, work sequence, and standard in-process stock at the workstation levelâit does not address facility-wide inventory investment.
Question 5: When a lean team uses the '5 Whys' technique, the goal is to:
- Identify five separate improvement opportunities at once
- Brainstorm all possible causes before selecting one
- Drill down to the root cause by repeatedly asking why a problem occurred (Correct answer)
- Rank problems by frequency using a Pareto chart
Correct answer: Drill down to the root cause by repeatedly asking why a problem occurred
The 5 Whys is a simple root cause analysis technique where asking 'why' iteratively leads from the symptom to the underlying cause driving the problem.
Question 6: In lean warehousing, 'right-sizing' equipment means:
- Purchasing the largest available equipment to handle peak demand
- Using equipment that matches the actual scale and flow requirements of the process (Correct answer)
- Replacing all manual processes with automated systems
- Standardizing on one equipment model throughout the facility
Correct answer: Using equipment that matches the actual scale and flow requirements of the process
Right-sized equipment is scaled to fit actual process needs, enabling flexible cell layouts, lower costs, and easier flow without over-engineering.
Question 7: Which lean metric tracks the percentage of orders delivered complete, on time, damage-free, and with accurate documentation?
- Inventory turnover ratio
- Perfect Order Rate (Correct answer)
- Takt time compliance
- Overall Equipment Effectiveness
Correct answer: Perfect Order Rate
The Perfect Order Rate measures the percentage of orders that meet all four criteriaâcomplete, on time, undamaged, and correctly documentedâreflecting true customer satisfaction.
CWLP Lean Operations 5
In lean logistics, 'cross-docking' reduces which waste most directly?