CMS Process Engineering & Optimization 3 — Questions and Answers
Question 1: Which lean concept focuses on producing only what is needed, when it is needed, and in the amount needed?
- 5S
- Just-In-Time (JIT) (Correct answer)
- Poka-Yoke
- Andon
Correct answer: Just-In-Time (JIT)
Just-In-Time (JIT) manufacturing eliminates overproduction waste by aligning production output with actual demand.
Question 2: A control chart shows data points consistently drifting upward over 8 consecutive points. This pattern is called:
- Common cause variation
- A run or trend signal (Correct answer)
- Normal distribution
- Specification drift
Correct answer: A run or trend signal
Eight consecutive points trending in one direction on a control chart signal a non-random (special cause) trend requiring investigation.
Question 3: What manufacturing layout arranges equipment in a U-shape to facilitate single-piece flow and flexible staffing?
- Process layout
- Fixed-position layout
- U-shaped (cellular) layout (Correct answer)
- Product layout
Correct answer: U-shaped (cellular) layout
A U-shaped cellular layout enables operators to handle multiple machines, reducing WIP and supporting single-piece flow.
Question 4: In Six Sigma, what sigma level corresponds to approximately 3.4 defects per million opportunities (DPMO)?
- 3 Sigma
- 4 Sigma
- 5 Sigma
- 6 Sigma (Correct answer)
Correct answer: 6 Sigma
Six Sigma quality level allows no more than 3.4 DPMO, accounting for a 1.5-sigma long-term process shift.
Question 5: Which type of waste in the lean framework refers to unnecessary movement of materials between process steps?
- Motion waste
- Transportation waste (Correct answer)
- Waiting waste
- Overprocessing waste
Correct answer: Transportation waste
Transportation waste involves moving materials or products unnecessarily, adding time and cost without adding value.
Question 6: A Pareto chart is used in process engineering primarily to:
- Map the flow of materials through a plant
- Identify which defect categories account for the majority of problems (Correct answer)
- Display process variation over time
- Determine optimal machine settings
Correct answer: Identify which defect categories account for the majority of problems
Pareto charts apply the 80/20 rule to prioritize the few defect types responsible for most quality problems.
Question 7: Which process engineering tool is used to error-proof a process and prevent defects from occurring or passing to the next step?
- Kanban
- Poka-Yoke (Correct answer)
- SIPOC
- Heijunka
Correct answer: Poka-Yoke
Poka-Yoke devices or methods are designed to make errors impossible or immediately detectable before they become defects.
CMS Process Engineering & Optimization 3
Which lean concept focuses on producing only what is needed, when it is needed, and in the amount needed?