CPIM Module 4 E
Which of the following techniques is the best indicator of where to concentrate efforts to solve a quality problem? Pareto analysis Fishbone diagram Run chart Histogram
Pareto analysis
Which of the following tools would most likely be used to identify negative variances that must be reviewed by senior management? Force-field analysis of negative variance Histogram showing changes over time Pareto analysis of the top 5% variance Any negative variance must be reviewed.
Pareto analysis of the top 5% variance
Which of the following tools would be most appropriate to use in the measure phase of the six sigma improvement methodology? Regression and correlation Cost of poor quality analysis Implementation plan Process map
Process map
Which type of flowchart is useful for identifying areas of waste in a process? Cause-and-effect diagram Mind map Control chart Process map
Process map Diagramming the flow of a process enables the identification of steps that are non-value-added or waste.
The goal of a six sigma program is to: improve the capability index to 6. create 3.4 DPMO. decrease process variation. improve from a five sigma program.
decrease process variation.
Failure mode and effects analysis (FMEA) rates failures based on the probability of their occurrence and their: likelihood of causing other failures. ease of mitigation. chance of occurring more than once. degree of severity.
degree of severity. FMEA is used to identify the factors that are critical to failure and rates them by the likelihood that they will occur and the consequences of the failure (severity). Corrective actions can then be applied to those failures based on their rankings for occurrence and severity.
Which of the following methods would be most effective for monitoring a process in a state of control? Conducting periodic audits Performing analysis of variance (ANOVA) Incorporating a process capability index Conducting frequent sampling
Conducting periodic audits If the process is under control, the cost of appraisal can be lessened by the use of quality audits rather than daily control.
The process that targets reducing defects and errors in existing products and services is: SPC. DMAIC. B7. DOE.
DMAIC. DMAIC identifies problems in existing products, determines root causes, and provides solutions.
What is the first step in the problem-solving cycle? Assign a management team. Define the problem. Evaluate the training. Determine the cause.
Define the problem.
The A in the DMAIC acronym stands for: act. assign. assess. analyze.
analyze. The steps of DMAIC are define, measure, analyze, improve, and control.
Using the nominal group technique to generate ideas is similar to: A3. force-field analysis. mind mapping. brainstorming.
brainstorming. The nominal group technique, which is similar to brainstorming, is used by teams to generate ideas on a particular subject.
How does the failsafe concept relate to equipment? Improper internal setup actions cannot be taken. An action that will produce defective parts is prevented. Equipment shuts down automatically if a defect is detected. Defective parts cannot be released to the next operation.
Improper internal setup actions cannot be taken.
What are four viable mitigation options for a situation in which a failure becomes external? Apologizing, refunding, reworking, providing compensation Replacing, reworking, refunding, having a dinner meeting with purchasing agent Refunding, reworking, replacing, canceling all business Refunding, replacing, reworking, threatening a lawsuit
Apologizing, refunding, reworking, providing compensation
Which cost of quality would be lowered during the production process by adding the use of statistical process control? Appraisal External failure Prevention Internal failure
Appraisal Appraisal costs determine the degree of conformance to quality.
Which of the following types of quality costs includes inspecting materials? Prevention Internal failure External failure Appraisal
Appraisal Typical appraisal costs include inspection, quality audits, testing, calibration, and checking time.
Which of the following techniques relies on something other than brainstorming for problem identification? Affinity diagram Cause-and-effect diagram Force-field relationship Bar chart
Bar chart Bar charts get data from a process, not from brainstorming.
Which of the following tools typically relies on a facilitator to ensure that all team members have a chance to contribute? Force-field analysis Brainstorming Affinity diagram Pareto chart
Brainstorming
The PDCA cycle of quality improvement can be used for which of the following? Exploring a range of solutions to a problem and piloting them in a controlled way before selecting one for implementation Planning quality concurrently with production planning Working toward a decision that satisfies all participants Prioritizing changes by identifying the problems that will be resolved by making these changes
Exploring a range of solutions to a problem and piloting them in a controlled way before selecting one for implementation The PDCA (plan-do-check-action) cycle is a four-step process for quality improvement. In the first step (plan), a plan to effect improvement is developed. In the second step (do), the plan is carried out, preferably on a small scale. In the third step (check), the effects of the plan are observed. In the last step (action), the results are studied to determine what was learned and what can be predicted.
Warranty claims and repair costs fall into which of the following categories of quality costs? External failure Internal failure Prevention Appraisal
External failure
Which of the following statistical process control tools shows the extent and type of variation in a set of data? Flowchart Pareto chart Histogram Scatter plot
Histogram A histogram charts the type of variance as well as the frequency distribution.
What is the first step in the A3 process? Research the possible solutions. Identify the required outcome. Map out the follow-up process. Identify the root cause and importance of the issue.
Identify the root cause and importance of the issue.
A supplier develops a plan-do-check-action (PDCA) strategy to mitigate customer-reported manufacturing problems. What would the supplier's next step be? Implementing lean processes starting with five Ss projects Implementing quality processes such as statistical process control Encouraging more involvement by cost accounting directly with shop floor supervisors Hiring black-belt-certified associates to address the problem
Implementing quality processes such as statistical process control PDCA helps to identify a solution to the problems, but, once the solution is implemented, statistical process control methods would be used to monitor and control the process and ensure that it operates at its full potential.
Which of the following applies to the number of levels in a cause-and-effect diagram? Limited by the physical dimensions of the paper Limited by the number of causes and subcauses Limited by the length of the brainstorming session Limited to two to three based on a significant few principles
Limited by the number of causes and subcauses
Which of the following actions can be used in design to eliminate potential fail points? Developing corrective action plans Mapping processes Increasing the ability to recover Building in redundancy
Mapping processes
Which process analysis tool is used to identify correlations between data points? P-chart Cause-and-effect diagram Scatter diagram Gantt chart
Scatter diagram A scatter diagram uses x and y axes so that correlations between data points can be seen.
Which of the following is an example of an internal failure cost of quality? Providing warranty field repair Scrapping products that do not meet specifications Processing customer complaints Testing products before shipment to customers
Scrapping products that do not meet specifications
The A3 methodology is used as a tool for which of the following? Replacing the plan-do-check-action (PDCA) process Solving problems Documenting manufacturing costs Tracking statistical process control
Solving problems
Which of the following is an example of what a process map can be used for? To visualize processes and improve them, such as streamlining processes to reduce unnecessary steps To determine the root cause of an issue or problem To prioritize changes by identifying the problems that will be resolved by making these changes To help a team generate ideas on a particular subject, having each person think creatively and write down as many ideas as possible
To visualize processes and improve them, such as streamlining processes to reduce unnecessary steps
Which of the following is a management approach to success through customer satisfaction? Total quality management (TQM) Total productive maintenance (TPM) Total quality control (TQC) Total quality engineering (TQE)
Total quality management (TQM)
The defect information shown below has been collected for a welding assembly. The quality team uses a Pareto analysis to prioritize the individual decisions that will most improve the situation. Using the Pareto principle, which of these issues should be addressed first? Weld is broken plus weld is cracked plus weld seam not ground smooth Weld is broken plus weld is cracked plus weld seam not ground smooth plus seam incompletely welded Weld is broken Weld is broken plus weld is cracked
Weld is broken plus weld is cracked The Pareto principle, which was developed by Italian economist Vilfredo Pareto, states that a small percentage of a group accounts for the largest fraction of its impact or value. It is sometimes referred to as the 80/20 rule. In the case of a quality improvement process, that would mean that 20% of factors create 80% of the problems. In this case, a total of 74 defects are recorded, and weld is broken plus weld is cracked make up 65 of those 75 instances. Solving these two issues will eliminate just under 88% of the total defects.
When is 100% inspection most appropriate for an incoming part used in a complex product assembly? When the inspection cost is less than the cost of loss resulting from failure of the part When the high cost of inspection is justified by the high cost of the part itself When there is a high probability of one or more failures within the inspection batch When there is a high cost of failure to the customer in normal use of the product
When the inspection cost is less than the cost of loss resulting from failure of the part Inspection at 100% would be appropriate when the inspection cost is less than the cost of loss resulting from failure of the part.
A fishbone diagram is most often used to identify: a process. the organizational flow. a cause. a problem.
a cause. A fishbone (cause-and-effect) diagram, one of the seven tools of quality, illustrates the main causes and subcauses leading to an effect (symptom).
Analyzing the movement of material within a process can be achieved by using: an R-chart. a flowchart. a scatter diagram. a statistical process control chart.
a flowchart.
Pareto analysis is a method used to: identify causes with the largest impact. determine product quality. categorize corrective actions. summarize possible causes of problems.
identify causes with the largest impact.
Using simulation in manufacturing is most beneficial for: training new employees. improving data collection. identifying potential continuous improvement areas. prototyping new technology.
identifying potential continuous improvement areas.
PDCA stands for: plan-do-check-action. plan-develop-check-accept. prepare-do-check-accept. plan-decide-coordinate-act.
plan-do-check-action.
When using a six sigma problem-solving approach, problems are identified using: financials. statistics. observations. brainstorming.
statistics. A six sigma process is well controlled, and data is used to investigate defects.
The seven tools that help organizations understand their processes in order to improve them are known as: the A3 problem-solving tools. ISO 9000. the basic seven tools of quality (B7). the14 points.
the basic seven tools of quality (B7). B7 refers to the tools that help organizations understand their processes in order to improve them.
