Quality Assurance and Improvement Flashcards

Which quality cost category includes rework, scrap, and re-inspection performed before product delivery?

Answer: Internal failure costs

Internal failure costs arise from defects discovered and corrected before the product reaches the customer.

A fishbone (Ishikawa) diagram categorizes potential causes under which classic set of headings in manufacturing?

Answer: Man, Machine, Material, Method, Measurement, Environment

The 6M categories (Man, Machine, Material, Method, Measurement, Environment) structure cause-and-effect analysis in manufacturing.

Process capability index Cpk differs from Cp in that Cpk:

Answer: Accounts for how well the process mean is centered between specification limits

Cpk adjusts for process centering by taking the minimum of the upper and lower capability ratios.

In the DMAIC improvement cycle, which phase is specifically focused on identifying and validating the root causes of the problem?

Answer: Analyze

The Analyze phase uses data and tools like hypothesis testing and fishbone diagrams to confirm root causes.

An organization receives a customer complaint about product quality after delivery. The corrective action cost to resolve this complaint is classified as:

Answer: External failure cost

External failure costs are incurred when defects reach customers, including warranty, returns, and complaint handling.

Which sampling method divides a population into subgroups and then randomly samples from each subgroup?

Answer: Stratified sampling

Stratified sampling ensures representation from each subgroup by sampling proportionally or equally from each stratum.

A SIPOC diagram is used during which phase of DMAIC?

Answer: Define

SIPOC (Suppliers, Inputs, Process, Outputs, Customers) is a high-level process map created in the Define phase to scope the project.