CLL Quality Assurance & Improvement 2 — Questions and Answers
Question 1: Which quality tool uses a structured tree diagram to break down broad goals into specific tasks and methods?
- Affinity diagram
- Tree diagram (Correct answer)
- Matrix diagram
- Interrelationship digraph
Correct answer: Tree diagram
A tree diagram systematically breaks down a goal into its component tasks, showing the hierarchy of actions needed to achieve it.
Question 2: In lean quality management, 'First Pass Yield' (FPY) measures:
- The percentage of units passing all steps without rework (Correct answer)
- The total units produced in the first shift
- The yield of the first production batch only
- The number of defects caught on first inspection
Correct answer: The percentage of units passing all steps without rework
First Pass Yield is the percentage of units that complete a process conforming to requirements without any scrap, rework, or repair.
Question 3: A quality circle is best described as:
- A circular inspection path on the shop floor
- A small group of employees who meet regularly to identify and solve work-related problems (Correct answer)
- A round-robin audit system among departments
- A graphical representation of quality metrics over time
Correct answer: A small group of employees who meet regularly to identify and solve work-related problems
Quality circles are voluntary groups of workers who regularly meet to identify, analyze, and solve quality and productivity problems in their area.
Question 4: Which of the following best describes 'Jidoka' in the context of quality assurance?
- Continuous flow production with no stoppages
- Automation with a human touch — machines stop automatically when abnormalities occur (Correct answer)
- A method for scheduling preventive maintenance
- A pull-based replenishment system for defective parts
Correct answer: Automation with a human touch — machines stop automatically when abnormalities occur
Jidoka (autonomation) empowers machines and workers to stop production immediately when a defect is detected, preventing defects from passing downstream.
Question 5: What does the 'C' in the DMAIC improvement cycle stand for?
- Calibrate
- Control (Correct answer)
- Check
- Correct
Correct answer: Control
In DMAIC, Control is the final phase where solutions are sustained through monitoring, control plans, and standardization.
Question 6: A Lean leader notices that defects are consistently found at one inspection station but not upstream. This most likely indicates:
- The inspection station is too strict
- Defects are being created upstream and passed forward (Correct answer)
- Workers at that station need more training on inspection only
- The control chart limits need adjustment
Correct answer: Defects are being created upstream and passed forward
Defects found at an inspection station are typically created upstream; the inspection only reveals problems that originated earlier in the process.
Question 7: Which quality concept states that quality should be built into the product rather than inspected in at the end?
- Acceptance sampling
- Quality by design (QbD) (Correct answer)
- Incoming quality control
- Final inspection protocol
Correct answer: Quality by design (QbD)
Quality by Design emphasizes designing quality into every step of the process so defects are prevented rather than detected after the fact.
CLL Quality Assurance & Improvement 2
Which quality tool uses a structured tree diagram to break down broad goals into specific tasks and methods?