CLS Quality Control & Process Improvement 3 — Questions and Answers
Question 1: Which quality control document formally defines the lubricant type, quantity, frequency, and method for each lubrication point on a machine?
- Lube route schedule
- Lubrication specification sheet (LSS) (Correct answer)
- Oil analysis trend report
- Preventive maintenance work order
Correct answer: Lubrication specification sheet (LSS)
A lubrication specification sheet (LSS) serves as the authoritative reference document for all lubrication parameters at each point.
Question 2: When analyzing a control chart for lubricant viscosity measurements, a run of 8 consecutive points above the mean but within control limits indicates:
- Natural random variation with no action needed
- A potential process shift that warrants investigation (Correct answer)
- Equipment failure and immediate shutdown
- Measurement error that requires recalibration of instruments
Correct answer: A potential process shift that warrants investigation
Eight consecutive points on one side of the mean is a Nelson rule violation signaling a process shift, even if limits are not breached.
Question 3: A lubrication improvement team uses a fishbone (Ishikawa) diagram. In what scenario is this tool most useful?
- Tracking lubricant consumption over time
- Brainstorming all potential causes of a recurring bearing failure (Correct answer)
- Scheduling preventive maintenance intervals
- Comparing the cost of two lubricant brands
Correct answer: Brainstorming all potential causes of a recurring bearing failure
A fishbone diagram systematically organizes all potential contributing causes of a problem to guide root cause analysis.
Question 4: What is the purpose of establishing a lubricant consolidation program in an industrial facility?
- To increase the number of lubricant suppliers for redundancy
- To reduce the number of lubricant types used, minimizing storage complexity and cross-contamination risk (Correct answer)
- To switch all equipment to synthetic lubricants regardless of OEM requirements
- To eliminate all oil analysis programs and rely on scheduled changes
Correct answer: To reduce the number of lubricant types used, minimizing storage complexity and cross-contamination risk
Lubricant consolidation reduces SKUs, simplifies inventory management, and lowers the risk of using the wrong lubricant.
Question 5: Which process improvement methodology uses the DMAIC framework specifically for reducing defects in existing processes?
- Total Productive Maintenance (TPM)
- Six Sigma (Correct answer)
- 5S methodology
- Root Cause Analysis (RCA)
Correct answer: Six Sigma
Six Sigma uses DMAIC (Define, Measure, Analyze, Improve, Control) to systematically reduce defects and process variation.
Question 6: A lubrication technician finds that a grease fitting is blocked and lubricant cannot be injected. According to best QC practices, what should be recorded?
- Nothing — skip the point and move to the next
- The blocked fitting should be noted on the route sheet and a corrective work order generated (Correct answer)
- Apply extra force to inject grease through the blockage
- Replace the entire bearing assembly immediately
Correct answer: The blocked fitting should be noted on the route sheet and a corrective work order generated
Documenting the finding and generating a corrective work order ensures the deficiency is tracked and properly resolved.
Question 7: In lubricant storage QC, what is the primary purpose of FIFO (First In, First Out) inventory rotation?
- To ensure older lubricant stock is used before newer stock to prevent shelf-life exceedance (Correct answer)
- To reduce the number of lubrication points on a machine
- To prioritize synthetic lubricants over mineral oils
- To allow bulk containers to settle before dispensing
Correct answer: To ensure older lubricant stock is used before newer stock to prevent shelf-life exceedance
FIFO ensures that lubricants are consumed in order of receipt, preventing degradation of stock that exceeds its recommended shelf life.
CLS Quality Control & Process Improvement 3
Which quality control document formally defines the lubricant type, quantity, frequency, and method for each lubrication point on a machine?