CPIM Quality and Continuous Improvement 3 — Questions and Answers
Question 1: What is the key distinction between Quality Assurance (QA) and Quality Control (QC)?
- QA is product-focused; QC is process-focused
- QA is process-focused and preventive; QC is product-focused and detective (Correct answer)
- QA uses statistical tools; QC uses management systems
- QA is performed by suppliers; QC is performed by customers
Correct answer: QA is process-focused and preventive; QC is product-focused and detective
QA focuses on preventing defects through process improvement, while QC focuses on detecting defects in finished products or work.
Question 2: In the context of ISO 9001, what is the purpose of a management review?
- To perform a detailed product inspection
- To evaluate the suitability, adequacy, and effectiveness of the QMS (Correct answer)
- To certify individual employees on quality standards
- To approve customer complaints
Correct answer: To evaluate the suitability, adequacy, and effectiveness of the QMS
Management reviews assess whether the quality management system remains suitable, adequate, and effective in meeting objectives.
Question 3: Which of the following best describes 'design of experiments' (DOE) in a quality improvement context?
- Randomly sampling finished goods for inspection
- A structured method for determining cause-and-effect relationships between process inputs and outputs (Correct answer)
- Documenting customer requirements into product specifications
- A visual tool for mapping process flows
Correct answer: A structured method for determining cause-and-effect relationships between process inputs and outputs
DOE systematically varies process inputs to understand which factors significantly affect output quality.
Question 4: What is a 'quality cost' category that includes scrap, rework, and warranty claims?
- Prevention costs
- Appraisal costs
- Internal failure costs and external failure costs (Correct answer)
- Conformance costs
Correct answer: Internal failure costs and external failure costs
Scrap and rework are internal failure costs; warranty claims are external failure costs — both result from nonconformance.
Question 5: When a company implements 5S, which step involves deciding what is necessary and removing what is not?
- Set in Order (Seiton)
- Shine (Seiso)
- Sort (Seiri) (Correct answer)
- Standardize (Seiketsu)
Correct answer: Sort (Seiri)
Sort (Seiri) is the first 5S step: identify and remove unnecessary items from the workplace.
Question 6: A supplier delivers a batch of 1,000 parts. The agreed AQL is 1.0%. Under acceptance sampling, what happens if the sample defect count exceeds the acceptance number?
- The batch is automatically scrapped
- The batch is returned and the supplier is audited
- The entire lot is rejected and dispositioned accordingly (Correct answer)
- All 1,000 parts are individually inspected
Correct answer: The entire lot is rejected and dispositioned accordingly
When the sample's defect count exceeds the acceptance number, the lot is rejected and then dispositioned (returned, 100% inspected, or scrapped).
Question 7: Which Deming principle emphasizes driving out fear so that people can work effectively?
- Institute training on the job
- Drive out fear (Correct answer)
- Break down barriers between departments
- Eliminate slogans and exhortations
Correct answer: Drive out fear
Deming's 8th point — Drive Out Fear — recognizes that fear of reprisal prevents workers from reporting problems and asking questions.
CPIM Quality and Continuous Improvement 3
What is the key distinction between Quality Assurance (QA) and Quality Control (QC)?