Quality Control and Process Optimization Flashcards
7 cards from real CPM practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 7 Quality Control and Process Optimization flashcards as text
A plant manager reviews a process FMEA. Which failure mode should receive the highest priority for corrective action?
Answer: Highest Risk Priority Number (RPN = Severity × Occurrence × Detection)
RPN combines all three risk dimensions; the failure mode with the highest RPN poses the greatest overall risk and should be addressed first.
What distinguishes a p-chart from a c-chart in statistical process control?
Answer: p-charts monitor proportion defective per sample; c-charts monitor count of defects per unit
A p-chart tracks the proportion (fraction) of defective items per sample, while a c-chart tracks the count of defects per unit of constant size.
A plant implements a pull system instead of a push system. What is the key operational difference?
Answer: Pull systems produce only when downstream demand signals authorization; push systems produce based on forecasts
In a pull system, production is triggered by actual downstream consumption (kanban signals), preventing overproduction and excess inventory.
When conducting a process audit, what is the main distinction between a compliance audit and a system audit?
Answer: Compliance audits assess whether procedures are followed; system audits evaluate whether the quality system is effective and adequate
Compliance audits verify adherence to established procedures, while system audits evaluate whether the overall quality management system is effective and appropriate.
In process optimization, what is the purpose of a response surface methodology (RSM)?
Answer: To model and optimize the relationship between multiple process inputs and the output response
RSM uses mathematical models to explore the relationships between factors and responses, identifying optimal process settings.
A plant's quality system requires first article inspection (FAI). When is FAI typically performed?
Answer: Before full production begins, to verify that a new or revised process can produce conforming parts
FAI is performed on the first production parts from a new or modified process to confirm all requirements are met before mass production begins.
Which lean waste category is represented when a skilled technician spends significant time searching for tools and materials?
Answer: Motion
Unnecessary motion — including searching, reaching, or walking to retrieve items — is one of the 8 wastes (Muda) in lean manufacturing.