CPP Process Analysis & Improvement Techniques 3 — Questions and Answers
Question 1: Which lean concept refers to producing only what is needed, when it is needed, and in the amount needed to eliminate overproduction waste?
- Jidoka
- Just-In-Time (JIT) (Correct answer)
- Kaizen
- Poka-yoke
Correct answer: Just-In-Time (JIT)
Just-In-Time production synchronizes output with demand, preventing excess inventory and overproduction—two forms of lean waste.
Question 2: A team notices that a process output variable correlates strongly with an input variable on a scatter diagram. What is the most appropriate next step?
- Immediately implement a process change
- Conduct a designed experiment to confirm causation (Correct answer)
- Close the project as complete
- Redesign the measurement system
Correct answer: Conduct a designed experiment to confirm causation
Correlation does not prove causation; a designed experiment (DOE) is needed to confirm whether the input variable truly drives the output.
Question 3: In Total Quality Management (TQM), which principle emphasizes that quality improvement is an ongoing, never-ending effort involving everyone in the organization?
- Zero defects
- Continuous improvement (Kaizen) (Correct answer)
- Statistical process control
- Quality function deployment
Correct answer: Continuous improvement (Kaizen)
Kaizen, a core TQM principle, promotes continuous incremental improvement by all employees as an ongoing organizational culture.
Question 4: A process that produces 99.99966% defect-free output is operating at approximately which Sigma level?
- 3 Sigma
- 4 Sigma
- 5 Sigma
- 6 Sigma (Correct answer)
Correct answer: 6 Sigma
Six Sigma quality corresponds to no more than 3.4 defects per million opportunities, equating to approximately 99.99966% defect-free output.
Question 5: Which analysis technique examines the potential failure modes in a process and their effects on the customer to prioritize corrective actions?
- FMEA (Failure Mode and Effects Analysis) (Correct answer)
- SIPOC
- Control chart analysis
- Regression analysis
Correct answer: FMEA (Failure Mode and Effects Analysis)
FMEA identifies failure modes, assesses their severity, occurrence, and detectability to calculate a Risk Priority Number (RPN) for prioritization.
Question 6: In value stream mapping, activities that consume resources but do not add value from the customer's perspective are classified as:
- Value-added steps
- Non-value-added waste (Correct answer)
- Necessary non-value-added steps
- Cycle time components
Correct answer: Non-value-added waste
Non-value-added waste includes activities that the customer would not willingly pay for, and lean improvement efforts focus on eliminating them.
Question 7: Which process analysis technique compares an organization's performance metrics and practices against industry best practices or top competitors?
- Root cause analysis
- Benchmarking (Correct answer)
- Statistical sampling
- Force field analysis
Correct answer: Benchmarking
Benchmarking identifies performance gaps and improvement opportunities by comparing internal processes to external best-in-class standards.
CPP Process Analysis & Improvement Techniques 3
Which lean concept refers to producing only what is needed, when it is needed, and in the amount needed to eliminate overproduction waste?