CPS Quality Assurance & Improvement 2 — Questions and Answers
Question 1: Which quality improvement tool uses a structured approach of Define, Measure, Analyze, Improve, and Control?
- PDCA
- Six Sigma DMAIC (Correct answer)
- 8D Problem Solving
- Kaizen
Correct answer: Six Sigma DMAIC
Six Sigma's DMAIC framework provides a data-driven methodology to improve existing processes by reducing defects and variation.
Question 2: A process capability index (Cpk) value of 1.33 indicates:
- The process is barely capable
- The process meets a 4-sigma quality level (Correct answer)
- The process is world-class
- The process is out of control
Correct answer: The process meets a 4-sigma quality level
A Cpk of 1.33 corresponds to a 4-sigma process, yielding approximately 6,210 defects per million opportunities.
Question 3: In quality management, a 'non-conformance' refers to:
- A process that exceeds customer expectations
- Failure to meet a specified requirement (Correct answer)
- A documented customer complaint
- An unplanned process improvement
Correct answer: Failure to meet a specified requirement
A non-conformance is any output or condition that fails to meet a defined requirement or specification.
Question 4: The primary purpose of a Quality Management System (QMS) is to:
- Reduce workforce headcount
- Ensure consistent processes that meet customer and regulatory requirements (Correct answer)
- Maximize production speed
- Document all company procedures
Correct answer: Ensure consistent processes that meet customer and regulatory requirements
A QMS provides a framework of processes, procedures, and responsibilities to consistently deliver products and services that satisfy customers.
Question 5: Which statistical tool is used to determine if a process is in statistical control by plotting data over time?
- Histogram
- Scatter diagram
- Control chart (Correct answer)
- Pareto chart
Correct answer: Control chart
Control charts display process data over time against control limits, distinguishing between common cause and special cause variation.
Question 6: Cost of Poor Quality (COPQ) includes which of the following categories?
- Prevention costs and appraisal costs
- Internal failure costs and external failure costs (Correct answer)
- Training costs and audit costs
- Inspection costs and certification costs
Correct answer: Internal failure costs and external failure costs
COPQ specifically refers to costs incurred because quality failures occur, including internal failures (scrap, rework) and external failures (warranty, returns).
Question 7: A quality audit finding classified as a 'major nonconformity' typically means:
- A minor documentation error was found
- A systemic breakdown that likely results in process failure or product nonconformance (Correct answer)
- An observation requiring future monitoring
- A suggestion for improvement with no urgency
Correct answer: A systemic breakdown that likely results in process failure or product nonconformance
A major nonconformity signals a complete absence or total breakdown of a system requirement, posing significant risk to process integrity.
CPS Quality Assurance & Improvement 2
Which quality improvement tool uses a structured approach of Define, Measure, Analyze, Improve, and Control?