Quality Management in Supply Chains Flashcards

In supplier quality management, a First Article Inspection (FAI) is PRIMARILY conducted to:

Answer: Verify that the first production units from a new or changed process conform to all engineering and design requirements before full production begins

FAI validates that a supplier's production process is capable of consistently producing parts to specification before full-scale production begins. It catches process problems early, preventing large quantities of non-conforming parts. It is a one-time or change-triggered check, not 100% inspection of every unit.

A supply manager reviewing a supplier's Statistical Process Control (SPC) chart notices that several consecutive data points are all above the process mean but within control limits. This pattern MOST likely indicates:

Answer: A potential systematic shift or special cause in the process that warrants investigation

In SPC, a run of seven or more consecutive points on one side of the mean (a 'run rule') signals a non-random pattern suggesting a systematic shift or special cause — even if no point exceeds control limits. This warrants investigation before defects appear. Random variation would be distributed on both sides of the mean.

ISO 9001 certification of a supplier PRIMARILY assures a buying organization that the supplier:

Answer: Has a documented quality management system that meets the standard's requirements and is regularly audited

ISO 9001 certifies that a supplier has implemented and maintains a quality management system (QMS) conforming to the standard's requirements for process documentation, continuous improvement, and customer focus. It does not guarantee zero defects or mandate any specific quality methodology like Six Sigma.

The Cost of Poor Quality (COPQ) includes which of the following categories?

Answer: Internal failure costs (e.g., scrap, rework) and external failure costs (e.g., warranty claims, returns)

COPQ specifically captures costs incurred because defects occurred: internal failures (scrap, rework, downtime) discovered before delivery, and external failures (warranty, returns, liability) discovered after delivery. Prevention and appraisal costs are costs of quality investment — not costs of poor quality.

A supply manager is implementing an Approved Supplier List (ASL). The PRIMARY purpose of an ASL is to:

Answer: Ensure that only suppliers who have been qualified against defined quality and performance criteria are used for production purchases

An ASL is a controlled list of suppliers who have been evaluated and approved to supply specific materials or services. It prevents use of unvetted suppliers, ensures minimum quality standards are met, and streamlines sourcing decisions. It does not mandate lowest-cost selection or automate purchasing.

In a Six Sigma context, a process operating at Six Sigma quality produces approximately how many defects per million opportunities (DPMO)?

Answer: 3.4 DPMO

Six Sigma quality, accounting for a 1.5-sigma process shift, yields approximately 3.4 defects per million opportunities — representing near-perfection. This is the benchmark that Six Sigma programs target. 66,807 DPMO corresponds to Three Sigma performance, which is a common baseline before improvement efforts.