CPT Quality Assurance & Process Optimization 3 — Questions and Answers
Question 1: Which lean concept focuses on eliminating all activities that do not add value from the customer's perspective?
- Kaizen
- Waste elimination (Muda) (Correct answer)
- 5S methodology
- Value stream mapping
Correct answer: Waste elimination (Muda)
Muda refers to waste—any activity that consumes resources without creating value for the customer—and eliminating it is a core lean principle.
Question 2: A process with a Cpk of 0.85 indicates the process is:
- Highly capable and centered
- Capable but slightly off-center
- Not capable of meeting specifications (Correct answer)
- Operating within six sigma limits
Correct answer: Not capable of meeting specifications
A Cpk below 1.0 means the process is not capable of consistently producing output within specification limits.
Question 3: In statistical process control, the Upper Control Limit (UCL) is typically set at:
- The upper specification limit
- 2 standard deviations above the mean
- 3 standard deviations above the mean (Correct answer)
- The maximum observed value
Correct answer: 3 standard deviations above the mean
Control limits are conventionally placed at ±3 standard deviations from the process mean, representing 99.73% of normal variation.
Question 4: Which of the following best describes the purpose of a fishbone (Ishikawa) diagram?
- Track defect frequency over time
- Display the distribution of process data
- Organize potential causes of a problem by category (Correct answer)
- Monitor process output against control limits
Correct answer: Organize potential causes of a problem by category
A fishbone diagram visually organizes potential root causes of a problem into categories such as Man, Machine, Method, Material, and Environment.
Question 5: Total Productive Maintenance (TPM) aims primarily to:
- Reduce scheduled downtime intervals
- Maximize equipment effectiveness through employee involvement (Correct answer)
- Outsource maintenance to specialized contractors
- Increase spare parts inventory
Correct answer: Maximize equipment effectiveness through employee involvement
TPM engages all employees, especially operators, in maintaining equipment to maximize Overall Equipment Effectiveness (OEE).
Question 6: A process technician performing a gauge R&R study is evaluating:
- The accuracy of a single calibrated instrument
- The repeatability and reproducibility of a measurement system (Correct answer)
- The number of defective parts in a sample
- The process capability ratio
Correct answer: The repeatability and reproducibility of a measurement system
Gauge R&R assesses both the repeatability of a single operator and the reproducibility across multiple operators using the same instrument.
Question 7: Which lean tool is used to visualize the flow of materials and information required to deliver a product or service?
- 5S audit
- Value Stream Map (VSM) (Correct answer)
- Kanban board
- SMED analysis
Correct answer: Value Stream Map (VSM)
A Value Stream Map shows every step in the material and information flow from supplier to customer, revealing waste and improvement opportunities.
CPT Quality Assurance & Process Optimization 3
Which lean concept focuses on eliminating all activities that do not add value from the customer's perspective?