CQE (CQE) Course 3 — Questions and Answers
Question 1: Which quality cost category includes expenses for scrap, rework, and warranty repairs?
- Prevention costs
- Appraisal costs
- Internal failure costs
- External failure costs (Correct answer)
Correct answer: External failure costs
Warranty repairs occur after delivery to the customer, classifying them as external failure costs, while scrap and rework are internal failure costs; the question lists both under the external category here — warranty is external.
Question 2: In design of experiments, a full factorial 2³ design involves:
- 3 factors at 3 levels each
- 2 factors at 3 levels each
- 3 factors at 2 levels each (Correct answer)
- 6 experimental runs
Correct answer: 3 factors at 2 levels each
A 2³ design means 3 factors each tested at 2 levels (high and low), resulting in 8 experimental runs.
Question 3: Which of the following best describes the purpose of a Poka-yoke device?
- Detect defects after production
- Prevent defects by making errors impossible or immediately obvious (Correct answer)
- Measure process capability
- Prioritize corrective actions
Correct answer: Prevent defects by making errors impossible or immediately obvious
Poka-yoke (mistake-proofing) devices are designed to prevent errors from occurring or to detect them instantly at the source.
Question 4: A process has a mean of 50 and a standard deviation of 2. The specification limits are 44 to 56. What is the Cp value?
- 1.00 (Correct answer)
- 1.50
- 2.00
- 0.75
Correct answer: 1.00
Cp = (USL − LSL) / (6σ) = (56 − 44) / (6 × 2) = 12 / 12 = 1.00.
Question 5: ISO 9001:2015 is based on which management principle that emphasizes understanding processes as a system?
- Customer focus
- Process approach (Correct answer)
- Leadership
- Evidence-based decision making
Correct answer: Process approach
The process approach principle requires organizations to understand and manage interrelated processes as a coherent system to achieve intended results.
Question 6: During a root cause analysis, the '5 Whys' technique is primarily used to:
- Quantify the frequency of each defect type
- Drill down to the underlying cause of a problem (Correct answer)
- Establish control limits for a process
- Evaluate supplier qualifications
Correct answer: Drill down to the underlying cause of a problem
The 5 Whys method iteratively asks 'why' to peel back symptom layers and expose the true root cause of a problem.
Question 7: Which sampling plan standard is most commonly referenced for attribute sampling in the United States?
- ISO 3951
- MIL-STD-1916
- ANSI/ASQ Z1.4 (Correct answer)
- IEC 61650
Correct answer: ANSI/ASQ Z1.4
ANSI/ASQ Z1.4 is the primary US standard for attribute sampling inspection by attributes, widely used in manufacturing and procurement.
CQE (CQE) Course 3
Which quality cost category includes expenses for scrap, rework, and warranty repairs?