CQE (CQE) Fundamentals 5 — Questions and Answers
Question 1: Which of the following BEST describes 'concurrent engineering' in a product development context?
- Sequential hand-offs between engineering and manufacturing
- Simultaneous development of product and process design to reduce time-to-market (Correct answer)
- Using multiple software tools in parallel for CAD modeling
- Outsourcing engineering tasks to multiple suppliers simultaneously
Correct answer: Simultaneous development of product and process design to reduce time-to-market
Concurrent engineering involves simultaneous development of product and process design, reducing cycle time and catching issues earlier.
Question 2: In Design of Experiments (DOE), a 'full factorial' design means:
- Only the most significant factors are tested
- Every possible combination of factor levels is tested (Correct answer)
- Factors are varied one at a time
- A fractional subset of runs is selected using orthogonal arrays
Correct answer: Every possible combination of factor levels is tested
A full factorial design tests all possible combinations of every factor level, allowing estimation of all main effects and interactions.
Question 3: The acceptable quality limit (AQL) in a sampling plan represents:
- The maximum defect rate a consumer is willing to accept
- The worst quality level still considered acceptable for routine acceptance (Correct answer)
- The target defect rate for the process
- The defect rate at which lots are always rejected
Correct answer: The worst quality level still considered acceptable for routine acceptance
AQL is the worst tolerable process average when a continuing series of lots is submitted for acceptance sampling.
Question 4: Which of the following quality improvement methodologies follows the DMAIC problem-solving framework?
- Lean Manufacturing
- Six Sigma (Correct answer)
- Total Quality Management (TQM)
- ISO 9001
Correct answer: Six Sigma
Six Sigma uses the DMAIC (Define, Measure, Analyze, Improve, Control) framework for structured problem solving and process improvement.
Question 5: A process produces 3.4 defects per million opportunities (DPMO). This corresponds to which sigma level?
- 3 sigma
- 4 sigma
- 5 sigma
- 6 sigma (Correct answer)
Correct answer: 6 sigma
Six Sigma quality by definition corresponds to 3.4 DPMO, which accounts for a 1.5 sigma long-term process shift.
Question 6: When conducting a supplier audit, which of the following findings would be classified as a MAJOR nonconformance?
- A minor documentation error in a work instruction
- Absence of a critical quality control step required by contract (Correct answer)
- A calibration sticker that is two days overdue
- One employee who cannot locate the quality policy
Correct answer: Absence of a critical quality control step required by contract
Absence of a contractually required quality control step represents a systemic failure that directly threatens product conformity — a major nonconformance.
Question 7: The concept of 'mistake-proofing' or 'poka-yoke' was developed as part of which quality system?
- Total Quality Control (TQC)
- Toyota Production System (TPS) (Correct answer)
- ISO 9000 series standards
- Malcolm Baldrige National Quality Program
Correct answer: Toyota Production System (TPS)
Poka-yoke was developed by Shigeo Shingo as part of the Toyota Production System to prevent human errors from causing defects.
CQE (CQE) Fundamentals 5
Which of the following BEST describes 'concurrent engineering' in a product development context?