CQIA Continuous Improvement 3 — Questions and Answers
Question 1: A process improvement team has identified five potential root causes for a quality problem. Which tool would BEST help them prioritize which cause to address first?
- Scatter diagram
- Pareto chart (Correct answer)
- Run chart
- Control chart
Correct answer: Pareto chart
A Pareto chart ranks causes by frequency or impact, helping teams focus on the vital few causes that account for most of the problem.
Question 2: In the context of continuous improvement, what is the purpose of establishing a 'baseline'?
- To set the minimum acceptable quality level
- To measure current performance before making changes (Correct answer)
- To define the target state after improvement
- To document compliance with regulatory requirements
Correct answer: To measure current performance before making changes
A baseline measures current process performance so that the impact of improvement actions can be quantified and compared.
Question 3: Which statement BEST describes the concept of 'value-added' activity in process improvement?
- Any activity that increases the cost of production
- An activity the customer is willing to pay for and that transforms the product (Correct answer)
- Any step performed by a skilled employee
- An activity required by internal company policy
Correct answer: An activity the customer is willing to pay for and that transforms the product
A value-added activity must meet three criteria: the customer cares about it, it physically changes the product or service, and it is done right the first time.
Question 4: A supervisor resists a process change proposed by the improvement team. According to change management principles, what should the team do FIRST?
- Escalate the issue to senior management
- Understand and address the supervisor's concerns (Correct answer)
- Implement the change without the supervisor's approval
- Abandon the improvement and choose a different project
Correct answer: Understand and address the supervisor's concerns
Engaging stakeholders by understanding and addressing resistance is a foundational change management practice that builds buy-in.
Question 5: What is the primary benefit of standardizing an improved process after a successful PDCA cycle?
- It eliminates the need for future improvement cycles
- It ensures the gains are maintained and provides a new baseline (Correct answer)
- It reduces the need for employee training
- It satisfies ISO certification requirements automatically
Correct answer: It ensures the gains are maintained and provides a new baseline
Standardization (the 'Act' phase) locks in improvements, prevents regression to old methods, and establishes the new baseline for further improvements.
Question 6: Which of the following BEST illustrates the concept of 'pull' in a Lean system?
- Producing goods based on a monthly forecast
- A downstream process requesting materials only when needed (Correct answer)
- Pushing inventory to warehouses before customer orders arrive
- Scheduling production based on machine availability
Correct answer: A downstream process requesting materials only when needed
A pull system triggers production or material flow based on actual downstream demand, reducing overproduction and excess inventory.
Question 7: A quality team uses a scatter diagram and finds a strong positive correlation between employee training hours and product defect rates decreasing. What conclusion is MOST appropriate?
- Training directly causes fewer defects
- There is a relationship between training and defect rates worth investigating further (Correct answer)
- Training hours should be doubled to eliminate all defects
- The scatter diagram has been constructed incorrectly
Correct answer: There is a relationship between training and defect rates worth investigating further
Correlation indicates a statistical relationship but does not prove causation; further investigation is needed before concluding that training causes the improvement.
CQIA Continuous Improvement 3
A process improvement team has identified five potential root causes for a quality problem.
Which tool would BEST help them prioritize which cause to address first?