CQIA Process Analysis & Improvement Techniques 2 — Questions and Answers
Question 1: A team notices that 20% of defect types account for 80% of total defects. Which tool best visualizes this relationship?
- Scatter diagram
- Pareto chart (Correct answer)
- Control chart
- Histogram
Correct answer: Pareto chart
A Pareto chart displays defect categories in descending order of frequency, making the 80/20 relationship immediately visible.
Question 2: Which of the following best describes a 'value-added' activity in process analysis?
- Any activity that consumes resources
- An activity the customer would pay for that transforms the product (Correct answer)
- An inspection step that prevents defects
- Any rework activity that corrects errors
Correct answer: An activity the customer would pay for that transforms the product
A value-added activity directly transforms the product or service in a way the customer recognizes and is willing to pay for.
Question 3: In a SIPOC diagram, what does the 'O' represent?
- Operations
- Outcomes
- Outputs (Correct answer)
- Objectives
Correct answer: Outputs
SIPOC stands for Suppliers, Inputs, Process, Outputs, and Customers — 'O' refers to the Outputs produced by the process.
Question 4: A value stream map shows a large amount of inventory between two process steps. This inventory most likely indicates:
- A highly efficient buffer
- A bottleneck or imbalance between the two steps (Correct answer)
- A sign of high customer demand
- A well-balanced pull system
Correct answer: A bottleneck or imbalance between the two steps
Excess inventory between steps typically signals a bottleneck or pace mismatch, a form of waste (muda) in lean thinking.
Question 5: Which mistake-proofing device category physically prevents an error from occurring rather than just detecting it?
- Detection poka-yoke
- Warning poka-yoke
- Control poka-yoke (Correct answer)
- Alarm poka-yoke
Correct answer: Control poka-yoke
A control poka-yoke physically stops the process or prevents the incorrect action, making the error impossible.
Question 6: During a process walk, a team documents every step including waits, inspections, and rework loops. This activity is called:
- Benchmarking
- Gemba walk with current-state mapping (Correct answer)
- Gap analysis
- Failure mode analysis
Correct answer: Gemba walk with current-state mapping
Walking the actual process (gemba) while mapping the current state captures all steps, waste, and flow issues firsthand.
Question 7: A team wants to reduce cycle time by eliminating non-value-added steps. Which lean concept directly guides this effort?
- Jidoka
- Muda elimination (Correct answer)
- Heijunka
- Kanban replenishment
Correct answer: Muda elimination
Muda elimination focuses on identifying and removing waste (non-value-added activities) to shorten cycle time and improve flow.
CQIA Process Analysis & Improvement Techniques 2
A team notices that 20% of defect types account for 80% of total defects.
Which tool best visualizes this relationship?