CQIA Process Improvement 2 — Questions and Answers
Question 1: Which tool is most useful for identifying the root cause of a recurring defect by asking 'why' repeatedly?
- Pareto chart
- 5 Whys (Correct answer)
- Control chart
- Scatter diagram
Correct answer: 5 Whys
The 5 Whys technique drills down to root causes by iteratively asking why a problem occurred.
Question 2: A process improvement team wants to reduce cycle time. Which lean concept directly targets the elimination of non-value-added waiting?
- Poka-yoke
- Takt time
- Pull system
- Muda elimination (Correct answer)
Correct answer: Muda elimination
Muda (waste) elimination in lean targets non-value-added activities including waiting, overproduction, and excess motion.
Question 3: When mapping a process with a flowchart, a diamond shape typically represents:
- A process step
- A decision point (Correct answer)
- A document
- The start or end
Correct answer: A decision point
In standard flowchart notation, a diamond symbol denotes a decision point with two or more possible outcomes.
Question 4: Which DMAIC phase focuses on identifying, validating, and selecting the root cause of a problem?
- Define
- Measure
- Analyze (Correct answer)
- Improve
Correct answer: Analyze
The Analyze phase uses data and tools like fishbone diagrams and 5 Whys to identify and confirm root causes.
Question 5: A team notices that 20% of their product types account for 80% of customer complaints. This is an example of:
- Normal distribution
- The Pareto principle (Correct answer)
- Regression analysis
- Stratification
Correct answer: The Pareto principle
The Pareto principle (80/20 rule) states that roughly 80% of effects come from 20% of causes.
Question 6: Which of the following best describes a 'pilot' in the context of process improvement?
- A full-scale rollout of a new process
- A small-scale test of a proposed solution (Correct answer)
- An audit of the existing process
- A training session for employees
Correct answer: A small-scale test of a proposed solution
A pilot is a small-scale, controlled trial of a proposed change before full implementation to test feasibility and effectiveness.
Question 7: In a value stream map, 'push' production means:
- Products are made based on actual downstream demand
- Products are made based on forecasted demand and pushed forward (Correct answer)
- Inventory is minimized at every stage
- Work is pulled only when a customer requests it
Correct answer: Products are made based on forecasted demand and pushed forward
Push production schedules work based on forecasts and pushes output to the next stage regardless of actual demand, often creating inventory buildup.
CQIA Process Improvement 2
Which tool is most useful for identifying the root cause of a recurring defect by asking 'why' repeatedly?