IST Industrial Problem Solving 1 — Questions and Answers
Question 1: A machine has been producing increasing numbers of defective parts over the past week. What is the BEST first step in troubleshooting?
- Replace the machine immediately
- Identify when the defects first appeared and what changed at that time (Correct answer)
- Increase inspection frequency and discard defects
- Contact the manufacturer for a new machine
Correct answer: Identify when the defects first appeared and what changed at that time
Identifying the timeline of the problem and what changed when it started is the most logical first step in root cause analysis.
Question 2: In the '5 Whys' problem-solving method, what is the goal?
- Ask five different workers for their opinions on a problem
- Ask 'why' repeatedly to trace a problem back to its root cause (Correct answer)
- Identify five possible solutions before choosing one
- Document five safety concerns related to a defect
Correct answer: Ask 'why' repeatedly to trace a problem back to its root cause
The 5 Whys method traces a problem to its root cause by repeatedly asking 'why' until the underlying cause is found.
Question 3: What does the term 'downtime' refer to in industrial production?
- Time when workers are on scheduled break
- Time when a machine or production line is not operating due to failure or maintenance (Correct answer)
- Overtime hours worked during night shifts
- The cooling-down period after a machine completes a run
Correct answer: Time when a machine or production line is not operating due to failure or maintenance
Downtime refers to periods when production equipment is not operational due to breakdowns, maintenance, or other interruptions.
Question 4: A production machine suddenly stops. What is the safest FIRST action?
- Immediately attempt to restart the machine
- Open the machine panels to inspect the internal components
- Notify the supervisor and follow LOTO procedures before investigating (Correct answer)
- Check the machine settings and reset all parameters
Correct answer: Notify the supervisor and follow LOTO procedures before investigating
The safest first action is to notify the supervisor and apply LOTO procedures before any investigation to prevent injury.
Question 5: What is the purpose of a control chart in industrial quality control?
- To set production quotas for each shift
- To monitor process variation over time and detect trends (Correct answer)
- To schedule preventive maintenance activities
- To track inventory levels of raw materials
Correct answer: To monitor process variation over time and detect trends
Control charts display process data over time, helping identify trends, shifts, or out-of-control conditions before defects occur.
Question 6: Which problem-solving approach involves creating a diagram that organizes potential causes into categories such as Machine, Method, Material, and Manpower?
- Pareto chart
- Fishbone (Ishikawa) diagram (Correct answer)
- FMEA (Failure Mode and Effects Analysis)
- Scatter diagram
Correct answer: Fishbone (Ishikawa) diagram
The fishbone (Ishikawa) diagram organizes possible causes into major categories to systematically identify the root cause of a problem.
IST Industrial Problem Solving 1
A machine has been producing increasing numbers of defective parts over the past week.
What is the BEST first step in troubleshooting?