LMC Quality Assurance & Improvement 2

Question 1

A manufacturing team notices that 80% of customer complaints stem from 3 out of 15 defect types. Which Lean quality tool best supports this finding?

Accepted Answer

Pareto chart

Answer

A Pareto chart visualizes the 80/20 rule, identifying the vital few defect types that cause the majority of problems.

Question 2

In a Lean quality system, 'jidoka' primarily means:

Accepted Answer

Automation with a human touch that stops on defects

Answer

Jidoka empowers machines and workers to stop production immediately when a defect is detected, preventing defect propagation.

Question 3

Which metric directly measures the percentage of units that complete a process without any defect or rework on the first attempt?

Accepted Answer

First Pass Yield (FPY)

Answer

First Pass Yield (FPY) measures the proportion of units produced correctly without rework or scrap on the first try.

Question 4

A process capability index (Cpk) of 0.85 indicates:

Accepted Answer

The process is not capable and produces defects

Answer

A Cpk below 1.0 means the process cannot consistently meet specifications, resulting in defects beyond acceptable limits.

Question 5

During a quality audit, the team finds that rework stations are located at the end of the production line. From a Lean perspective, this is problematic because:

Accepted Answer

It delays defect detection, increasing waste and cost

Answer

Detecting and correcting defects late in the process is far more costly than catching them at the source, violating the principle of built-in quality.

(LMC) Lean Management Certification Practice Test

(LMC) Lean Management Certification Practice Test

LMC Quality Assurance & Improvement 2