Chapter 9

Question 1

9.1 When investigating TPM, which of the following would be considered one of the 6 big negative contributors to equipment effectiveness?

Answer 1

a. Setup and adjustments

Question 2

9.2 Id the most likely result of adopting standardized work procedures:

Answer 2

d. They perserve know-how and expertise

Question 3

9.3 There are several types of control plans. Id the appropriate control plan to be used for part mockup

Answer 3

a. Prototype

Question 4

9.4 A p chart:

Answer 4

c. Plots either the fraction or percent defective in order of time

Question 5

9.5 What is a jidhoka?

Answer 5

d. A device that stops the machine whenever a defective is produced

Question 6

9.6 A particular department is using an X-bar chart with specification limits instead of control limits for monitoring a key characteristic. The department supervisor states that the specifications have more real meaning than the control limits. The best immediate reaction should be to:

Answer 6

c. Stop the process immediately and replace the specification limits with control limits

Question 7

9.7 A lean six sigma project has progressed to the point that a control plan is required. Control plan activities can be considered closed after which of the following?

Answer 7

d. The control plan is a “living document” and is rarely closed

Question 8

9.8 A process is in control with p-bar= 0.10 and n=50. The 3 sigma control limits for the np control chart are which of the following?

Answer 8

b. 0, 11.36
UCL/LCL=np(+/-) 3[np(1-p)]^1/2
5(+/-)3[5(.90)]^1/2
5(+/-)6.36

Question 9

9.9 After the successful completion and implementation of the first 4 phases of DMAIC, the control phase should be completed by which of the following?

Answer 9

d. The complete team is the most desirable option

Question 10

9.10 Standard work sheets are required for standard operations. Which element is included on the sheets?

Answer 10

a. Cycle time based on takt time

Question 11

9.11 Many training instructors have developed approaches to emphasize multiple sense learning. Which of the following options would be generally recognized to best foster student retention?

Answer 11

c. Seeing and speaking

Question 12

9.12 Considering that some of the following terms have benefits, which would most likely affect product quality?

Answer 12

a. Muda elimination and 5S

Question 13

9.13 If one were to summarize the results of a training needs analysis into a few words, what would be the best selection from the choices presented below?

Answer 13

c. Identifying performance gaps

Question 14

9.14 An X-bar and R chart was prepared for an operation using 20 samples with 5 pieces in each sample; X-double bar was found to be 33.6 and R-bar was 6.20. During production, a sample of 5 was taken and the pieces measured 36,43,37,25, and 38. At the time this sample was taken:

Answer 14

d. Only the range was outside control limits

Question 15

9.15 The visual factory would be supported to the greatest extent by:

Answer 15

b. Kanban and 5S

Question 16

9.16 Which of the following is a normally accepted control chart interpretation rule violation?

Answer 16

c. Two of three points in zone C

Question 17

9.17 Process A consists of several machines that combine their output into a common stream. Once combined, it is impossible to trace single pieces to specific machines. Process B receives the mixed pieces. A corrective action required finding the root cause of a defect found in some of these pieces. A team assigned to this problem is thinking of using SQC to detect the source of the problem. Where should SQC be implemented?

Answer 17

b. At each machine in Process A

Question 18

9.18 Pre-control starts a process specifically centered between:

Answer 18

b. Specification limits

Question 19

9.19 A p chart has exhibited statistical control over a period of time. However, the average fraction defective is too high to be satisfactory. Internal improvement can be obtained by:

Answer 19

a. A change in the basic design of the product or system

Question 20

9.20 Which of the following would be a device associated with the visual factory?

Answer 20

b. Andon board

Question 21

9.21 Advantages of control charts include:

Answer 21

a. They can detect treads of statistical significance

Question 22

9.22 After a six sigma team reached the improve phase of the DMAIC cycle, it was clear that a full redesign of the part was the right path to take. From then on, the DMAIC project became a DFSS project. Which control phase should be used for the newly redesigned part?

Answer 22

d. Prototype

Question 23

9.23 Control limits are set at the 3 sigma level because:

Answer 23

c. This level reduced the probability for looking for trouble in the process when none exists

Question 24

9.24 Training needs for an individual are based on which of the following?

Answer 24

b. The company’s objectives and the employee’s performance

Question 25

9.25 Standard work as visualized by the Japanese means:

Answer 25

b. Working safer and productively

Question 26

9.26 A process is checked by inspection of random samples of 4 shafts after a polishing operation, and X-bar and R chart are maintained. A person making a spot check picks out two shafts, measures them accurately, and plots the average value on the X-bar chart. The point falls just outside the control limits. The department foreman is advised to stop the process. This decision indicated that:

Answer 26

d. The person is not using the chart correctly

Question 27

9.27 Ultimate responsibility for training is vested with:

Answer 27

d. The employee

Question 28

9.28 The factor D4, in X-bar and R control charts is used to:

Answer 28

a. Determine the upper control limits of a range chart

Question 29

9.29 Which of the following tools would be part of control plan development?

Answer 29

a. Cause-and-effect analysis

Question 30

9.30 The Japanese techniques that compliment the visual factory concept are:

Answer 30

a. Kanban and 5S

Question 31

9.31 Which of the following indicated an out-of-control condition?

Answer 31

c. 2 of 3 consecutive points outside the two sigma warning limits

Question 32

9.32 What is the importance of the reaction plan in a control plan?

Answer 32

a. It describes what will happen if a key variable goes out of control

Question 33

9.33 The ideal setting for training:

Answer 33

c. Will have environmental conditions go unnoticed by the student

Question 34

9.34 The control chart that is most sensitive to variation in a measurement is:

Answer 34

d. X-bar and R chart

Question 35

9.35 Which of the following Japanese techniques helps control machine maintenance?

Answer 35

c. TPM

Question 36

9.36 Given that resistors are produced in lots of 1,000 and the average number of defective resistors per lot is 12.7, what are the upper and lower limits for the control chart appropriate for this process?

Answer 36

a. LCL= 2.0 UCL =23.4
LCL=12.7-3(3.56)=2.0
UCL=12.7+3(3.56)=23.4

Question 37

9.37 During variable control charting, a trend of 4 consecutive points is noted on both the average and range charts. The average chart is increasing and the range chart is decreasing. One may make which of the following conclusions?

Answer 37

d. No conclusions may be made yet

Question 38

9.38 After the successful implementation of an “improve” stage, a DMAIC team is considering control charts to monitor the new gains for a process. Which approach would provide the best results?

Answer 38

b. Chart the most important input variables associated to the CTQs

Question 39

3.39 What % of product should fall between the P-C lines (green zone) on a pre-control chart, assuming that the process is stable?

Answer 39

c. 86.0%

Question 40

3.40 Which control chart pattern best represents an in control process?

Answer 40

c. A ransom distribution of points on both sides of the centerline

Question 41

9.41 An R chart is generally used to:

Answer 41

c. Determine if the process variance is in control

Question 42

9.42 Which of the following elements is part of a control plan form?

Answer 42

c. Key input and output variables

Question 43

9.43 Which of the following charts have upper control limits, but frequently lave lower control limits of zero?

Answer 43

d. R and sigma charts

Question 44

9.44 The design of a control plan for a particular part incorporates information from a variety of sources such as flow charts, QFD, FMEAs, designed experiments, and statistical studies. It is a tool to monitor and control the part or process. If used properly, the control plan avoids which of the following problems?

Answer 44

a. Becoming a substitute for written operator instructions

Question 45

9.45 Standard work relies on which of the following toold?

Answer 45

b. 5S and Kanban

Question 46

9.46 The single most important factor in establishing an effective company training effort is:

Answer 46

a. Top management support

Question 47

9.47 An R chart is most closely related to which of the following

Answer 47

b. S chart

Question 48

9.48 What lean technique is most widely used to make problem visible?

Answer 48

b. 5S