Management and Leadership

Question 1

Who is the father of “scientific manufacturing”, giving “gauging” more legitimacy?

Answer 1

Frederick W. Taylor

Question 2

When was quality first viewed as a distinct management responsibility and an independent function?

Answer 2

1922, G.S. Radford’s Control of Quality Manufacturing

Question 3

Which Bell lab employee gave the discipline of quality a scientific footing, with their publication “Economic Control of Quality of Manufactured Product”

Answer 3

W.A. Shewhart

Question 4

Who first devised a method for addressing the overall level of quality produced by a manufacturing effort, rather than just a specific lot? (Average outgoing quality limit)

Answer 4

Harry Dodge and Harry Romig

Question 5

Int he 1950s to 60s, quality evolved into a broader discipline. What are the 4 elements that contributed to this growth?

Answer 5

1. Quantifying the costs of quality
2. Total quality control
3. Reliability engineering
4. Zero defects

Question 6

Joseph Juran published the first edition of what book?

Answer 6

Quality Control Handbook

Question 7

The Department of Defense published a report on reliability engineering which ultimately resulted in which practice?

Answer 7

FMEA

Question 8

The manufacturing of what led to the implementation of the “zero defects” program?

Answer 8

Pershing missile for the US Army

Question 9

Quality was redefined in the 60s to 80s with what 4 elements?

Answer 9

1. Customers have the final say on how well a product meets their expectations
2. Satisfaction is related to competitive offerings
3. Satisfaction is former over the product lifetime
4. A composite of attributes is needed to provide the most satisfaction

Question 10

What was the US company that suffered extreme competition from others who produced higher quality products at a lower cost?

Answer 10

Motorola

Question 11

When did the Quality Control/ Statistical Control Era take place?

Answer 11

1924 to 1950

Question 12

Who/What are key during the Quality Control/Statistical Control Era?

Answer 12

Shewhart and Bell Labs, WWII demands

Question 13

When did the Quality Assurance Era take place?

Answer 13

1950 to 1963

Question 14

Who/What are key during the Quality Assurance Era?

Answer 14

Joseph Juran and Quality Control Handbook, Zero defects, Department of Defense report

Question 15

When did the Strategic Quality Management Era take place?

Answer 15

1963-1970

Question 16

When did the Six Sigma Era take place?

Answer 16

1960s to present

Question 17

What is the first Era identified by David Garvin?

Answer 17

Inspection Era

Question 18

Who makes up the Pre-Inspection Era?

Answer 18

Craftsmen and guilds

Question 19

Which country took the lead in applying and being successful at quality control?

Answer 19

Japan

Question 20

Japanese companies turned to which American quality experts to learn quality concepts?

Answer 20

Deming and Juran

Question 21

Who are some Japanese quality experts?

Answer 21

Taguchi and Ishikawa

Question 22

What is a major technique in the Strategic Management Era?

Answer 22

QFD - Quality Function Deployment

Question 23

What is Quality Function Deployment?

Answer 23

A flexible and comprehensive group decision making technique that result in visible graphs and matrices that can be reused for future product/service deployments.

Question 24

Who was QFD developed by?

Answer 24

Drs. Akao and Mizuno

Question 25

What is the Ishikawa diagram also known as?

Answer 25

Fishbone diagram

Question 26

What is Inspection associated with?

Answer 26

Mistakes and errors detected after production

Question 27

What is Statistical Control associated with?

Answer 27

Reducing defects by controlling the processes that produced the products

Question 28

What is Quality Assurance associated with?

Answer 28

Total quality control and top management taking responsibility for quality throughout the organization

Question 29

What is Strategic Management associated with?

Answer 29

Quality being defined from the customer's point of view and the organizations strategy being centered on quality

Question 30

Who is credited with started the modern quality improvement movement?

Answer 30

Deming

Question 31

What was Deming's theory?

Answer 31

Management is key - 85% of problems are due to the system, only 15% are due to employees. Deming has famous 14 points for management.

Question 32

What was one of the first American corporations to seek help from Deming?

Answer 32

Ford Motor Company

Question 33

What is Six Sigma?

Answer 33

A continuous improvement tool, the best of the best, major components are culture of organization, improvement tools, and support systems for the tools.

Question 34

What is Lean Thinking?

Answer 34

A continuous improvement tool, focuses on removal of waste in space, storage, inspection, rework, transportation, and work movement

Question 35

What is 5S?

Answer 35

A continuous improvement tool, work place organization and standardization, Sort, Set in Order, Shine, Standardize, Sustain

Question 36

What is Kaizen?

Answer 36

Continuous improvement, process-oriented

Question 37

What is a quality circle?

Answer 37

A volunteer group for making improvements in an area of the company

Question 38

What is Value Stream Mapping?

Answer 38

A lean thinking tool used to create a material and information flow map of a product of process. Maps the flow of products from raw material through finished product.

Question 39

What is the Theory of Constraints?

Answer 39

Focuses on system improvement by finding the weakest link of the system (constraint) and correcting it.

Question 40

What is robustness?

Answer 40

Resistance to the effect of variation by some factor.

Question 41

What does Taguchi consider to achieve robustness?

Answer 41

1. System design 2. Parameter design 3. Tolerance design

Question 42

What are the 3 primary factors that control a product process, from Taguchi's robustness concept?

Answer 42

1. Control factors - predictor variable that is controlled 2. Signal factors - strongly affect response of process but are controllable and have little effect on variation 3. Noise factors - predictor variable that is hard to control or is not desired to be controlled

Question 43

What is the signal to noise ratio?

Answer 43

Quantifies the effect of variation in controllable factors on the variation in the process output.

Question 44

What function are S/N ratio calculations derived from?

Answer 44

Quality loss function

Question 45

What is the quality loss function?

Answer 45

There is an increasing loss (both for producers and society) which is a function of the deviation or variability from the ideal or target value of any parameter.

Question 46

What is Poka-Yoke?

Answer 46

Japanese term that means "to avoid inadvertent errors". Error proofing - prevent errors by designing the manufacturing process, tools, etc that an operation cannot be performed incorrectly

Question 47

What are the 6Ms in a fishbone diagram?

Answer 47

Man, Method, Mother nature, Materials, Measurements, Machines

Question 48

What ISO standards are the foundation for the Quality Management System?

Answer 48

ISO 9000 standards, 9001, 9004, 19011

Question 49

What is the first step in strategic planning?

Answer 49

Analysis

Question 50

What is benchmarking?

Answer 50

The process of identifying best practices in organizations with comparable processes or comparable customer issues for the purpose of determining the current state and a desired future state.

Question 51

What are the parts of benchmarking, as a process?

Answer 51

1. Planning 2. Analysis 3. Integration 4. Action 5. Maturity

Question 52

What are the four benchmarking levels?

Answer 52

1. Internal 2. Competitive 3. Functional 4. Generic

Question 53

What are process performance metrics?

Answer 53

Establish the process's current situation, compare current status to target

Question 54

What is Defects per Unit (DPU)?

Answer 54

The measure of capability for discrete data, found by dividing the number of defects by the number of units - a measurement of yield

Question 55

How can you analyze DPU?

Answer 55

Create Pareto chart or DPU histogram

Question 56

What is Parts Per Million (PPM)?

Answer 56

A measurement that is expressed by dividing the data set into 1 million equal parts - DPU x 1,000,000