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FNH 403 > Quality Tools > Flashcards

Quality Tools Flashcards

1
Q

What are the 7 quality tools?

A
  1. Process map (flow process)
  2. Process control chart
  3. Pareto diagram/chart
  4. Cause and Effect Diagram (Fishbone diagram)
  5. Histogram
  6. Check Sheet
  7. Scatter chart
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2
Q

What is the objective of brainstorming?

A

Generate lots of ideas

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3
Q

What is the objective of a cause and effect diagram?

A

Graphically display all possible causes

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4
Q

What is the objective of a flow chart?

A

Identify the sequence of a process

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5
Q

What is the objective of a check sheet?

A

Validate how frequently a cause occurs

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6
Q

Histograms help to determine percent of product or service not meeting customer requirements.
True or False?

A

False.

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7
Q

Histograms display large amounts of data that are difficult to interpret in tabular form.
True or False?

A

True.

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8
Q

Histograms show the relative frequency of occurence of the various data times.
True or False?

A

True.

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9
Q

Histograms reveal the centering, variation, and shape of the data.
True or False?

A

True.

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10
Q

Scatter diagrams are useful in problem solving because they show relationships between variables.
True or False?

A

True.

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11
Q

Scatter diagrams are useful in problem solving because they eliminate the trivial many.
True or False?

A

False.

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12
Q

Scatter diagrams are useful in problem solving because they display the significant few.
True or False?

A

False.

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13
Q

Scatter diagrams are useful in problem solving because they highlight assignable causes.
True or False?

A

False.

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14
Q

Use the following data to prepare a Pareto chart using Excel.
A project team is studying the downtime of a soft-drink bottling line. Data analysis, in thousands of dollars, for a 3-month period are:
back pressure regulator, 30;
adjust feed worm, 15;
jamming of copper head, 6;
lost cooling, 52;
valve replacement, 8;
and other, 5.
What is the cumulative frequency from your Pareto diagram for each cause?

A
  • Start with the largest problem
  • Sum the frequencies
  • Take the % of the largest problem
  • Take the % of the next largest problem and sum to the first (=cumulative)
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15
Q

Process flow diagrams would be most useful to prioritize customer complaints for the past several years.
True or False?

A

False.

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16
Q

Control charts would be most useful to prioritize customer complaints for the past several years.
True or False?

A

False.

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17
Q

Pareto charts would be most useful to prioritize customer complaints for the past several years.
True or False?

A

True.

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18
Q

Histograms would be most useful to prioritize customer complaints for the past several years.
True or False?

A

False.

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19
Q

Twenty samples of size 6 were collected for a variable measurement.
Determine the upper control limit (UCL) and lower control limit (LCL) for an R-chart if the sum of the sample ranges equals 88.0.

A

Rbar = 88/20 = 4.4
D4 = 2.004
D3 = 0
4.4 x 2.004 = 8.8176
4.4 x 0 = 0.0000
UCL = 8.8176 | LCL = 0.0000

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20
Q

A process is deemed out of control when random variation is present.
True or False?

A

False.

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21
Q

A process is deemed out of control when data varies around the mean.
True or False?

A

False.

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22
Q

A process is deemed out of control when special causes are present.
True or False?

A

True.

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23
Q

A process is deemed out of control when common causes are present.
True or False?

A

False.

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24
Q

Control charts show what kind of data the competition is using.
True or False?

A

False.

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25
Q

Control charts show how the average data compares to a desired average.
True or False?

A

True.

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26
Q

Control charts show what the customers are buying the most.
True or False?

A

False.

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27
Q

Control charts show the maximums and minimums of the data.
True or False?

A

False.

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28
Q

A process that is in “control” means the process is consistent and that variation is due to common causes. A process that is in control always meet customer specifications.
True or False?

A

False.
Do not confuse control limits with customer specification limits. Specification limits are related to customer requirements, not process variation.

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29
Q

A process that is in “control” means the process is consistent and that variation is due to common causes. A process that is in control does not always meet customer specifications.
True or False?

A

True.
Do not confuse control limits with customer specification limits. Specification limits are related to customer requirements, not process variation.

30
Q

Give 3 reasons to use brainstorming.

A
  • When a broad range of options is desired
  • When creative, original ideas are desired
  • When participation of the entire group is desired
31
Q

What are the rules of brainstorming? [4]

A
  • No criticism, no evaluation, no discussion of ideas
  • All ideas are valid and worthy of consideration
  • All ideas are recorded
  • Piggybacking—combining, modifying, expanding others’ ideas—is encouraged
32
Q

Give 2 reasons to use a fishbone (i.e., cause and effect) diagram.

A
  • When identifying possible causes for a problem
  • When a team’s thinking tends to fall into ruts
33
Q

What are generic headings to begin a cause-and-effect diagram? [6]

A
  • Methods
  • Machines (equipment)
  • People (manpower)
  • Materials
  • Measurement
  • Environment
34
Q

Give 3 reasons when use of a check sheet is appropriate.

A
  • When data can be observed and collected repeatedly by the same person or at the same location
  • When collecting data on the frequency or patterns of events, problems, defects, defect location, defect causes, or similar issues
  • When collecting data from a production process
35
Q

What are the 6 steps in a check sheet procedure?

A
  1. Decide what event or problem will be observed. Develop operational definitions.
  2. Decide when data will be collected and for how long.
  3. Design the form. Set it up so that data can be recorded simply by making check marks or X’s or similar symbols and so that data do not have to be recopied for analysis.
  4. Label all spaces on the form.
  5. Test the check sheet for a short trial period to be sure it collects the appropriate data and is easy to use.
  6. Each time the targeted event or problem occurs, record data on the check sheet.
36
Q

Give 5 reasons to use a control chart.

A
  1. When controlling ongoing processes by finding and correcting problems as they occur
  2. When predicting the expected range of outcomes from a process
  3. When determining whether a process is stable (in statistical control)
  4. When analyzing patterns of process variation from special causes (non-routine events) or common causes (built into the process)
  5. When determining whether your quality improvement project should aim to prevent specific problems or to make fundamental changes to the process
37
Q

What is the basic procedure of the control chart? [4]

A
  1. Choose the appropriate control chart for your data.
  2. Determine the appropriate time period for collecting and plotting data.
  3. Collect data, construct your chart and analyze the data.
  4. Look for “out-of-control signals” on the control chart. When one is identified, mark it on the chart and investigate the cause. Document how you investigated, what you learned, the cause and how it was corrected.
38
Q

Describe the basic components of a control chart.

A
  • The control chart is a graph used to study how a process changes over time.
  • Data are plotted in time order.
  • A control chart always has a central line for the average, an upper line for the upper control limit, and a lower line for the lower control limit.
  • These lines are determined from historical data.
  • By comparing current data to these lines, you can draw conclusions about whether the process variation is consistent (in control) or is unpredictable (out of control, affected by special causes of variation).
39
Q

How are control charts for variable data used?

A
  • In pairs
  • The top chart monitors the average, or the centering of the distribution of data from the process.
  • The bottom chart monitors the range, or the width of the distribution.
  • If your data were shots in target practice, the average is where the shots are clustering, and the range is how tightly they are clustered.
40
Q

What is a flow chart?

A
  • A flowchart is a picture of the separate steps of a process in sequential order.
  • It is a generic tool that can be adapted for a wide variety of purposes, and can be used to describe various processes, such as a manufacturing process, an administrative or service process, or a project plan.
41
Q

What elements may be included in a flowchart? [6]

A
  • A sequence of actions
  • materials or services entering or leaving the process (inputs and outputs)
  • decisions that must be made
  • people who become involved
  • time involved at each step
  • and/or process measurements.
42
Q

List 6 reasons to use a flowchart.

A
  • To develop understanding of how a process is done
  • To study a process for improvement
  • To communicate to others how a process is done
  • When better communication is needed between people involved with the same process
  • To document a process
  • When planning a project
43
Q

What are the 6 steps in a basic flowchart procedure?

A
  • Define the process to be diagrammed. Write its title at the top of the work surface.
  • Discuss and decide on the boundaries of your process: Where or when does the process start? Where or when does it end? Discuss and decide on the level of detail to be included in the diagram.
  • Brainstorm the activities that take place. Write each on a card or sticky note.
  • Arrange the activities in proper sequence.
  • When all activities are included and everyone agrees that the sequence is correct, draw arrows to show the flow of the process.
  • Review the flowchart with others involved in the process (workers, supervisors, suppliers, customers) to see if they agree that the process is drawn accurately.
44
Q

What is a histogram?

A

A frequency distribution shows how often each different value in a set of data occurs.

45
Q

When do you use a histogram? [7]

A
  • The data are numerical
  • You want to see the shape of the data’s distribution, especially when determining whether the output of a process is distributed approximately normally
  • Analyzing whether a process can meet the customer’s requirements
  • Analyzing what the output from a supplier’s process looks like
  • Seeing whether a process change has occurred from one time period to another
  • Determining whether the outputs of two or more processes are different
  • You wish to communicate the distribution of data quickly and easily to others
46
Q

Give 4 reasons to use a Pareto chart.

A
  • When analyzing data about the frequency of problems or causes in a process
  • When there are many problems or causes and you want to focus on the most significant
  • When analyzing broad causes by looking at their specific components
  • When communicating with others about your data
47
Q

What is processing capability?

A

Process capability is defined as a statistical measure of the inherent process variability of a given characteristic. You can use a process-capability study to assess the ability of a process to meet specifications.

48
Q

Give three reasons to use a scatter diagram.

A
  • When you have paired numerical data
  • When your dependent variable may have multiple values for each value of your independent variable
  • When trying to determine whether the two variables are related
49
Q

Give 2 reasons for collecting data.

A
  • To identify and solve problems that cause inferior products
  • To monitor and modify processes
50
Q

Most problems are …

A

Most problems are made up of smaller problems, each with several causes

51
Q

Describe the process of data collection.

A

Cyclic

52
Q

What is variable data?

A

Data that can be measured

53
Q

What is attribute data?

A

Data that can be counted
E.g., # of dented cans

54
Q

How do we ensure we’re collecting good data? [4]

A
  • We need to make sure that the data being collected is what we need
  • What is the purpose of collecting the data?
  • If we aren’t sure why we are collecting the data maybe the data doesn’t represent the situation we want to look at
  • We need to make sure that the instrument we are using is accurate and appropriate
55
Q

What does a check sheet aim to do?

A

To allow a team to systematically record and compile data from historical sources, or observations as they happen, so that patterns and trends can be clearly detected and shown

56
Q

What does a good check sheet design include [4] and ensure?

A
  • Present data in form that is quickly and easily used and analyzed
  • Individualize for the situation
  • User friendly
  • Include time and location
    * Ensure that the data are collected carefully and accurately for process control and problem solving
57
Q

Give 4 things checklists can be used to record.

A
  • Sanitary condition of equipment / facilities before processing starts
  • Routine equipment maintenance checks
  • Calibration of equipment
  • Batch reports
58
Q

How is a check list constructed and used? [4]

A

Step 1 Agree on Definitions
Step 2 Plan the Data Collection
Step 3 Design the Check Sheet
Step 4 Collect the Data

59
Q

Describe 3 key success behaviours associated with check sheets.

A
  • Reassure data collectors that “negative” data will not result in blame or poor performance reviews
  • Train the data collectors
  • Remember “ease of use” when designing the form
60
Q

What are the key steps for a successful quality control program?

A
  • Ability to recognize problems
  • Trace root causes of problems
  • Implement corrective actions
61
Q

What are 4 mistakes decision makers make when designing quality control programs?

A
  • Do not specify the purpose of the decision
  • Act without looking at the alternatives
  • Make poor use of available information
  • Fail to look at consequences of their actions and assess its future costs
62
Q

What are the elements of the scientific method that relate to elements of the problem analysis method?

A
  • Identify the problem
  • Gather, evaluate and summarize relevant
    existing data
  • Formulate a hypothesis
  • Design and conduct experiments
  • Evaluate hypothesis
63
Q

What are 3 basic concepts of problem analysis?

A
  • A problem can not be solved unless its cause is known
  • Every problem is a deviation from some standard of expected performance
  • A change of some kind is always the cause of the problem
64
Q

In a cause and effect diagram, explain how you would identify main cuases from level 1-3 causes.

A
65
Q

What are three advantages of a cause and effect diagram?

A
  • Enables a team to focus on the content of the problem
  • Creates a snapshot of the collective knowledge and
    consensus of a team around a problem
  • Focuses the team on causes, not symptoms
66
Q

What is the purpose of a cause and effect diagram?

A

To allow a team to identify, explore, and graphically display, in increasing detail, all of the possible causes
related to a problem or condition to discover its root causes.

67
Q

What are the 6 main causes that can be added to any fish bone diagram to get it started?

A

People
Materials
Work Methods
Environment
Equipment
Measurement

68
Q

Name 4 brainstorming methods.

A
  • Structured
  • Unstructured
  • Visual
  • Analogies/free word association
69
Q

How is the centerline calculated for X bar and R charts?

A
70
Q

How is the UCL calculated for Xbar and R charts?

A
71
Q

How is the LCL calculated for Xbar and R charts?

A

FNH 403 (9 decks)

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