9.1 When investigating TPM, which of the following would be considered one of the 6 big negative contributors to equipment effectiveness?
a. Setup and adjustments
9.2 Id the most likely result of adopting standardized work procedures:
d. They perserve know-how and expertise
9.3 There are several types of control plans. Id the appropriate control plan to be used for part mockup
9.4 A p chart:
c. Plots either the fraction or percent defective in order of time
9.5 What is a jidhoka?
d. A device that stops the machine whenever a defective is produced
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:
c. Stop the process immediately and replace the specification limits with control limits
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?
d. The control plan is a “living document” and is rarely closed
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?
b. 0, 11.36
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?
d. The complete team is the most desirable option
9.10 Standard work sheets are required for standard operations. Which element is included on the sheets?
a. Cycle time based on takt time
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?
c. Seeing and speaking
9.12 Considering that some of the following terms have benefits, which would most likely affect product quality?
a. Muda elimination and 5S
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?
c. Identifying performance gaps
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:
d. Only the range was outside control limits
9.15 The visual factory would be supported to the greatest extent by:
b. Kanban and 5S
9.16 Which of the following is a normally accepted control chart interpretation rule violation?
c. Two of three points in zone C
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?
b. At each machine in Process A
9.18 Pre-control starts a process specifically centered between:
b. Specification limits
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:
a. A change in the basic design of the product or system
9.20 Which of the following would be a device associated with the visual factory?
b. Andon board
9.21 Advantages of control charts include:
a. They can detect treads of statistical significance
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?
9.23 Control limits are set at the 3 sigma level because:
c. This level reduced the probability for looking for trouble in the process when none exists
9.24 Training needs for an individual are based on which of the following?
b. The company’s objectives and the employee’s performance
9.25 Standard work as visualized by the Japanese means:
b. Working safer and productively
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:
d. The person is not using the chart correctly
9.27 Ultimate responsibility for training is vested with:
d. The employee
9.28 The factor D4, in X-bar and R control charts is used to:
a. Determine the upper control limits of a range chart
9.29 Which of the following tools would be part of control plan development?
a. Cause-and-effect analysis
9.30 The Japanese techniques that compliment the visual factory concept are:
a. Kanban and 5S
9.31 Which of the following indicated an out-of-control condition?
c. 2 of 3 consecutive points outside the two sigma warning limits
9.32 What is the importance of the reaction plan in a control plan?
a. It describes what will happen if a key variable goes out of control
9.33 The ideal setting for training:
c. Will have environmental conditions go unnoticed by the student
9.34 The control chart that is most sensitive to variation in a measurement is:
d. X-bar and R chart
9.35 Which of the following Japanese techniques helps control machine maintenance?
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?
a. LCL= 2.0 UCL =23.4
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?
d. No conclusions may be made yet
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?
b. Chart the most important input variables associated to the CTQs
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?
3.40 Which control chart pattern best represents an in control process?
c. A ransom distribution of points on both sides of the centerline
9.41 An R chart is generally used to:
c. Determine if the process variance is in control
9.42 Which of the following elements is part of a control plan form?
c. Key input and output variables
9.43 Which of the following charts have upper control limits, but frequently lave lower control limits of zero?
d. R and sigma charts
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?
a. Becoming a substitute for written operator instructions
9.45 Standard work relies on which of the following toold?
b. 5S and Kanban
9.46 The single most important factor in establishing an effective company training effort is:
a. Top management support
9.47 An R chart is most closely related to which of the following
b. S chart
9.48 What lean technique is most widely used to make problem visible?