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CQE > Part 5: Continuous Improvement > Flashcards

Part 5: Continuous Improvement Flashcards

1
Q

A team at a cell phone manufacturer would like to reduce the number of defects in the manufacture of their cell phones. They identify potential defects of the cell phone. What quality control tool is most appropriate to determine the most frequent defects?

A) Pareto Chart
B) Scatter diagram
C) Flowchart
D) Control Chart

A

A) Pareto Chart

Used to identify the most frequent issues in a process, 80/20 rule.

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2
Q

A team at a radiology clinic in a hospital wants to improve patient flow in their clinic. Before making changes to their process, the team discusses potential causes of disruptions in the patient flow. Which quality control tool will best help this team organize this information?

A) Flow Chart
B) Scatter diagram
C) Cause and effect diagram
D) Check sheet

A

C) Cause and effect diagram

Also called fishbone or Ishikawa diagrams. They are used to identify all major and minor factors that contribute to a problem. These diagrams can help the team identify the best opportunities for improvement in patient flow in the clinic

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3
Q

The team in the radiology clinic has collected data on patient visit time. The team suspects that the data are heavily skewed. Which of the following quality control tools would be the most appropriate to confirm the team’s suspicions?

A) Histogram
B) Scatter Diagram
C) Pareto Chart
D) Control Chart

A

A) Histogram

They provide a visual depiction of the shape and spread of the data and can therefore help the team determine whether the data are skewed, symmetric, bimodal, etc.

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4
Q

A team at a manufacturing facility is in the beginning stages of a performance improvement project to reduce the number of defects in a toy they produce. he team would like to collect data in order to decide the best opportunities for improvement. Which quality control tool is most appropriate to organize this data?

A) Flow Chart
B) Check Sheet
C) Scatter diagram
D) Histogram

A

B) Check Sheet

(Tally sheet) These are useful tools for summarizing counts of events, for example the count of different types of defects. The data collected from a check sheet can then be graphically represented.

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5
Q

A team at a bank want to improve the time it takes to process a loan application. In order to identify any bottlenecks in the process or targets for improvement, which quality control tool is most appropriate to use?

A) Pareto chart
B) Check sheet
C) Scatter Diagram
D) Flow Chart

A

D) Flow Chart

They are a graphical representation of the process and can help identify areas for improvements (such as bottlenecks)

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6
Q

The bank has implemented changes to their loan application process and would like to monitor their improvement to ensure they are sustained. Which of the following quality control tools would best help this effort?

A) Control Chart
B) Flow Chart
C) Check Sheet
D) Scatter diagram

A

A) Control Chart

These can be used to monitor quality characteristics, in this case time for processing. A time that plot beyond the control limits will indicate a special case has occurred. This alert will help the team correct the problem and to maintain their improvements.

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7
Q

A team suspects that two variables are related. Which of the following quality control tools will help them determine this?

A) Histogram
B) Flowchart
C) Pareto chart
D) Scatter diagram

A

D) Scatter Diagram

These can graphically depict the relationship between two continuous variables

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8
Q

A project team in a company comprises a large group of employees from different departments. The project has many complex components that depend on the progress of the various departments. Which of the following tools would help this team maintain a schedule for their project?

A) Prioritization Matrix
B) Activity network diagram
C) Tree diagram
D) Interrelationship Digraph

A

B) Activity network diagram

These help to organize complex schedules or sequences or events. These diagrams, in particular, can help with time scheduling and help avoid bottlenecks.

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9
Q

A clinic in a hospital is beginning a project to improve patient wait times. The project team is determining critical to quality factors. Which tool would be most appropriate to use?

A) Value stream map
B) Cause and effect diagram
C) PVC diagram
D) SIPOC diagram

A

D) SIPOC diagram

This is a process map that contains information on the Suppliers, Inputs, Outputs, and Customers of a process. The diagram helps to capture the voice of the customer and the critical to quality factors.

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10
Q

A national print and copy company is considering changing the layout of their stores across the country to better serve their customers. The store is in the early phase of implementing their rollout plan for these changes. Which of the following tools would help the company evaluate their rollout plan to ensure there are minimal disruptions?

A) Matrix diagram
B) Process decision program chart
C) Activity network diagram
D) Prioritization matrix

A

B) A process decision program chart (PDPC)

This would help the company assess their national rollout plan at a high level since they are at the beginning phases of there implementation plan. These charts help to determine potential disruptions to a process plan so that the company can prepare for any necessary contingency plans.

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11
Q

An accident has recently occurred in a factory’s shipping area. A team was put together to analyze potential actions that could lead to similar accidents. The goal is for the team to help determine the risk associated with these actions and to prevent future accident from occurring. Which quality tool would help this team visualize this scenario?

A) Fault Tree
B) Affinity Diagram
C) Matrix Diagram
D) Process decision program chart

A

A) Fault Tree

Provides visualization of hierarchical relationships of events that lead to some failure (or other undesirable final outcome). The team here wishes to determine other potential actions that can lead to a similar accident. The fault tree would help the team identify and communicate other potential causes of the accident. The fault tree would also provide a means to qualify the risks of these potential causes.

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12
Q

A management team has a brainstorming meeting to identify opportunities to improve communication within their department. Which quality tool will best help them organize al the ideas generated by the team?

A) Tree diagram
B) Matrix diagram
C) Affinity diagram
D) Activity network diagram

A

C) Affinity diagram

These are used to help a group of people organize or summarize facts, opinions, or ideas. Often, these types of diagrams are built using stick notes that are grouped into common these or categories.

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13
Q

Which of the following tools is common in quality function deployment and used to map customer requirements with technical specifications of a product?

A) Prioritization matrix
B) Activity network diagram
C) Matrix diagram
D) Interrelationship digraph

A

C) Matrix diagram

These are used to display qualitative relationships between two sets of characteristics or factors. Therefore, these diagrams are common in quality function deployment because they clearly display the relationships between customer requirements and a product’s technical specifications.

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14
Q

A medical team meets to discuss potential cause and effect relationships of actions that could lead to unfavorable outcomes during a patient surgical operation. The team consists of nurses, doctors, physician assistants, and technologists. Which of the following tools would best help this team visualize and hopefully identify factors that cause unfavorable outcomes?

A) Affinity diagram
B) Interrelationship digraph
C) Prioritization matrix
D) Activity network diagram

A

B) Interrelationship digraph

Theses provide a means to identify sequential or cause and effect relationships of a problem or situation.

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15
Q

A cell phone manufacturer is developing a new cell phone. The research and development team has been given several required components of the phone, but have not decided on a design plan. Which of the following quality tools would help this team explore potential design plans for the new cell phone.

A) Fault tree
B) Prioritization matrix
C) Concept fan
D) Process decision program chart

A

C) Concept fan

This is a type of tree diagram that allows a team to explore alternate concepts that achieve the same goals or requirements.

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16
Q

The research and development team have now proposed several designs for the new cell phone. The team is now considering which of the designs to pursue to build a prototype. Which of the following tools would best help the team reach a decision on which of the designs to use?

A) Prioritization matrix
B) Affinity diagram
C) Interrelationship digraph
D) Process decision program chart

A

A) Prioritization Matrix

They are useful in the decision phase since they allow us to make relative comparisons of different ideas or concepts with consistent criteria.

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17
Q

A team in the packing department of a shoe company noticed some inefficiencies in their packing process. The team first reduced the amount of walking employees had to do my moving the labeling station next to the packing station. The tam continued to make incremental changes to their process, each of which led to a small improvement of the process. Which improvement technique has this team made use of?

A) Six Sigma
B) Total Quality Management (TQM)
C) Kaizen
D) Plan-Do-Check-Act

A

C) Kaizen

The packing team has made several minor changes to their process, each of which led to a small improvement This describes kaizen, a methodology that encourages employees to make incremental changes continually to improve a process. Each change may not make a larger improvement, but does help employees.

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18
Q

In the PDCA cycle, in which stage of this improvement method does a team define the problem and develop an action plan?

A) P
B) D
C) C
D) A

A

A) P - Plan

In the Plan phase of the PDCA cycle, the quality team decides/plans on a potential change to the process.

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19
Q

Which of the following continuous improvement methods focuses on a business’s customer, quality built into the work culture, and strong leadership involvement in quality efforts?

A) Kaizen
B) TQM
C) PDCA
D) Theory of Constraints (TOC)

A

B) TQM

Total quality management (TQM) is an organization wide quality program that focuses on customers involvement in determining quality, employees obligation to quality, and strong leadership from upper management in quality improvement efforts.

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20
Q

A quality team in a semiconductor factory, using the PDCA cycle, has proposed a change to their process. They have implemented the change and are currently analyzing the results. In which step of the PDCA cycle is this quality team.

A) P
B) D
C) C
D) A

A

C) C - Check

The quality team has already implemented the proposed change and are analyzing the results. This describes the CHECK step of the PDCA. In this step, the quality team should carefully analyze the results of their change to determine whether the change was successful or not.

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21
Q

What is the primary goal of kaizen improvement?

A) Eliminate waste
B) Reduce the number of defects produced in a process
C) Redesign a process to make large improvements in quality.
D) Make small incremental changes to a process

A

D) Make small incremental changes to a process

The primary goal is for employees to make continual, incremental changes to a process to achieve small improvements.

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22
Q

A product in a shipping company goes through many sub-processes as it is shipped to customer. Customer were experiencing long wait times until their product arrived. The shipping company examined their current process and discovered that packing the product was the slowest sub process. The and discovered that packing the product was the slowest sub process. the company decided to focus their improvement efforts on this sub process. Which of the following improvement methods does this scenario describe?

A) TOC
B) TQM
C) Kaizen
D) PDCA

A

A) TOC

Theory of constraints focuses on the weakest process in a string of processes to improve the overall system. In the shipping company, product cannot be delivered more quickly unless the bottleneck in packing is improved.

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23
Q

What is one of the primary goals of Six Sigma as a continuous improvement method?

A) Eliminate waste in a process
B) Reduce the number of defects produced in a process
C) Redesign a process to make large improvement in quality
D) Make small, incremental changes to a process.

A

B) Reduce the number of defects produced in a process

24
Q

What is the primary strength of the theory of constraints?

A) Incremental changes to a process can lead to great improvements.
B) A system cannot improve by focusing improvement solely on individual process
C) Team-based projects are more effective than individual-based projects.
D) A data-driven improvement strategy is necessary for process improvement.

A

B) A system cannot improve by focusing improvement solely on individual processes.

TOC focuses on the weakest link in a chain of processes. Therefore, it’s a systems approach to process improvement. Focusing on an individual process in a chain of many will not provide the best result.

25
Q

In Six Sigma, what value of sigma (σ), the standard deviation of a process, is used to account for typical shifts or drifts from the mean?

A) +/- 2σ
B) +/- 6σ
C) +/- 3σ
D) +/- 1.5σ

A

D) +/- 1.5σ

26
Q

A restaurant with a particularly large kitchen and lots of empty space had long delays preparing and serving patrons. After careful planning, the restaurant completely redesigned their kitchen and ordering procedures, and immediately saw a vast decrease in serving times. They also noticed an increase in customers after this change. Which of the following improvement methods does this scenario describe?

A) PDCA
B) TQM
C) Reengineering
D) Kaizen

A

C) Reengineering

Reengineering a process involves a complete and radical redesign of a procedure. In this case, the restaurant has completely redesigned their kitchen and ordering procedure in order to achieve large improvement in their serving time and sales - an example of reengineering.

27
Q

What value of Cp is associated with a six sigma quality level process?

A) 1.33
B) 1.51
C) 2.0
D) 2.5

A

C) 2.0

Six sigma quality level process has a Cp value of 2.0 and a Cpk value of 1.5.

28
Q

Which of the following methods is the most effective way to implement Six Sigma in an organization?

A) Start a Six Sigma program
B) Develop a Six Sigma infrastructure.
C) Roll out Six Sigma methods on a project-by-project basis
D) None of the above.

A

B) Develop a Six Sigma infrastructure.

One of the drawbacks of Six Sigma is that they often lack buy-in across the entire organization because they focus on the tools only. Therefore, results tend to be very limited. A Six Sigma infrastructure provides employees not just with the tools, but also with the problem-solving methods for specific projects. identified by management.

29
Q

Which of the following tools is typically used first in a lean system?

A) 5S
B) Kanban
C) Value Stream Map
D) Visual Control

A

C) Value Stream Map

The goal of a lean system is to eliminate waste from a process. The first step is to identify opportunities for improvement which can be found using a value stream map. Value stream maps are a visual representation of all the steps in a process, including information about timing. Value stream maps also identify the value added and non value added activities in a process.

30
Q

A restaurant is analyzing their current work flow. Employees in the restaurant must walk back and forth throughout the kitchen to retrieve various cooking tools during preparation of a meal. How might the restaurant classify this action?

A) Waiting
B) Excess motion
C) Excess movement of material
D) Excess processing

A

B) Excess motion

The employees walk more than they should to retrieve supplies. This is an example of waste - specifically, that of excess motion. A redesign of the kitchen or a new layout that moves the cooking tools closer to where they are required could help reduce the excess walking and shorten the time it takes to prepare the meal.

31
Q

The restaurant is also examining their front of house operations. They found that where is frequently a long line of customer standing by the chicken counter while staff turn over tables. What king of waste is occurring at the front of the house at this restaurant?

A) Waiting
B) Excess movement of material
C) Defect correction
D) Excess motion

A

A) Waiting

32
Q

After creating a value stream map of a process, on which steps in the process should a quality team focus their efforts?

A) Value-added activities
B) Standardized work
C) Non-value-added activities
D) All of the above

A

C) Non-value-added activities

33
Q

What is the primary goal of 5S?

A) To radically change a process
B) To make slow, incremental changes to a process
C) To organize the workplace environment
D) To reduce defects produced in a process

A

C) To organize the workplace environment

34
Q

A toy company paints a certian toy white by default. The toys are then painted other colors as requested by customers. What type of waste is this?

A) Defect correction
B) Excess motion
C) Excess processing
D) Excess production

A

C) Excess processing

35
Q

What is the main benefit of implementing a kanban system?

A) The weakest step in a chain of processes is improved
B) There is less inventory and a smoother flow of supplies
C) The workplace is better organized
D) Products are not process until a customer places an order.

A

B) There is less inventory and a smoother flow of supplies.

36
Q

A deli has newly instituted a few changes to their work area. The workers now have a schedule for cleaning their workstations, have standardized practices, and have created designated locations for all their equipment. What improvement method has this deli employed?

A) Kanban
B) visual control
C) Define, measure, analyze, improve, control
D) 5S

A

D) 5S

37
Q

A factory uses an illuminated indicator light when a certain process is in progress. This is an example of:

A) waste
B) standardized work
C) visual control
D) kanban

A

C) Visual control

38
Q

In a convenience store, items are stacked in front of a card that lists details on the product, including the location of additional boxes in their storage room as well as a number to call to reorder. What type of system has this convenience store implemented?

A) Kaizen
B) 5S
C) TQM
D) Kanban

A

D) Kanban

39
Q

To complete a process, parts must travel through 4 departments located in different areas of a manufacturing facility. What type of waste is this?

A) Excess movement of material
B) Defect correction
C) Excess processing
D) Excess motion

A

A) Excess movement of material

40
Q

A manufacturing facility has painted arrows on the floor to show the flow of products through the facility. Which lean tool has this facility implemented?

A) Kanban
B) Visual control
C) 5S
D) Kaizen

A

B) Visual control

41
Q

The principle that each process should be done the same way, every time, by every employee is called:

A) Kanban
B) 5S
C) Standardized work
D) Pull system

A

C) Standardized work

42
Q

Which of the following lean tools measures the time from the last good part of one type to the first good part of the next?

A) Takt time
B) Single-minute exchange of die (SMED)
C) Cycle time
D) 5S

A

B) Single-minute exchange of die

43
Q

What is the difference between cycle time and takt time?

A) Cycle time incorporates data from suppliers; takt time does not.
B) Takt time is based on customer demand; cycle time measures the time to complete an activity
C) Takt time measures the time to complete an activity; cycle time incorporates customer demand.
D) There is no difference they both measure the same time.

A

B) Takt time is based on customer demand; cycle time measures the time to complete an activity.

44
Q

A shoe company routinely makes more components than are needed within assembling their product. What time of waste is this?

A) Inventory
B) Overproduction
C) Excess movement of material
D) Excess processing

A

B) Overproduction

45
Q

A university has released a document detailing all the require actions instructors should take when proctoring an exam. All instructors across the university are expected to follow these directions. What tool has the university implemented?

A) Standardized work
B) 5S
C) Visual control
D) Value stream map

A

A) Standardized work

46
Q

A company has received an order for 550 items that they need to produce in an eight-hour workday. In seconds, what is the takt time for this product?

A) 0.87 seconds
B) 68.75 seconds
C) 52.36 seconds
D) None of the above

A

C) 52.36 seconds

47
Q

A caterer had a lunch order for a group of 50 people and had two hours to complete the order. However, after two hours, the caterer was only able to complete 45 lunch. Which of the following might be true?

A) Cycle time < Takt time
B) Cycle time > Takt time
C) Cycle time = Takt time
D) None of the above

A

B) Cycle time > Takt time

48
Q

A radiation clinic treats patients with different types of cancer. The position of each patient on the table is different depending on the type of cancer. Therefore after one patient is treated, another patient, requiring a different set up than the previous patient arrives. Which lean tool would best help a quality team in this clinic?

A) Cycle time
B) 5S
C) SMED
D) Kanban

A

C) SMED

Single-minute exchange of die

49
Q

A supplier has received an order from one of their customer. They must complete an order of 750 items in a daytime shift that is 10 hours long. The cycle time for this process is 50 seconds. Without any changes in their current production, will the supplier be able to meet the customer’s demands?

A) No, cycle time < takt time
B) Yes, cycle time < takt time
C) No, cycle time > takt time
D) Yes, cycle time > takt time

A

C) No, cycle time > takt time

50
Q

What is one of the most common causes of failures in problem solving?

A) Poor definition of the problem
B) Multifunctional teams
C) Selecting projects that require the least amount of effort
D) The project charter

A

A) Poor definition of the problem

51
Q

During the correction phase of the corrective action cycle, which of the following is instrumental in success?

A) A clear problem statement
B) Team meetings
C) Creativity
D) Cause and effect diagram

A

C) Creativity

52
Q

A team in a food production plant has recently instituted changed to one of their bottling processes. What should the team do to avoid the process backsliding?

A) Identify key metric in the process to monitor
B) Specify who performs each task in the process
C) Institute process certification for operators
D) All of the above

A

D) All of the above

53
Q

In which phase of the corrective action cycle does a team seek to continuously improve the performance of a process by holding regular reviews of the process?

A) Problem identification
B) Correction
C) Recurrence control
D) Effectiveness assessment

A

D) Effectiveness assessment

54
Q

Which of the following is another name for poka-yoke?

A) Waste
B) Error proofing
C) Orderliness
D) Pull system

A

B) Error proofing

55
Q

A food company produces cookie dough. All a customer must do is slice the cookie dough and bake it in their oven for approximately 8 minutes. The company’s cookie dough recipe was developed so that the cookie quality is not vastly affected by difference in ovens, elevation, or other environmental conditions. This cookie dough is an example of:

A) Poka-yoke
B) Reengineering
C) Robust design
D) Kaizen

A

C) Robust design

56
Q

A printer that will only run when the paper trays are closed is an example of which of the following concepts?

A) Robust design
B) Poka-yoke
C) Lean process
D) Kaizen

A

B) Poka-yoke

57
Q

Before the next step in a process, a sorting machine is used to remove components that are above the upper specification limit. What principle or error-proofing is implemented in this process?

A) Elimination
B) Replacement
C) Facilitation
D) Detection
E) Mitigation
A

D) Detection

CQE (8 decks)

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