PQM 101 - Production, Quality and Manufacturing Fundamentals

Identify the item that is not a characteristic of a mature process. Correct answer- The process requires further process engineering improvements. Establishing manufacturing capabilities focuses on Correct answer- manufacturing process planning and production resource planning. Producibility Engineering and Planning focuses on key processess and key product characteristics as well as: Correct answer- Identifying any new processes or materials as soon as possible and planning development concurrently with the product design. Integrated Management Planning (IMP) is __________________. Correct answer- the merging of manufacturing and production planning and development activities and quality practices Four keys to achieving quality are: Correct answer- Quality of design, conformance to requirements, fitness for use, and cost. Identify the key element(s) necessary to achieve quality products and services when performing quality assurance planning. Correct answer- All of the choices apply Select a manufacturing metric that applies during Production. Correct answer- Process variance data used to monitor and maintain process capability What is a group of activities that address process and product design and system engineering? Correct answer- Manufacturing Engineering Preparing finished products for shipment to the customer is: Correct answer- Packaging Which of the following might be considered a key product characteristic of a work boot? Check all that apply: Correct answer- Sole durability Sole traction Steel toe thickness Verification that the key processes are achieving the key product characteristics is accomplished by conducting which of the following? Correct answer- Dedicated process demonstrations A key step in the control system methodology is: Correct answer- Decide if corrective action is warranted What processes are responsible for achieving key product characteristics? Correct answer- Key Processes Which of the following is NOT an example of a material management approach (Push or Pull system)? Correct answer- DFARS What measurement is used to judge the quality of incoming material from a particular supplier? Correct answer- Purchased materials acceptance rate What is the production control method most often used in industries that process liquid or gaseous materials? Correct answer- Flow Control What is a document that lists all of the assemblies, parts, and components that make up the final product? Correct answer- Bill-of-material Why are quality systems developed? Correct answer- Because technical specifications alone do not guarantee that the customer's requirements will be consistently met A company wants to manufacture a closet door that has the following specifications: Height: 7'1", Width: 2'6", and Thickness: 1 5/8". Which of the doors below meet the manufacturer specifications? Correct answer- Height: 7'1", Width: 2'6", and Thickness: 1 5/8" Which of the following is NOT one of the steps when applying the "Concept of Control Systems"? Correct answer- Set an arbitrary value Which process may be used to verify that identified key processes are achieving the associated key product characteristics? Correct answer- Review of test article experience and process demonstrations. What type of Material Management System is "Just-In-Time"? Correct answer- Pull System Which of the following describes the DOD policy regarding a contractor's selection and use of a quality system? Correct answer- Contractors may be allowed to develop their own quality systems that meet contractual requirements; they are not restricted only to ISO/ANSI/ASQ 9000 criteria. What is continuous process improvement? Correct answer- All of the above What confirms the actions taken to achieve the target? Correct answer- Study Results What is a quick and easy way for a group to prioritize large lists without creating a "win/lose" situation? Correct answer- Multi-voting The Pareto Chart can be best described as: Correct answer- all of the above Which tool uses either a tabular and/or pictorial depiction of the collected data? Correct answer- Check Sheet What is the difference between a histogram and a scatter diagram ? Correct answer- Answers A and C. The Bell-shaped curve is a graphical representation of a set of sample data points known as Abnormal Distribution. Correct answer- False This rule is used to represent the probabilities of many common occurrences. Correct answer- Empirical Rule Being one of the most frequently used distributions, the Bell Shaped Curve is the basis for the _____________________. Correct answer- Statistical Process Control (SPC) What is a meaure that slices the bell-shaped curbe into increments of equal width, each represented in the graphic by the Greek letter Sigma? Correct answer- Standard Deviation What are the characteristics of a normal distribution? Correct answer- Approximately 68% of the data should lie within one standard deviation of the mean, about 95% of the data should lie between 2 standard deviations from the mean, approximately 99.7% of all data should lie within three deviations of the mean. What is the difference between a run chart and a control chart? Correct answer- A run chart is a graph that shows the changes in a process measurement over time that recognizes abnormal behavior in a process. A control chart is a graph that shows how a process varies over time, while identifying special causes of variation and changes in performance. What is good for preventing nonconformances and truly controlling a process, but data is hard (costly) to obtain? Correct answer- X-R What data requires collecting 10 to 20 subgroups (samples) of data and computing the subgroup statistics and control limits for the type of chart used? Correct answer- Attribute What process capability decision describes a process whose variability is greater than the specification limits and is experiencing a large number of nonconformances? Correct answer- Incapable process How are Cp and CpK related? Correct answer- Answers a and c What happens when the Cp and Cpk are the same value, and both are 1.33? Correct answer- The process is both precise and accurate. Which of the following matches each term to its correct value? (Carry out the values to the second decimal place). 1.m 2.n ll mean of X ge of R 5.A2 6.D3 7.D4 A. 2.28 B. 20 C. 0 D. 0.73 E. 4 F. 5.75 G. 46.29 Correct answer- m=20, n=4, overall mean of X=46.29, average of R=5.75, A2=0.73, D3=0, D4=2.28 Which of the following matches each term to its correct value? (Carry out the values to the second decimal place). 1.Upper Control Limit for the average of x chart 2.Lower Control Limit for the average of x chart 3.Centerline for the average of x chart 4.Upper Control Limit for the R chart 5.Lower Control Limit for the R chart 6.Centerline for the R chart A. 13.11 B. 5.75 C. 0 D. 50.49 E. 46.29 F. 42.09 Correct answer- 1-D, 2-F, 3-E, 4-A, 5-C, and 6-B Which one of the following "Tools" shows the possible relationship between one variable and another? Correct answer- Scatter Diagram Which of the following are computed from process performance data? Correct answer- Process Control Limits Which of the following Process Capability Ratios asks the question: "Is the Process Capable"? Correct answer- Cp The Shewhart Cycle or Ishikawa Circle has which of the following activities? Correct answer- All the choices apply When using the Empirical Rule (Bell-Shaped-Curve), what percent of the data can we expect to fall within 2 standard deviations? Correct answer- 95% Which type of control chart provides a good management overview, but provides little value from a troubleshooting or prevention perspective? Correct answer- p and np control chart What is a merger of computer technology and mechanical drawing? Correct answer- CAD What is a third-level system that uses computer simulated trials to project into the future and assist in decision making? Correct answer- Decision Support What are some advantages of using modeling and simulation for the DoD? A. Reduced costs for testing, training and DoD weapon acquisition B. Increased effectiveness of the design, test, and manufacturing functional specialists C. Increased real life trial and error testing D. Answers A and B E. Answers A and C Correct answer- Answers A and B Why is modeling and simulation especially important in the manufacturing process? Correct answer- Manufacturing expertise is integrated into the design process What is the purpose of prototyping? -To generate information concerning the design -To give a visual and tactile description of the design -To achieve a desirable level of functionality -All of the above Correct answer- All of the above Which characteristic sets rapid prototyping apart from other types of prototyping? Correct answer- The ability to create actual, physical models from the computer simulation models Stereolithography is: A. A mechanical drafting tool B. The most widely used rapid protoypting and manufacturing technique C. A rapid prototyping tool D. Answers B and C E. All of the above Correct answer- Answers B and C What has a variety of product lines and a significant amount of output? Correct answer- FCIM systems Why has the Army Materials Command (AMC) been so successful in utilizing FCIM at all AMC sites and in industry? -By establishing teaching factories -By teaching workshops and implementing networks to and with vendors -By sharing flexible manufacturing centers -All of the above Correct answer- All of the above Which of the following is a method for developing the technology and infrastructure to integrate various business processes within an enterprise to rapidly design, manufacture, repair, and deliver complex parts on demand? Correct answer- FCIM Which of the following is an advantage of using M&S in DOD manufacturing processes? Correct answer- Reduction of process time What is the result when a control structure is provided that creates process discipline? Correct answer- Product quality and defect free products What does the Master Production Schedule Identify? -All of the choices apply -Due date of deliverable end-items -Quantity -Configuration Correct answer- All of the choices apply The ANSI/ISO/ASQ 9000 Series is a set of three individual, but related standards on Quality Management and Quality Assurance that commonly serve as a __________ in the DOD to evaluate systems. Correct answer- Guide Which type of data is usually less expensive to collect, easier to interpret, and training is less complex? Correct answer- Attribute data Which of the following describes Cpk? Correct answer- The actual performance of a process is measured If a manufacturing process sustained a small degree of variation over time, one can assume which of the following? Correct answer- The value of sigma for the process is small The Shewart Cycle or Ishikawa Circle is which type of improvement model? Correct answer- Process Which of the following are required in order to implement an FCIM application? -All the choices apply -Automated processes -Automated material handling -Computer controls linked by Local Area Network (LAN) Correct answer- All the choices apply A weapon system developer is currently designing the production system for full-scale production. Which of the following would be a potential reason(s) for the contractor to use simulation instead of other methods of analyzing the system? Correct answer- It is not economically feasible to build a physical (actual working model) prototype of the system. What are some possible disadvantages of converting to a CAD-based system? -All of the choices apply -High initial capital investment in computers and CAD tools -Retraining of drafting personnel -Sensitive technical design data is more easily copied or stolen Correct answer- All of the choices apply What is used by decision-makers to assess if the acquisition makes good business sense, effectively implements laws and policies, and reflects priorities? Correct answer- Acquisition Strategy Which of the following does not apply to negotiated procurements? Correct answer- Used when product design is stable and requirements and specifications are adequate What type of contract and basic provisions are anticipated by the government? Correct answer- Model Contract What function would assess the offerers accounting system and document the information on the SFI 408 (acct syst)? Correct answer- Auditors One main purpose of source selection is to select a proposal which best meets the government requirements because it _________________. Correct answer- is the best value What indicates a low probability of satisfying the requirement and has significant but correctable deficiencies? Correct answer- Yellow Which of the following does not apply to source selection? -CRs identify areas in a proposal that are unclear and need clarification -Offerors and the government arrive at a common understanding of the proposal essentials during discussion and negotiation -Information for past performance evaluation is based solely on the information offerors submit with their proposals -After BAFOs have been requested, the government can no longer discuss proposals with any offerors Correct answer- Information for past performance evaluation is based solely on the information offerors submit with their proposals