Deck 12: Design For Quality And Product Excellence

Question 1

Process capability is valid when measured in the presence of common cause variation.

Answer 1

True

Question 2

Most process capability index calculations are based on the assumption that the distribution of the output is normally distributed.

Answer 2

True

Question 3

The interrelationships between technical requirements are positioned in the "basement" of the House of Quality.

Answer 3

False

Question 4

The purpose of failure mode and effects analysis is to predict and prevent failures.

Question 5

The voice of the designer is the primary input to the quality function deployment process.

Question 6

Quality function deployment focuses on the supplier-manufacturer link of the value chain.

Question 7

A process capability index of 1.0 is more desirable than an index of 2.0.

Question 8

Repeatability refers to a product's ability to perform as expected over time.

Question 9

Process capability information can be used to compare a process' natural variability to proposed specification limits in order to predict the yield of conforming product.

Question 10

According to the Taguchi loss function,any deviation from nominal represents a monetary loss.

Question 11

Competitive evaluation is done after the House of Quality is completed.

Question 12

It is advocated in Six Sigma that design features and characteristics be dominated by engineering considerations rather than by customer requirements.

Question 13

The probability of failure equals 1.0 minus the probability of survival.

Question 14

Design failure mode and effects analysis is primarily used to determine cause of failure of products returned by customers.

Question 15

Technical requirements are also called design characteristics.

Question 16

One minus the failure rate is equal to the mean time to failure.

Question 17

Manufacturing specifications consist of nominal dimensions and tolerances.

Question 18

Although similar to quality function deployment,concept engineering does not provide a clear link back to the voice of the customer.

Question 19

The Taguchi loss function measures monetary loss as a linear function of the deviation between a product measurement and nominal.

Question 20

The Taguchi loss function L(x)= k(x-T)² is appropriate for which case?

A)Smaller is better
B)Nominal is best
C)Larger is better
D)Ordinal is best

Question 21

The upper and lower one-sided process capability indexes for a process are 0.90 and 2.80,respectively.The Cpk for this process is _____.

A)0.90
B)1.85
C)2.80
D)3.70

Question 22

The first step in building the House of Quality is to:

A)identify customer requirements.
B)evaluate the competition.
C)identify technical requirements.
D)identify selling points.

Question 23

A process has a Cp equal to 3.5.Determine the standard deviation of the process if the design specifications are 16.08 inches plus or minus 0.42 inches.

A)0.02
B)0.04
C)0.21
D)0.84

Question 24

When stating a manufacturing specification,_____ refers to the ideal dimension or the target value that manufacturing seeks to meet and _____ refers to the permissible variation,recognizing the difficulty of meeting a target consistently.

A)accuracy, precision
B)nominal, tolerance
C)repeatability, reproducibility
D)conformance value, noise

Question 25

The acronym "QFD" stands for:

A)quality forming dimensions.
B)quality function deployment.
C)quality feedback dissemination.
D)quality focused design.

Question 26

A product's quality characteristic has a specification (in inches)of 0.200 ± 0.020.If the value of the quality characteristic exceeds 0.200 by the tolerance of 0.020 on either side,the product will require a repair of $150.The Taguchi loss function for this example is given by:

A)L(x)= 60(x-T)2
B)L(x)= 150(x-T)
C)L(x)= 375,000(x-T)2
D)L(x)= 30(x-T)2

Question 27

Which of the following statements is INCORRECT regarding quality function deployment?

A)It reduces the time for new product development.
B)It allows companies to simulate the effects of new design ideas.
C)It is a useful tool for competitive analysis by top management.
D)It is a means for deploying quality assurance throughout the production process.

Question 28

Given the following Taguchi loss function and specifications,determine the estimated loss if the quality characteristic under study takes on a value of 6.30 inches.
Taguchi loss function: L(x)= 8,500(x-T)²
Specifications (in inches): 6.00 ± 0.25.

A)$765.00
B)$2,550.00
C)$21.25
D)$1,349.21

Question 29

All products that are produced within tolerance specifications are equally acceptable.This statement illustrates:

A)the underlying principle of the Taguchi loss function.
B)a manufacturing orientation that emphasizes precision.
C)the Japanese approach to product design.
D)the goalpost mentality.

Question 30

Consider the quality specification: 'twenty plus or minus five.' The 'plus or minus five' is referred to as the:

A)tolerance.
B)nominal dimension.
C)target value.
D)precision.

Question 31

The Cp equals 2.0 and the process standard deviation equals 1.0.Determine the tolerance spread.

A)1.0
B)2.0
C)6.0
D)12.0

Question 32

Wide tolerances tend to increase all of the following EXCEPT:

A)material utilization.
B)manufacturing costs.
C)labor productivity.
D)machine throughput.

Question 33

Reliability is expressed in terms of:

A)number of failures.
B)probability.
C)time period.
D)an index.

Question 34

Consider a process that is centered at nominal.The manufacturing specifications are: nominal is 'a' and tolerance is 'plus or minus a/8'.Which of the following Cpk values reflects the largest process standard deviation?

A)1.0
B)1.5
C)2.0
D)2.5

Question 35

Which of the following tools is most closely associated with quality function deployment?

A)Concept Engineering
B)Taguchi Loss Function
C)House of Quality
D)Design Failure Mode and Effects Analysis

Question 36

A bottling machine fills soft drink bottles with an average of 12.000 ounces with a standard deviation of 0.002 ounces.Determine the process capability index,Cp,if the design specification for the fill weight of the bottles is 12.000 ounces plus or minus 0.015 ounces.

A)1.25
B)2.5
C)7.5
D)12.5

Question 37

A Cp value of _____ occurs when the natural variation of the process equals the tolerance spread.

A)0
B)1.0
C)3.0
D)6.0

Question 38

The roof of the House of Quality shows the interrelationships between:

A)technical requirements.
B)customer requirements and technical requirements.
C)cost requirements and profit requirements.
D)customer requirements.

Question 39

Where are customer requirements listed in the House of Quality?

A)In the roof
B)Across the top
C)Down the left column
D)Across the bottom

Question 40

Which of the following is NOT a process capability index?

A)Cpk
B)Cpu
C)Cp
D)Cpz

Question 41

The number of failures per unit time during the duration under consideration is called:

A)mean time between failures.
B)failure rate.
C)mean time to failure.
D)conformance rate.

Question 42

______ represents a set of tools and methodologies used in the product development process for ensuring that goods and services will meet customer needs and achieve performance objectives,and that the processes used to make and deliver them achieve Six Sigma capability.

A)Concept engineering
B)Design for Six Sigma
C)Concurrent engineering
D)Deming tools

Question 43

This phase in the product development process usually includes prototype testing.

A)Idea generation
B)Product development
C)Preliminary concept development
D)Market evaluation

Question 44

Determine the probability of system failure for a two-component parallel system if the individual component reliabilities are 0.95 and 0.96,respectively.

A)0.088
B)0.045
C)0.040
D)0.002

Question 45

The predicted reliability that is determined by the design of a product or process is called:

A)partitioned reliability.
B)technical reliability.
C)inherent reliability.
D)anticipated reliability.

Question 46

_____ alleviate(s)the problems in product development arising out of poor intraorganizational cooperation.

A)Quality circles
B)Concurrent engineering
C)Cross-functional training
D)Third-party design teams

Question 47

A reliability of 0.98 means that,on average:

A)98% of items will fail to perform as expected.
B)98 of 1000 items will fail to perform as expected.
C)98 of 100 items will perform as expected.
D).02 of 100 items will fail to perform as expected.

Question 48

The system reliability for a two-component parallel system is 0.99968.If the reliability of the first component is 0.992,determine the reliability of the second component.

A)0.996
B)0.999
C)0.008
D)0.960

Question 49

Which of the following is NOT a phase in the product development process?

A)Preliminary concept development
B)Product/Process development
C)Compliance assessment
D)Market evaluation

Question 50

The reliability function for a component is R(T)= e??T.This function represents:

A)the probability that the component will not fail within ?T time units.
B)the probability that the component will not fail within T time units.
C)the expected remaining time until the component fails.
D)the expected total time the component will survive.

Question 51

The early failure period in a reliability study is sometimes called the:

A)short-life period.
B)break-in period.
C)infant mortality period.
D)initial dropout period.

Question 52

Six units were tested over an 80-hour period.One unit failed after 5 hours and a second unit failed after 60 hours.The remaining four units performed satisfactorily until the end of the test.The failure rate is:

A)0.0052 units/hour.
B)0.0250 units/hour
C)0.0308 units/hour.
D)0.1354 units/hour.

Question 53

Product failure that occurs at the beginning of a product's life as a result of manufacturing or material defects is called:

A)functional failure.
B)catastrophic failure.
C)premature failure.
D)reliability failure.

Question 54

The functions of multifunctional teams involved in concurrent engineering are all of the following EXCEPT to:

A)develop the concept and decide what design methods and production methods are appropriate.
B)analyze product functions so that all design decisions are focused on the customer.
C)determine whether the design can be improved without affecting performance.
D)conduct market evaluations and collate data to enhance the design and delivery system.

Question 55

_____ is a process in which all major functions involved with bringing a product to market are continuously involved with product development from conception through sales.

A)Concurrent engineering
B)Non-linear engineering
C)360-degree designing
D)Bottom-up engineering

Question 56

The acronym MTBF stands for:

A)minimum time between failures.
B)minimum time before failure.
C)maximum time before failure.
D)mean time between failures.

Question 57

According to the text,one of the most significant barriers to efficient product development is poor:

A)design process.
B)intraorganizational cooperation.
C)management focus on innovation.
D)market intelligence.

Question 58

If no serious problems are found,the company releases the product to manufacturing or service delivery teams at this stage in the product development process.

A)Preliminary concept development
B)Product/Process development
C)Full-scale production
D)Market introduction

Question 59

Determine the probability that a three-component series system will survive for 200 hours if the individual components have failure rates of 0.003,0.004,and 0.001 per hour,respectively.Assume the reliability function is exponential.

A)0.064
B)0.202
C)0.992
D)0.996

Question 60

Which of the following activities is NOT part of DFSS?

A)Concept development
B)Product development
C)Design optimization
D)Design verification

Question 61

In a tolerance design process,a _____ is needed to account for engineering uncertainty regarding the maximum variation allowable and compatibility with satisfactory product performance.

A)process variation limit
B)covariance factor
C)factor of safety
D)capacity variance

Question 62

Under QFD,all operations of a company are driven by:

A)intraorganizational consensus.
B)the voice of the customer.
C)management directives.
D)Six Sigma principles.

Question 63

The _____ house(s)of quality utilize the knowledge of about 80 percent of a company's employees-supervisors and operators.

A)first
B)second and fourth
C)third
D)third and fourth

Question 64

Which of the following is NOT a step in concept engineering?

A)Understanding the customer's environment
B)Converting understanding into requirements
C)Operationalizing what has been learned
D)Product development

Question 65

The _____ step in the DMADV process gathers the voice of the customer and identifies the vital CTQs.

A)define
B)measure
C)analyze
D)verify

Question 66

_____ is a focused process for discovering customer requirements and using them to select superior product or service concepts that meet those requirements.

A)Concept development
B)Concept engineering
C)Concurrent engineering
D)Product development

Question 67

_____ is the process of applying scientific,engineering,and business knowledge to produce a basic functional design that meets both customer needs and manufacturing or service delivery requirements.

A)Concurrent engineering
B)Concept development
C)Product development
D)DFSS

Question 68

_____ involves determining the permissible variation in a dimension.

A)System design
B)Tolerance design
C)Boundary value design
D)Covariance design

Question 69

_____ is a planning process to guide the design,manufacturing,and marketing of goods by integrating the voice of the customer throughout the organization.

A)Design for Six Sigma
B)Quality function deployment
C)Design for manufacturability
D)Quality concept development

Question 70

_____ uses a type of matrix diagram to present data and information.

A)Quality function deployment
B)Concept engineering
C)DMADV
D)Concept development

Question 71

DMADV stands for:

A)Define, Measure, Adapt, Deploy, and Verify.
B)Design, Monitor, Assess, Deploy, and Verify.
C)Develop, Measure, Assess, Deliver, and Verify.
D)Define, Measure, Analyze, Design, and Verify.

Question 72

_____ is an emerging concept that includes many design-related initiatives such as concurrent engineering,design for manufacturability,design for assembly,design for environment,and other "design for" approaches.

A)Design for optimization
B)Design for manufacturability
C)Design for environment
D)Design for excellence

Question 73

The first question one must ask during concept development is:

A)What is the product (good or service)intended to do?
B)What should be the USP (unique selling proposition)of the product/service?
C)What is the profile of the target customer?
D)How can the product/service fit into existing processes?

Question 74

The vast majority of applications of QFD in the United States concentrate on the _____ houses of quality.

A)first
B)second
C)third
D)fourth

Question 75

_____ is the process of designing a product for efficient production at the highest level of quality.

A)Design for disassembly
B)Design for manufacturability
C)Design for excellence
D)Tolerance design

Question 76

The analyze step in the DMADV process is focused on:

A)concept development.
B)detailed specifications, design reviews, and approvals.
C)prototype development and testing and implementation planning.
D)defining the issue to be addressed.

Question 77

Practices such as designing for recyclability and disassembly are included in the process of:

A)design for manufacturability.
B)design for environment.
C)design for excellence.
D)design for optimization.

Question 78

DFM is intended to prevent all of the following EXCEPT:

A)designing a product for efficient production at the highest level of quality.
B)product designs that simplify assembly operations but require more complex and expensive components.
C)designs that simplify component manufacture while complicating the assembly process.
D)designs that are simple and inexpensive to produce but difficult or expensive to service or support.

Question 79

In the QFD process,a _____ forms the basis for a quality control plan delivering those critical characteristics that are crucial to achieving customer satisfaction,as specified in the last house of quality.

A)control point
B)key process
C)quality parameter
D)key result area

Question 80

Concept development is a highly creative activity that can be enhanced by such techniques as _____ and _____.

A)process mapping; modeling
B)IQ assessments; self-assessments.
C)training; brain-mapping
D)brainstorming ; Brainwriting