DMD Quality Management & Control 2 — Questions and Answers
Question 1: What does 'Cpk' measure in manufacturing quality?
- Process capability relative to specification limits and centering (Correct answer)
- Cycle time per part
- Cost per defect
- Control point key performance
Correct answer: Process capability relative to specification limits and centering
Cpk measures how centered and capable a process is relative to its specification limits, accounting for process mean offset.
Question 2: Which quality cost category includes scrap, rework, and warranty claims?
- Failure costs (Correct answer)
- Appraisal costs
- Prevention costs
- Conformance costs
Correct answer: Failure costs
Failure costs (internal and external) include scrap, rework, warranty claims, and customer returns resulting from quality defects.
Question 3: In digital manufacturing, what is the role of an Automated Optical Inspection (AOI) system?
- To detect surface defects and dimensional errors using cameras and image processing (Correct answer)
- To program CNC machines automatically
- To generate 3D CAD models from scans
- To balance assembly line workloads
Correct answer: To detect surface defects and dimensional errors using cameras and image processing
AOI uses high-resolution cameras and image processing algorithms to automatically detect surface defects, missing components, or dimensional errors.
Question 4: What is the purpose of a Failure Mode and Effects Analysis (FMEA)?
- To proactively identify potential failure modes and their impact on product or process quality (Correct answer)
- To document completed quality audits
- To track supplier performance metrics
- To certify operators on quality procedures
Correct answer: To proactively identify potential failure modes and their impact on product or process quality
FMEA systematically evaluates potential failure modes before they occur, assigning Risk Priority Numbers (RPN) to prioritize corrective actions.
Question 5: Which statistical technique in Six Sigma helps determine which input variables significantly affect a process output?
- Design of Experiments (DOE) (Correct answer)
- Pareto analysis
- Run chart
- Control chart
Correct answer: Design of Experiments (DOE)
Design of Experiments (DOE) systematically varies input factors to identify which ones have the greatest effect on the process output.
Question 6: What is the main difference between precision and accuracy in manufacturing measurements?
- Precision is consistency of repeated measurements; accuracy is closeness to the true value (Correct answer)
- Precision is closeness to true value; accuracy is consistency
- They are interchangeable terms in quality
- Precision applies to length; accuracy to weight
Correct answer: Precision is consistency of repeated measurements; accuracy is closeness to the true value
Precision refers to how repeatable a measurement is, while accuracy describes how close measurements are to the actual true value.
DMD Quality Management & Control 2
What does 'Cpk' measure in manufacturing quality?