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Process Analysis & Improvement Techniques Flashcards

7 cards from real CPP practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

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  1. Which lean concept refers to producing only what is needed, when it is needed, and in the amount needed to eliminate overproduction waste?

    Answer: Just-In-Time (JIT)

    Just-In-Time production synchronizes output with demand, preventing excess inventory and overproduction—two forms of lean waste.

  2. A team notices that a process output variable correlates strongly with an input variable on a scatter diagram. What is the most appropriate next step?

    Answer: Conduct a designed experiment to confirm causation

    Correlation does not prove causation; a designed experiment (DOE) is needed to confirm whether the input variable truly drives the output.

  3. In Total Quality Management (TQM), which principle emphasizes that quality improvement is an ongoing, never-ending effort involving everyone in the organization?

    Answer: Continuous improvement (Kaizen)

    Kaizen, a core TQM principle, promotes continuous incremental improvement by all employees as an ongoing organizational culture.

  4. A process that produces 99.99966% defect-free output is operating at approximately which Sigma level?

    Answer: 6 Sigma

    Six Sigma quality corresponds to no more than 3.4 defects per million opportunities, equating to approximately 99.99966% defect-free output.

  5. Which analysis technique examines the potential failure modes in a process and their effects on the customer to prioritize corrective actions?

    Answer: FMEA (Failure Mode and Effects Analysis)

    FMEA identifies failure modes, assesses their severity, occurrence, and detectability to calculate a Risk Priority Number (RPN) for prioritization.

  6. In value stream mapping, activities that consume resources but do not add value from the customer's perspective are classified as:

    Answer: Non-value-added waste

    Non-value-added waste includes activities that the customer would not willingly pay for, and lean improvement efforts focus on eliminating them.

  7. Which process analysis technique compares an organization's performance metrics and practices against industry best practices or top competitors?

    Answer: Benchmarking

    Benchmarking identifies performance gaps and improvement opportunities by comparing internal processes to external best-in-class standards.