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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.

Read the first 7 Process Analysis & Improvement Techniques flashcards as text

  1. In Design of Experiments (DOE), a full factorial experiment with 3 factors at 2 levels each requires how many experimental runs (ignoring replication)?

    Answer: 8

    A full factorial with k factors at 2 levels requires 2^k runs; for 3 factors, that is 2^3 = 8 runs.

  2. Which process improvement technique uses time-series data plotted with control limits to distinguish common cause variation from special cause variation?

    Answer: Statistical Process Control (SPC) chart

    SPC charts plot process data over time with upper and lower control limits to detect special cause variation that signals a process change.

  3. A team implementing a 5S program completes sorting, setting in order, shining, and standardizing. What is the fifth and final step?

    Answer: Sustaining

    The fifth S, 'Sustain' (Shitsuke), focuses on maintaining and embedding the 5S practices through discipline, training, and regular audits.

  4. In process capability analysis, a Cpk value less than 1.0 indicates that the process:

    Answer: Cannot consistently meet specification limits

    A Cpk below 1.0 means the process spread or centering is insufficient to consistently produce output within specification limits.

  5. Which technique uses a structured team approach to rapidly implement improvements in a focused area over a short period, typically 3–5 days?

    Answer: Kaizen event (Rapid Improvement Event)

    A Kaizen event (also called a Rapid Improvement Event or blitz) concentrates a cross-functional team on a specific problem to achieve quick, targeted improvements.

  6. When analyzing process data, a bimodal distribution in a histogram most likely suggests:

    Answer: Two distinct populations or process conditions are present in the data

    A bimodal histogram with two peaks typically indicates that data comes from two different process streams, shifts, machines, or conditions mixed together.

  7. The concept of 'mistake-proofing' (poka-yoke) in process improvement aims to:

    Answer: Design processes so that errors are prevented or immediately detected at the source

    Poka-yoke devices or methods are built into the process to prevent errors from occurring or to immediately signal them before they become defects.