B6 - Process Management

Question 1

Process management also referred to as PDCA. What is PDCA?

Answer 1

Plan
Do
Check - monitor
Act - continuously commit to the process and reassess the degree of improvement.

Question 2

Rational assessment for process improvement initiatives

Answer 2

Strategic gap analysis (external and internal)
Review competitive priorities - price, quality, or other
Review production objectives
Choose improvement program

Question 3

Appraisal cost

Answer 3

Is a type of conformance cost (the other conformance cost is prevention costs). Includes testing and inspection, statistical quality checks, maintenance of the laboratory.

Question 4

Internal failure cost (nonconformance cost)

Answer 4

Rework
Scrap
Tooling changes
Costs to dispose
Cost of lost unit 
Downtime

Question 5

TQM - Total Quality Management (7 areas)

Quality and continuous improvement

Answer 5

1. Customer (External & Internal)
2. Continuous improvement
3. Workforce involvement (quality circles)
4. Top managemnet support
5. Objective measures
6. Timely recognition
7. Ongoing training

Question 6

Six Sigma

Answer 6

Rigorous metrics to evaluate goal achievement

A continuous quality-improvement program that requires specialized training

Question 7

Six Sigma - Existing product

Answer 7

1. Define problem
2. Measure key aspects of current process (collect data)
3. Analyze data
4. Improve or optimize current process
5. Control & monitor using statistical tools

Question 8

Six Sigma - New product

Answer 8

1. Define design goals
2. Measure CTQ (critical to quality issues)
3. Analyze design alternatives
4. Optimize design using modeling techniques
5. Verify the design (implement and test)