PROJECT QUALITY MANAGEMENT FINAL EXAM
A. Please answer the following True or False questions:
1) A process is capable if the variations fall within the control limits.
True
False
2) Random variation falls outside the control limits.
True
False
3) Control charts are used to determine if there are unexpected changes in the process.
True
False
4) 4 items in parallel, each having a reliability of 0.85 have an overall system reliability of 0.999.
True
False
5) A non-conforming product may work fine and be non-defective
True
False
6) A process in control may still produce bad output.
True
False
7) Affinity diagram is used to identify the root causes of a problem.
True
False
8) A Six Sigma process must have a process capability index of 2.0 or higher.
True
False
9) In a true 6 Sigma Process the defect rate should be less than 0.02 per million
True
False
10) A Control Chart is a Trend Chart (or Run Chart) that has control limits
True
False
B. Please answer the following multiple choice questions:
1. Which of the following tools are used to collect data for histograms.
A) Trend chart
B) Pareto charts
C) Tree diagram
D) Check sheets
E) Control charts
2. Which of the following tools are used to examine the relationships between variables.
A) Scatter plot
B) Fishbone diagram
C) Tree diagram
D) Check sheet
E) Control chart
3. Which of the following is true of random variation?
A) It is uncontrollable.
B) It is centered around the mean.
C) It occurs with a somewhat consistent amount of dispersion.
D) All of the above.
E) None of the above
4. A fishbone diagram is used during which phase of a Six Sigma project.
A. Define
B. Measure
C. Analyze
D. Improve
E. Control
5. An R chart is used to monitor the __________ of the process.
A. Process capability
B. Dispersion
C. Mean
D. Trends
C. Please respond to the following questions:
1) A product is made up of two subsystems in series. The first subsystem consists of 20 components in series. The second subsystem consists of 3 components in parallel. The components in subsystem 1 are all of the same design and each has a 1/10,000 chance of failure. The parallel components each has a 3/10,000 chance for failure. What is the overall reliability of the system?
2) A quality control engineer monitors the quality of a cylinder production line. He regularly selects a sample of 5 units and measures the diameters. The specification requires the diameter to be 6 inches plus/minus 0.1 inch. The following is a record of his measurements. Is the production process in control? Please use X bar and R charts to make an assessment.
|
Sample
|
Item 1
|
Item 2
|
Item 3
|
Item 4
|
Item 5
|
|
1
|
6.10
|
6.15
|
5.35
|
5.98
|
5.95
|
|
2
|
6.35
|
6.02
|
6.20
|
6.10
|
5.70
|
|
3
|
5.85
|
5.90
|
6.20
|
6.12
|
6.08
|
|
4
|
6.00
|
5.80
|
5.70
|
6.04
|
6.17
|
|
5
|
6.15
|
5.60
|
6.25
|
5.99
|
6.01
|
3) For the data in Problem 2, if the true mean and standard deviation of the process are 6.05 and 0.04.
a. Is this process capable of meeting its specification? Calculate its Cp and CPk.
b. What % of cylinders are out of specs?
Q4) A customer relationship manager decided to track customer complaints as part of his ongoing customer satisfaction improvement program. After collecting data for two months, their check sheet appears as follows:
|
Type of Problem
|
Frequency (number of times)
|
|
Call went to voice mail
|
8
|
|
Items damaged when received
|
21
|
|
Literature not in the box
|
9
|
|
Parts missing
|
13
|
|
Unit not working
|
2
|
|
Delivery was late
|
3
|
Construct a Pareto chart including the cumulative % frequency.What is the cumulative percentage of the two leftmost bars?
5) A product manager has conducted a customer satisfaction survey of 30 customers on a scale of 1 to 5. The survey data is shown below. Calculate the mean and standard deviation of the survey and plot a histogram of the data. Does the distribution approximate Normal?
|
Customer
|
Satisfaction rating
|
|
1
|
4
|
|
2
|
3
|
|
3
|
2
|
|
4
|
5
|
|
5
|
5
|
|
6
|
2
|
|
7
|
1
|
|
8
|
4
|
|
9
|
3
|
|
10
|
4
|
|
11
|
4
|
|
12
|
5
|
|
13
|
3
|
|
14
|
3
|
|
15
|
2
|
|
16
|
1
|
|
17
|
5
|
|
18
|
3
|
|
19
|
4
|
|
20
|
3
|
|
21
|
4
|
|
22
|
2
|
|
23
|
4
|
|
24
|
4
|
|
25
|
3
|
|
26
|
3
|
|
27
|
3
|
|
28
|
2
|
|
29
|
2
|
|
30
|
3
|
6) A project manager at System Design Corporation has collected the following data on the size of software programs and the length of programming time. The company is bidding on a new system that is estimated to consist of 250000 lines of code. Use the data to find the correlation function of coding time to the program size and estimate the number of days it would take to code the system.
|
Module
|
Size in 1000 lines of code (KLOC)
|
Number of days to code
|
|
1
|
160
|
68
|
|
2
|
158
|
66
|
|
3
|
148
|
70
|
|
4
|
135
|
59
|
|
5
|
178
|
72
|
|
6
|
170
|
68
|
|
7
|
158
|
64
|
|
8
|
138
|
65
|
|
9
|
200
|
70
|
|
10
|
195
|
68
|
|
11
|
189
|
65
|
|
12
|
173
|
68
|
|
13
|
159
|
70
|
|
14
|
163
|
71
|
|
15
|
150
|
66
|
|
16
|
140
|
65
|
|
17
|
206
|
73
|
|
18
|
144
|
64
|
|
19
|
157
|
70
|
|
20
|
183
|
74
|
|
21
|
195
|
75
|
|
22
|
190
|
77
|
|
23
|
182
|
69
|
|
24
|
152
|
65
|
|
25
|
174
|
69
|