Support for Quality Testing Program

Test Module # 5: Problem Resolution and Prevention

The best example of a cross functional problem solving team is;

  • Quality Manager
  • Plant Manager, Quality Manager
  • Quality Manager, Quality Engineer, Operator, Production Manager
  • Quality Manager, Quality Engineer, Quality Technician

A customer has just issued a notice for rejected material at their facility. What is the first thing to do as part of the problem-solving process?

  • Contact your Quality Manager
  • Set up containment
  • Stop the line
  • Notify all other customers

A customer has just issued a notice for rejected material at their facility. What internal documents need to be reviewed in order to support the problem-solving process?

  • PSW and Control Plan
  • Previous Corrective Actions, PFMEA and Control Plan
  • PFMEA and Control Plan
  • PFMEA and PSW

The proper flow of the problem solving process is best outlined as:

  • Containment, Corrective Action, Root Cause Analysis, Problem Statement
  • Stop the process, Scrap Parts, Identify certified material, notify production supervisor
  • Identify Problem, Contain the Problem, Root Cause Analysis, Corrective Action Verification, Lessons Learned
  • Describe the problem, Build the team, Prevent Recurrence, Congratulate the team

The main objective of the problem solving process is:

  • Solve problems with our products
  • Solve problems created by suppliers
  • Respond to customer complaints
  • Comply with TS Requirements

Which of these is NOT an escape point?

  • Rework process not followed
  • Inspection not completed
  • Tolerance too tight to manufacture
  • Wrong inspection standard used

When setting up containment, what must be considered? (choose all that apply)

  • Stock at the customer
  • Material in rework
  • Identification method of clean parts
  • Updating the Control Plan
  • Reviewing Lessons Learned
  • Parts in process/not finished goods

When a Quality Alert is in place, it is okay to pass a nonconforming part on to the next process as long as you do not mark it as certified.

  • True

Which of these is incorrect? Nonconforming product found during internal containment shall be ____________.

  • Clearly identified.
  • Tracked for containment results
  • Communicated to the customer on a daily tracking sheet.
  • Segregated off of the line in properly identified containers / areas.

100% visual inspection is:

  • Safe and reliable for attribute data only.
  • Safe and reliable when performed by trained people.
  • Safe and reliable as long as a Gage R&R was done.
  • Not 100% safe and reliable.

The problem solving process is started:

  • Within 24 hours of receiving a written concern from the customer.
  • As soon as the Leather Division is found responsible.
  • Within 1 week of identifying a defect.
  • Once Corrective Actions are defined.

When an issue is discovered the first action should be:

  • Put containment in place to protect the customer
  • Brainstorm possible corrective actions
  • Contact engineering to do testing on the failed part
  • Start a six sigma project

Which one of the following are NOT conditions requiring containment?

  • New Product Launches
  • Engineering Changes
  • New line supervisor
  • Process Changes

You receive a rejection notice from the customer and the part is to specification. What should you do?

  • Complete the problem-solving process through containment.
  • Dispute the complaint with a detailed response.
  • Nothing is required since it is not the Leather Division responsibility.
  • None of the above.
  • Both answers A & B.