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.
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.