OPMT 3240 Quality Management – Sample Final Exam
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Student Number
circle your set
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Date
Multiple-choice Questions:
Short Answer Questions:
Total
30 X 1 marks each = 30 marks possible
4 X variable
= 50 marks possible
80 marks
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Print your Name and Student Number on this document and circle your set number.
Time allotted is 120 minutes.
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Formula sheet and calculation worksheet are attached.
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3240 Example final exam1
page 1 of 6
1. A machined part is returned to the drilling department from the assembly department, for rework. The
additional labour that is used to correct the quality problem with the part is a cost due to:
a. external failure
b. appraisal
c. process measurement
d. prevention
e. internal failure
2. A product characteristic that is measured on a continuous scale is a(n)
a. attribute
b. variable measure
c. p-chart
d. qualitative evaluation
Refer to the House of Quality diagram above for the following four questions.
3. Where are customer evaluation and key selling points recorded?
a) C
b) D
c) E
d) F
e) G
4. Where are the technical requirements recorded that provide the foundation for the product?
a) A
b) B
c) C
d) D
e) E
5. Failure mode and effects analysis (FMEA) is
a. a software systems that uses computer graphics to assist in designing products
b. a systematic approach to analyzing the causes and effects of product failures
c. a visual method for analyzing the interrelationships among failures
d. a structured process that translates the voice of the customer into technical design requirements
6. The central factor behind Failure Mode and Effects Analysis is:
a. design
b. quality
c. risk
d. volume
e. b and c
3240 Example final exam1
page 2 of 6
Table 1.0
You have been presented with the following cost data for the 1995 year of operations for Acme Electronics.
labour in the rework department
labour in the final inspection department
labour to perform warranty repairs
labour to write test procedures
labour to recycle scrap
scrapped product
labour to perform final assembly
operations
new test oscilloscope and bench
$ 25,000
$ 50,000
$ 20,000
$ 1,000
$ 2,000
$ 60,000
$ 35,000
$ 5,000
$ 198,000
7. Using table 1.0, what was the total cost of quality for the year?
a. $163,000
b. $198,000
c. $196,000
d. $173,000
e. $148,000
8. Using table 1.0, what was the total internal failure cost for the year?
a. $20,000
b. $87,000
c. $92,000
d. $55,000
e. non of the above
11. Which of the following is not true regarding control charts?
a. control charts can be used to monitor a process for the existence of special cause variation
b. the major components of a control chart are the upper and lower control limits, and the centre line
c. control charts alone can determine the source of problems
d. control charts are similar to run charts in that data is plotted versus time
e. control charts are a form of concurrent control
12. Which of the following is identified as a random cause of poor quality?
a) errors due to lack of training
b) variability resulting from natural, common occurrences
c) equipment which is out of adjustment
d) operator fatigue
e) defective raw materials
14. A manufacturing company uses a production process designed to mill components to an average
thickness of .005 inch, with an average range of .0015 inch. Using samples of size 2, what is the
upper control limit on the xbar-chart? (Round your answer. Factors Table in appendix.)
a) .005
b) .010
c) .007
d) .008
e) none of the above
3240 Example final exam1
page 3 of 6
19. The process capability ratio (Cp) may mislead if:
I
II
III
A)
B)
C)
D)
E)
the process is not stable.
the process output is not normally distributed.
the process is not centered.
I and II
I and III
II and III
II only
I, II and III
Fig. 2
LSL
USL
20. The process data shown in Fig. 2 indicates that
a) Cp < 1
b) Cp > 1
c) Cpk = 0
d) Cpk = 1
e) None of the above
22. Sam's Long Life 75 watt light bulbs are designed to have a life of 1125 hours with tolerances of +/- 210
hours. The process that makes light bulbs has a mean of 1050 hours, with a standard deviation of 55
hours. The process capability ratio is
a) 1.27
b) 12.70
c) 0.82
d) 1.72
e) 17.2
23. The process capability index for the 75 watt light bulbs at Sam's Long Life is
a) 1.27
b) 12.70
c) 0.82
d) 1.72
e) 17.2
27. Which of the following is considered a "prevention cost" of quality?
a) quality planning
b) product design
c) process costs
d) training costs
e) all of the above are considered "prevention costs"
3240 Example final exam1
page 4 of 6
Select 4 of the next 6 questions (20 points)
32. Define the major components of a Supplier Verification System. Explain the overall purpose of this type
of system and how the various components link in order to achieve this goal(s)?
33. Explain the difference between common and special causes of variation. How can this be used to
control a process? How is this related to design specification limits and capability
36. A Measurement System can be divided into two key pieces: What to measure and How to measure.
Explain the critical items that must be defined and understood in order to ensure that how you measure is
comprehensive and effective (i.e. what things must be considered?).
37. Describe Failure Mode and Effects Analysis and how it is connected to the design process.
OPMT 3240 Final Exam Formula sheet
Control Limits for p-Charts
(
p 1− p
UCL = p + z
(
p 1− p
LCL = p − z
p =
Control Limits for c-Charts
n
)
)
n
total defectives
total sample observation
UCL = c + z c
LCL = c − z c
c = total number of defects
number of samples
Control Limits for R-Charts
UCL = D4 R
LCL = D R
3
R = ∑R
k
Control Limits for X-Charts
When x bar-chart is used in conjunction with the R-chart:
UCL = x + A R
2
LCL = x − A R
2
x = ∑ sample means
number of samples
Process Capability Ratio
3240 Example final exam1
Cp = upper specification limit – lower specification limit
6σ
page 5 of 6
Process Capability Index
Cpk = minimum
 x − lower specification,
upper specification - x 
,


3σ
3σ


Factors for Determining Control Limits
Sample size A2
D3
D4
2
1.88
0
3.27
3
1.02
0
2.57
4
0.73
0
2.28
5
0.58
0
2.11
6
0.48
0
2.00
7
0.42
0.88
1.92
8
0.37
0.14
1.86
9
0.34
0.18
1.82
10
0.31
0.22
1.78
total quality costs
(100)
base
Quality Index Numbers
Quality index =
Product Yield
Y = (I) (%G) + (I) (1 - %G) (%R)
Manufacturing Cost per Product
Product cost =
Multistage Product Yield
Y = (I) (%g1) … (%g2)
QPR =
(K )(I) + (K )( R)
d
r
Y
good quality units
(input)(processing cost) + (reworked units)(rework cost)
AOQ = Pac x p
3240 Example final exam1
page 6 of 6
(100)