Automotive Industry Quality Assurance Quiz

Spending time on problem solving is important because it allows for the identification of the correct root causes of the problem. By understanding the root causes, an efficient action plan can be implemented to prevent the problem from recurring in the future. This approach ensures that the issue is addressed effectively and prevents wasted time and resources on ineffective solutions.

The correct answer is A continuous improvement method mainly based on cleanliness and order. 5S is a methodology that focuses on maintaining a clean and organized workplace to improve efficiency, productivity, and safety. It involves five steps: Sort, Set in Order, Shine, Standardize, and Sustain. By implementing 5S, organizations can create a more visually appealing and efficient work environment, reduce waste, and enhance overall quality.

The correct order for 5S is Sort, Set in order, Shine, Standardize, Sustain. This order follows the systematic approach of organizing and maintaining a clean and efficient workspace. By first sorting and eliminating unnecessary items, then setting the remaining items in order, followed by cleaning and shining the workspace, standardizing processes, and finally sustaining the improvements made, the 5S methodology helps to improve productivity, safety, and overall organization in the workplace.

The main use of the control plan is to list the controls carried out on the process or the product to have a good overview of them. This helps in ensuring that the necessary controls are in place and being implemented effectively to maintain the quality and consistency of the process or product. It also allows for easy monitoring and tracking of the controls, making it easier to identify any deviations or issues that may arise.

Having a chart describing the organization is important for a company, regardless of its size. It allows everyone to understand their roles and responsibilities within the company, as well as the importance placed on quality. This chart helps to create a clear structure and hierarchy within the organization, ensuring that everyone is aware of their position and how they contribute to the overall quality standards.

A poka yoke is any device that helps prevent making a mistake. It is a technique used in lean manufacturing to avoid errors or defects in a product or process. These devices are designed to make it impossible or difficult to make a mistake, by providing warnings, guides, or physical barriers. The purpose of poka yoke is to improve quality and productivity by eliminating errors at the source, rather than relying on inspection or rework.

In order to comply with the ISO TS standard, a company is required to have meeting minutes of their quality meetings. This is not just a matter of red tape or inefficient paperwork, but a direct requirement outlined in the norm. The purpose of having meeting minutes is to document discussions, decisions, and actions taken during the meetings, which helps in maintaining transparency, accountability, and continuous improvement within the company's quality management system.

Pareto's Law, also known as the 80/20 rule, states that 80% of the effects come from 20% of the causes. This means that a majority of the problems or outcomes can be attributed to a small portion of the underlying causes. In other words, a minority of factors or actions have a significant impact on the overall result. This principle is widely applied in various fields, such as business management, economics, and quality improvement, to prioritize efforts and resources towards the most influential factors.

Regularly checking process parameters is necessary because it helps to avoid unwanted changes. By monitoring the process parameters, any deviations or abnormalities can be identified and addressed promptly, preventing any potential negative impact on the final product. This ensures that the production process remains stable and consistent, leading to better quality control and overall efficiency. Additionally, regularly checking process parameters allows for continuous improvement and optimization of the manufacturing process.

Setting rules to analyze quality results/charts is necessary because it helps define what is considered a drift and ensures that action plans are efficient. Without rules, it would be difficult to determine if there is a deviation from the expected quality standards and to take appropriate measures to address the issue. Monitoring quality results on a weekly basis is also important, but it is not sufficient without clear rules to guide the analysis and interpretation of the data. Additionally, the fact that suppliers react to customer claims does not negate the need for rules in quality analysis.

Internal audits are conducted to check conformity to internal procedures, ensuring that the organization is following its own established protocols and guidelines. Additionally, internal audits aim to find opportunities for improvement within the organization, identifying areas where processes can be enhanced or streamlined. This allows the organization to continuously improve its operations and achieve greater efficiency and effectiveness.

The correct answer is that the worker should put the non-conforming parts aside in a red box. This suggests that there is a designated area or container specifically for non-conforming parts, which is the red box. This helps to separate them from the conforming parts and indicates that they need to be handled differently, possibly for further analysis or disposal.

The given arrangement of the values in descending order fits the creation of a Pareto chart. A Pareto chart is a type of bar chart that displays data in descending order of frequency or impact. It helps to identify and prioritize the most significant factors contributing to a problem or issue. In this case, arranging the values of "Part broke down", "Strange noise", "Scratches", and "Wrong color" in descending order allows for a clear visualization of the most common causes of customer dissatisfaction.

The Ishikawa diagram, also known as a fishbone diagram or a cause-and-effect diagram, is a visual tool used to identify and organize potential causes of a problem or an effect. It is represented in a fishbone or tree shape, with the effect or problem at the head and the potential causes branching out from it. This diagram helps to conduct a thorough analysis by visually displaying the various factors that contribute to the problem, making it easier to identify the root cause and develop effective solutions.

The main use of the 6M diagram is to avoid focusing on one single obvious cause and enable deep root cause analysis. By looking at each branch of the 6M (Machine, Method, Materials, Maintenance, Man, and Mother Nature), it allows for a comprehensive examination of all potential factors contributing to a problem. This approach helps to identify underlying causes that may not be immediately apparent and allows for a more thorough analysis.

The correct answer is that the ISO TS requirements could be reinforced on the theme of the pre-production/pre-series phase and ramp-up phase. This is because these phases are only mentioned slightly, indicating that there may be a need for further reinforcement and emphasis on these areas in order to meet the ISO TS requirements effectively. The building of a control plan and the use of FMEA are not mentioned, suggesting that they may not require reinforcement in relation to the ISO TS requirements.

The primary purpose of conducting a Root Cause Analysis (RCA) is to find the underlying cause of a problem rather than just addressing its symptoms. By identifying the root cause, organizations can implement effective corrective actions to prevent the problem from recurring, ensuring long-term quality improvement and reducing costs associated with repeated issues. RCA is an essential tool in quality management for continuous improvement and maintaining high standards in products and processes.

Using analysis tools when solving a problem is necessary for all problems. Analysis tools help in examining and understanding the problem thoroughly, identifying the root cause, and finding the most effective solution. They provide a systematic and structured approach to problem-solving, ensuring that all relevant factors are considered and evaluated. By using analysis tools, one can make informed decisions and improve the efficiency and effectiveness of problem-solving processes. Therefore, regardless of the nature or complexity of the problem, using analysis tools is essential.

"MIS" usually stands for "Months in Service" when talking about warranty issues. This term refers to the number of months that a product has been in use since its purchase. It is an important factor in determining whether a product is still covered under warranty or if the warranty has expired.

The usual meaning of "D=10" in FMEA (Failure Mode and Effects Analysis) is low efficiency detection, as the D score is high. This suggests that the current detection method is not effective in identifying and preventing failures or errors. A high D score indicates that the detection process is not efficient and needs improvement.

A standard quality claim report in the automotive industry typically involves several steps, such as identifying the issue, gathering relevant data, conducting an investigation, analyzing the root cause, proposing corrective actions, implementing the actions, monitoring the effectiveness, and closing the claim. Therefore, the correct answer is 8.

For a company to be ISO TS 16949 certified, it is important to review at least its internal processes as stated by their process map. However, in addition to that, process audit and product audit should also be conducted. This is because auditing the industrial process is necessary as the quality of the product is a result of a good process. Similarly, auditing the products is necessary to ensure customer satisfaction. Therefore, reviewing all these items and subjects through internal audits is essential for the company to meet the requirements for ISO TS 16949 certification.

The given answer states that achieving a 10ppm (6 months cumulative ppm) for parts like a seat collection is mathematically possible. However, it also mentions that it is close to impossible given the type of parts. This suggests that while it may be theoretically possible, in practical terms, it would be extremely challenging to achieve such a low ppm for this type of parts.

The usual meaning of "D<4" is efficient detection, such as a Pokayoke. This means that the detection method being used is effective and efficient in identifying and preventing errors or defects. It implies that the system in place is capable of quickly and accurately detecting any issues or abnormalities, ensuring high quality and reliability.

The explanation for the given correct answer is that the Pareto law is an empirical law, meaning it is based on observations and data rather than theoretical principles. It is usually relevant when starting to work on an issue because it helps identify the most significant factors or causes that contribute to a problem or outcome. However, it is not always applicable in every situation, as it can only be applied to stable processes where the distribution follows a normal pattern.

The letters A, B, C, D, and the numbers 1, 2, 3, ILUO, and Magic square refer to FMEA (Failure Mode and Effects Analysis) scores. These are classifications used within FMEA to indicate the level of risk or priority for addressing potential failures. The categories help in evaluating the severity, occurrence, and detection of potential failure modes, guiding the development of action plans to mitigate risks in the automotive industry.

You should block the next deliveries to the customer because there is a complaint about a missing component. This will prevent any further incorrect deliveries and allow you to investigate and resolve the issue before sending out any more parts.

The answer suggests that using customer complaints as a way to assess efficiency is not a good practice. This implies that the absence of complaints from the customer for the past 6 weeks does not necessarily indicate that the action plan is efficient. It is important to consider other factors and metrics to determine the effectiveness of the action plan.

Measurables are important to deploy quality because they allow for the measurement of progress and results of action plans. They also help in reflecting customer satisfaction and can be broken down to the process and explained to the workers. By using measurables, organizations can track their performance, identify areas for improvement, and ensure that the actions taken are resulting in desired outcomes. Additionally, measurables provide valuable data that can be used for decision-making and continuous improvement. Therefore, both options A and C are correct as they highlight the importance of measurables in deploying quality.

The FMEA (Failure Mode and Effects Analysis) should be checked and updated on a yearly basis to ensure that it is still relevant and accurate. Additionally, it should be updated after each claim to incorporate any new information or insights gained from the claim process. Therefore, both options A (on a yearly basis) and C (after each claim) are correct.

The quality of the parts/cars we sell is important because if customers trust our products, we can increase the selling price. Additionally, warranty issues can be costly, so it is better to sell reliable cars to save money.

To ensure a thorough analysis and prevent the reoccurrence of a problem, it is important to study the main types of causes. These include occurrence, which refers to the factors that led to the problem happening in the first place. Escape (outflow, non-detection) causes should also be examined, which involve the reasons why the problem went unnoticed or was not addressed properly. Lastly, systemic causes need to be studied, focusing on the underlying issues within the system that contributed to the problem. Considering all of these causes is crucial for a comprehensive analysis and effective prevention of future problems.