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MGT 325: Exam 2
Chapters 3 and 4: SPC and Product Design
77
Management
Undergraduate 4
09/21/2014

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Term
Statistical process control (SPC)
Definition
Involves monitoring the production process to detect and prevent poor quality; statistical procedure using control charts to see if any part of a production process is not functioning properly
Term
True or False:
Employee training in SPC is not a fundamental principle of TQM.
Definition
False
Term
Sample
Definition
A subset of the items produced to use for inspection
Term
All processes have variability - __________ and ___________.
Definition
random; nonrandom
Term
___________ variability is identifiable and correctable.
Definition
Nonrandom
Term
SPC is a tool for identifying problems in order to ________________________.
Definition
make improvements
Term
Attribute
Definition
A product characteristic that can be evaluated with a discrete response (good/bad, yes/no); qualitative
Term
Variable measure
Definition
A product characteristic that is continuous and can be measured (weight, length); quantitative
Term
A ______________ is a failure to meet customer requirements.
Definition
service defect
Term
Control chart
Definition
A graph that establishes the control limits of a process
Term
Control limits
Definition
The upper and lower bands of a control chart
Term
What are the four types of commonly used control charts?
Definition
• p-charts
• c-charts
• mean charts
• range charts
Term
What are the attribute control charts?
Definition
• p-charts
• c-charts
Term
What are the variable control charts?
Definition
• mean charts
• range charts
Term
Sigma limits are:
Definition
the number of standard deviations.
Term
True or False:
A sample point can be within the control limits and the process still be out of control.
Definition
True
Term
p-chart
Definition
Uses the proportion defective in a sample
Term
c-chart
Definition
Uses the number of defective items in a sample
Term
A c-chart is used when:
Definition
it is not possible to compute a proportion defective and the actual number of defects must be used.
Term
Range (R-) chart
Definition
Uses the amount of dispersion in a sample
Term
Mean (x-bar) chart
Definition
Uses the process average of a sample
Term
Range
Definition
The difference between the smallest and largest values in a sample; reflects the process variability
Term
True or False:
Both the process average and variability must be in control.
Definition
True
Term
A _________ can indicate and out-of-control process even if sample values are within control limits.
Definition
pattern
Term
Run
Definition
A sequence of sample values that display the same characteristic
Term
Pattern test
Definition
Determines if the observations within the limits of a control chart display a nonrandom pattern
Term
What are the general guidelines associated with the zones for identifying patterns in a control chart?
Definition
• eight consecutive points on one side of the center line
• eight consecutive points up or down
• 14 points alternating up or down
• two out of three consecutive points in zone a
• four out of five consecutive points in zone a or B on one side of the centerline
Term
Attribute charts require ________ sample sizes.
Definition
larger
Term
Variable charts require _________ sample sizes.
Definition
smaller
Term
Tolerances
Definition
Design specifications reflecting product requirements
Term
Process capability
Definition
The range of natural variability in a process; what we measure with control charts
Term
If the natural variability in a process exceeds tolerances:
Definition
the process cannot meet design specifications.
Term
In 6-sigma quality, we have ____ defective PPM, or _____ defects.
Definition
3.4; zero
Term
What is the difference between attribute control charts and variable control charts?
Definition
Attribute charts use discrete values. Variable charts use continuous values.
Term
What is the purpose of a pattern test?
Definition
To identify if the observations within the limits are showing a nonrandom pattern
Term
What determines the width of the control limits in a process chart?
Definition
The limits are based on a number of standard deviations (z) from the process average according to a normal distribution. The smaller the value of z, the more narrow the control limits are.
Term
Under what circumstances should a c-chart be used instead of a p-chart?
Definition
If the proportion defective in a process cannot be determined (i,e., blemishes on a car)
Term
What is the difference between tolerances and control limits?
Definition
Tolerances are design specs and are externally imposed by designers. Control limits are a statistical measure of the production process and reflect process variability.
Term
Why have companies traditionally used control charts with 3-sigma limits instead of 2-sigma limits?
Definition
With wider limits, management is less likely to conclude that the process is out of control when points outside of the limits are due to normal, random variations.
Term
Design can provide a _________________ by bringing new ideas to the market quickly.
Definition
competitive edge
Term
Perceptual map
Definition
Visual method of comparing customer perceptions of different products or services
Term
Benchmarking
Definition
Comparing a product or process against the best-in-class product
Term
Reverse engineering
Definition
Carefully dismantling a competitor's product to improve your own product
Term
A feasibility study consists of:
Definition
A market analysis, an economic analysis, and a technical/strategic analysis.
Term
Market analysis
Definition
Assesses whether there's enough demand for the proposed product to invest in developing it further
Term
Economic analysis
Definition
Looks at estimates of production and development costs and compares them to estimated sales volume
Term
Rapid prototyping
Definition
Creating, testing, and revising a preliminary design model
Term
Concurrent design
Definition
A new approach to design that involves the simultaneous design of products and processes by design teams
Term
Form design
Definition
How the product will look
Term
Functional design
Definition
How the product will perform; performance characteristics considered during this phase of design or reliability, maintainability, and usability
Term
Reliability
Definition
The probability that a product will perform its intended function for a specified period of time
Term
Maintainability
Definition
The ease with which a product is maintained or repaired
Term
MTBF
Definition
Mean time between failures
Term
MTTR
Definition
Mean time to repair
Term
Usability
Definition
Ease-of-use of a product or service
Term
Production design
Definition
How the product will be made
Term
Simplification
Definition
Reduces the number of parts, assemblies, or options in a product
Term
Standardization
Definition
When commonly available and interchangeable parts are used
Term
Modular design
Definition
Combines standardized building blocks, or modules, to create unique finished products
Term
Design for manufacture (DFM)
Definition
Designing a product so that it can be produced easily and economically
Term
Computer aided design (CAD)
Definition
Assists in the creation, modification, and analysis of a design
Term
Computer aided engineering (CAE)
Definition
A software system that tests and analyzes designs on the computer screen
Term
Computer-aided design/computer-aided manufacturing (CAD/CAM)
Definition
The ultimate design to manufacture connection
Term
CAD and its related technologies produce _______ designs _______.
Definition
better; faster
Term
Product lifecycle management (PLM)
Definition
Managing the entire lifecycle of a product; storing, retrieving, and updating design data from the product concept through manufacturing, revision, service, and retirement of the product
Term
Collaborative product design (CPD)
Definition
A software system for collaborative design and development among trading partners
Term
Failure mode and effects analysis (FMEA)
Definition
Systematic method of analyzing product failures; objective is to anticipate failures and prevent them from occurring
Term
Fault tree analysis (FTA)
Definition
Visual method for analyzing the interrelationships among failures
Term
Value analysis (VA)
Definition
A procedure for eliminating unnecessary features and functions
Term
Extended producer responsibility (EPR)
Definition
When companies are held responsible for their product even after its useful life
Term
Eco-labeling
Definition
A seal of approval for environmentally safe products
Term
Carbon footprint
Definition
A measure of greenhouse gases
Term
Sustainability
Definition
Meeting present needs without compromising future generations
Term
Design for environment (DFE)
Definition
Designing a product from material that can be recycled or easily repaired rather than discarded
Term
Quality function deployment (QFD)
Definition
Translates the voice of the customer into technical design requirements
Term
Robust design
Definition
Yields a product or service designed to withstand variations
Term
Tolerances
Definition
Allowable ranges of variation
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