Deck 7: Design for Quality and Product Excellence

Question 1

If an idea survives the concept stage of product development,the actual design process begins by evaluating design alternatives and determining engineering specifications for all materials,components,and parts.

Answer 1

True

Question 2

Narrow tolerances in product design tend to raise manufacturing costs and also increase the interchangeability of parts within the plant and in the field,product performance,durability,and appearance.

Answer 2

True

Question 3

Innovation is built upon strong research and development (R&D)processes.

Answer 3

True

Question 4

A product failure which occurs at the start of product life due to manufacturing or material defects such as a missing connection or a faulty component is referred to as functional failure.

Question 5

The axiomatic design method of product development tends to lessen design time.

Question 6

A tolerance reserve or factor of safety in product design is needed to account for engineering uncertainty regarding the maximum variation allowable and compatibility with satisfactory product performance.

Question 7

A typical scheme of the House of Quality uses the symbol Ä to denote a strong relationship between any pair of technical requirements.

Question 8

In practice,product design reliability is determined by the number of failures per unit time during the duration under consideration.

Question 9

The Taguchi loss function can be used to set product design tolerances in an economical fashion.

Question 10

One of the most significant barriers to efficient product development is the adaption of concurrent engineering within an organization.

Question 11

In series systems failure of an individual component is less critical than in parallel systems.

Question 12

Wide tolerances in product design have a positive impact on product characteristics.

Question 13

After basic technical requirements have been established in product development process,designers must set specific dimensional or operational targets and tolerances for critical manufacturing or service characteristics.

Question 14

The methodology of axiomatic design is based on the premise that good design is governed by laws similar to those in natural science.

Question 15

When decisions about the safety,life,serviceability,and maintainability of products are dominated by customer requirements rather than by engineering considerations,poor designs that fail in the market are often the result.

Question 16

The quality function deployment tool increases the time for new product development.

Question 17

The idea generation phase of product development usually includes prototype testing,in which a model is constructed to test the product's physical properties or use under actual operating conditions.

Question 18

Under quality function deployment,all operations of a company are driven by the voice of the customer rather than by edicts of top management.

Question 19

The outcome of innovation in product development is a discontinuous or breakthrough change and results in new and unique goods and services that delight customers and create competitive advantage.

Question 20

The principles of axiomatic design help designers better apply tools such as TRIZ and quality function deployment.

Question 21

Which of the following activities included in the DMADV process gathers the voice of the customer,identifies the vital characteristics that are most important to customers,and outlines the functional requirements of the product that will meet customer needs?

A)Design
B)Analyze
C)Measure
D)Verify

Question 22

According to the theory of strict liability,anyone who sells a product that is defective or unreasonably dangerous is subject to liability for any physical harm caused to the user,the consumer,or the property of either.

Question 23

Which of the following phases of product development usually includes prototype testing?

A)Product/process development
B)Idea generation
C)Full-scale production
D)Market evaluation

Question 24

Redundant components,when used in a parallel system,tend to decrease the reliability of the system.

Question 25

Which of the following activities of the design for six sigma (DFSS)focuses on developing specific requirements and design parameters such as specifications and tolerances to ensure that the product fulfills the functional requirements of the concept?

A)Concept development
B)Design verification
C)Design optimization
D)Detailed design

Question 26

_____ involves the adoption of an idea,process,technology,product,or business model that is either new or new to its proposed application.

A)Concurrent engineering
B)Total quality management (TQM)
C)Design optimization
D)Innovation

Question 27

Which of the following is the first phase of a typical product development process?

A)Product/process development
B)Preliminary concept development
C)Idea generation
D)Market introduction

Question 28

_____ is a process in which all major functions involved with bringing a product to market are continuously involved with product development from conception through sales.

A)Organizational learning
B)Concurrent engineering
C)Six Sigma
D)Axiomatic design

Question 29

The DMADV process incorporates the principal activities of the design for six sigma.Which of the following activities included in DMADV focuses on identifying and understanding the market need or opportunity?

A)Design
B)Measure
C)Analyze
D)Define

Question 30

Redundancy in a parallel system increases the cost,size,and weight of the system.

Question 31

Which of the following activities involved in the DMADV process involves prototype development,testing,and implementation planning for production?

A)Verify
B)Measure
C)Design
D)Define

Question 32

Which of the following activities included in the DMADV process is focused on concept development from engineering and aesthetic perspectives and often includes the creation of drawings,virtual models,or simulations to develop and understand the functional characteristic of the product?

A)Measure
B)Define
C)Verify
D)Analyze

Question 33

New ideas are studied for feasibility in the _____ phase of product development.

A)market evaluation
B)process development
C)full-scale production
D)preliminary concept development

Question 34

Which of the following activities included in the DMADV process focuses on developing detailed specifications,purchasing requirements,and so on,so that the concept can be produced?

A)Measure
B)Define
C)Design
D)Analyze

Question 35

Which of the following activities of the design for six sigma (DFSS)seeks to refine designs to identify and eliminate potential failures,achieve high reliability,and ensure that it can be easily manufactured,assembled,or delivered in an environmentally-responsible manner?

A)Detailed design
B)Design verification
C)Concept development
D)Design optimization

Question 36

Product designs with numerous parts decrease the incidence of part mix-ups,missing parts,and test failures.

Question 37

Which of the following activities of the design for six sigma (DFSS)ensures that the quality level and reliability requirements of the product are achieved?

A)Design verification
B)Design optimization
C)Detailed design
D)Concept development

Question 38

The product is distributed to customers in the _____ phase of product development.

A)preliminary concept development
B)market introduction
C)idea generation
D)full-scale production

Question 39

Which of the following activities of the design for six sigma (DFSS)focuses on creating and building a product idea and determining its functionality based upon customer requirements,technological capabilities,and economic realities?

A)Detailed design
B)Design verification
C)Concept development
D)Design optimization

Question 40

Accelerated life testing involves overstressing components to reduce the time to failure and find weaknesses.

Question 41

_____ is a method to describe combinations of conditions or events that can lead to a failure.

A)Axiomatic design
B)Quality function deployment
C)Fault tree analysis
D)Total quality management

Question 42

_____ is the process of designing a product for efficient production at the highest level of quality.

A)Design for manufacturability
B)Concurrent engineering
C)Design for disassembly
D)Design for environment

Question 43

The matrix used by the quality function deployment to ensure that the voice of the customer is carried throughout the production/delivery process is called the _____.

A)Hidden Factory
B)Quincunx
C)Likert Scale
D)House of Quality

Question 44

The final House of Quality relates:

A)process operations to component requirements.
B)customer requirements to technical requirements.
C)technical requirements to component requirements.
D)process operations to quality control plans.

Question 45

The predicted reliability determined by the design of the product or process is called the _____ reliability.

A)achieved
B)perceived
C)inherent
D)nominal

Question 46

_____ is seeing things in new or novel ways.

A)Flexibility
B)Agility
C)Creativity
D)Quality assurance

Question 47

A personal computer system is composed of the processing unit,graphics board,and keyboard with reliabilities of 0.976,0.785,and 0.893,respectively.This is a series system and even if one component fails,the computer will not function correctly.The reliability of this system is:

A)0.684
B)0.953
C)2.654
D)0.857

Question 48

An electric component has a failure rate of ë= 0.0035 failure per hour.For this component,the mean time to failure(è)is _____.

A)356.8 hours
B)285.7 hours
C)532.7 hours
D)258 hours

Question 49

In the context of manufacturing specifications,the term "tolerance" refers to:

A)the target value that manufacturing seeks to meet.
B)the specification that best represents the requirements of the customer.
C)the specification which leads to the development of the least costly product.
D)the permissible variation, recognizing the difficulty of meeting a target consistently.

Question 50

The first House of Quality relates:

A)component requirements to process operations.
B)process operations to quality control plans.
C)customer requirements to a product's overall technical requirements.
D)technical requirements of a product to component requirements.

Question 51

Robust design refers to designing goods and services that:

A)make the most efficient use of the available resources.
B)are insensitive to variation in manufacturing processes and when consumers use them.
C)create a competitive advantage for the organization in the market.
D)are the least costly to produce.

Question 52

In the context of the axiomatic design method,the information axiom states that:

A)good design occurs when the functional requirements of the design are independent of one another.
B)developing specific requirements and design parameters such as specifications and tolerances leads to the creation of a high quality product.
C)all the departments in an organization should be continuously involved with product development from conception through sales.
D)good design corresponds to minimum complexity.

Question 53

Accelerated life testing involves:

A)using the fault tree analysis technique to find the defects in the product.
B)using the TRIZ tool to identify faults in the designing of the product.
C)overstressing components to reduce the time to failure and find weaknesses.
D)finding the degree to which the product meets the customer requirements.

Question 54

Which of the following symbols is used to denote a very strong relationship between any pair of technical requirements in a typical House of Quality?

A)*
B)Ä
C)^
D)•

Question 55

Which of the following symbols is used to denote a weak relationship between any pair of technical requirements in a typical House of Quality?

A)•
B)*
C)Ä
D)#

Question 56

In the context of the axiomatic design method,the independence axiom states that:

A)good design occurs when the functional requirements of the design are separate from one another.
B)developing specific requirements and design parameters such as specifications and tolerances leads to the creation of a high quality product.
C)good design corresponds to minimum complexity.
D)all the departments in an organization should be continuously involved with product development from conception through sales.

Question 57

_____ is a methodology used in the product design process,developed by Dr.Nam Suh from MIT,which is based on the premise that good design is governed by laws similar to those in natural science.

A)Fault tree analysis
B)Axiomatic design
C)Design failure mode and effects analysis (DFMEA)
D)Six sigma

Question 58

Which of the following tools is most likely to be used for establishing technical design requirements that meet customer needs and placing them in subsequent production activities?

A)Likert scale
B)Quality function deployment
C)Cause-and-effect diagram
D)Fault tree analysis

Question 59

Which of the following is the first House of Quality matrix?

A)Customer requirement planning matrix
B)Process operations matrix
C)Technical requirement planning matrix
D)Component characteristics matrix

Question 60

Which of the following is a creativity tool that finds extensive use in product design?

A)TRIZ
B)Fault tree analysis
C)Likert scale
D)Cause-and-effect diagram

Question 61

Which of the following products marked Shure's entry into the manufacturing in 1932? ?

A)Digital signal processors
B)Microphones
C)Mixers
D)Hands-free cell phones

Question 62

List the four different types of innovations classified by The Small Business Administration with examples.

Question 63

Which of the following customer requirements was given high importance in the House of Quality which was created by the result of the managed care organizations' QFD study?

A)Clarity
B)Conciseness
C)Timeliness
D)Accuracy

Question 64

List the six basic steps involved in building the house of quality.

Question 65

Describe the microphone drop test procedure used by Shure Inc.

Question 66

Describe the product/process development phase in a typical product development process.

Question 67

Describe the perspiration test procedure used by Shure Inc.

Question 68

The managed care organizations (MCOs)used the QFD process to redesign their handbook.List the steps followed by the focus groups in giving input for this QFD process.

Question 69

List the key customer requirements identified by the managed care organizations (MCOs)while redesigning their handbook.

Question 70

The managed care organizations (MCOs)used the QFD process to redesign their handbook.Describe the two stages in which the focus group process was administered to obtain inputs for this QFD process.

Question 71

Describe the test used by Shure Inc.to determine ability of their product to withstand extreme temperature for extended periods of time.

Question 72

Which of the following remains Shure's flagship product to this day?

A)Hands-free cell phones
B)Mixers
C)Microphones
D)Digital signal processors

Question 73

What helped Shure's products to be known early on for their outstanding quality and durability?

Question 74

Describe concurrent engineering.

Question 75

Describe Fault Tree Analysis.

Question 76

Which of the following tests is conducted by Shure Inc.to determine the ability of stylus to withstand accidental drops and side impacts?

A)Microphone drop test
B)Cartridge drop and scrape test
C)Perspiration test
D)Cable and cable assembly flex test

Question 77

What is the mission and philosophy of Shure Inc.?

Question 78

The managed care organizations (MCOs)used the QFD process to redesign their handbook.List the criteria based on which the participants for the focus groups,who gave input for this QFD process,were selected.

Question 79

Explain how the Absolute Quality Weight and the Percentage of Importance was determined in the House of Quality created by the result of the MCOs' QFD study.

Question 80

The managed care organizations (MCOs)used the QFD process to redesign their handbook.List the technical requirements identified through this QFD process that describe how the organization will respond to the customer requirements.