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7 A team has an issue with oil leaks in the vehicle. They search under the hood and
find an oil cooler leaking. They notice the oil is coming out between a shaft and a
seal. They tear the oil cooler apart and find nicks on a shaft. A walk of the process
of shaft manufacturing uncovers a gauge fixture that is creating the nicks. What
problem solving strategy did the team use to find the cause of the leaks?
A). Working backwards from Y to X.
B). Transfer function physics.
C). Contrast and convergence.
D). Acceleration to degradation and or failure.
E). Stress strength interference.
8 A process for manufacturing door trim panels has rejects for a profile greater than
0.01”. The lower the profile dimension, the better the panels fit to the door. The
team decided to select 3 samples from each of the ends of the distribution to study
differences. What strategy did the team choose?
9 A weld breaks during assembly. What method is appropriate for solving this issue?
A). Working backwards from Y to X. B). Transfer function physics. C). Contrast
and convergence. D). Acceleration or degradation E). Stress strength interference.
10 A headlight has 0.01% fallout for weld failure in the vehicle. The team creates a test
to apply increasing pressure until the weld fails. Which strategy is the team using?
A). Working backwards from Y to X. B). Transfer function physics.
C). Contrast and convergence. D). Acceleration to degradation and or failure.
E) . Stress strength interference
Gear
12 Two CNC machines are used to make wheel hubs. Is there a significant difference
in the median diameter of the hubs built by each machine?
A). End count is 7 but there are not enough samples to prove a significance.
B). End count is 7 and there is a significant difference
C). End count is 4 but there is not enough data to prove significance
D). End count is 3 but there is not enough data to prove significance
13 Team is having an issue with plastic welds breaking. There are two welding
machines used to make the parts. The team believes that welder #1 makes stronger
parts than #2. Correct?
A). Yes – the end count is > to 7 so welder #1 is making stronger parts.
B). No – Not enough data to prove significance.
C). No – the end count is > 7 but welder #2 is making the stronger parts. D).
No – the end count is not > 7 which is not enough to prove significance.
A). Yes – The average noise level of the Kluber appears to be less than the Krytox.
B). No – The data sets have complete overlap so the end count is much < 7.
C). Yes – Kluber Grease has parts that are less than the Krytox Grease parts.
D). No – The Tukey end count is only 4, fail to reject the null.
17 “A” and “B” show variation from the same process. What is the difference?
19 Two measurements systems were evaluated for use on problem solving. Which of
the following two measurement systems would you use? Gauge 1
22 A team completes a study of cavity pressure and time a gate valve is open
versus
the height of a part. Is there an
interaction between pressure
and gate valve time?
24. What is the Tukey end count for cavity pressure at 3100 psi?
25 A Designed Experiment main effects plots are shown below. Which variables
appear to have the biggest influence on the pressure at which the part leaks?
27 Team is working to mean center a body panel stamping. What is the issue?
A). Geometry B). Physics
28. A machining process sometimes gets a metal chip between the chuck and the part
causing the part to have an out of specification runout. What type of issue is this?
A). Geometry B). Physics
29 Which of the following tactics exemplify step “B” (The physics of how a product or
process is supposed to work) ?
A). Team reviews detailed process flow chart and decides temperature and
pressure might be critical variables. A DOE for molding height is completed
and results in the following equation: Molding height = 52 + 0.25*temperature
+ 0.45*pressure + 0.05*weld temperature*pressure.
B). Team implements SPC to continue to control the process. They observe out of
control points and investigate. 100% inspection is put in place anytime the
process is shown to be out of control.
C). Should be based on what experts say is important.
31 Statistical Thinking recognizes that everything is a process, all processes vary, and
reducing key variation is the path to process success.
A). True. B). False.
34 Identify the following descriptions as CTQ, CTQ Error State, KPOV, or KPIV factors:
Description Factor
2 Psi to Leak KPOV
I like my Engine CTS
50 Micron Gap KPIV
100 R/1000 CTS error state
35 The team theorizes that going to a Mexican restaurant takes longer than other local
restaurants (see data below). Is the team’s theory statistically significant?