Chapter 7 QUIZ Questions PDF

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Chapter 7 practical multiple choices and short answer questions...

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Managing Quality: Integrating the Supply Chain, 5e (Foster) Chapter 7 Quality and Innovation in Product and Process Design 1) What is the first step in the product development process? A) project customer needs B) generate product ideas C) process technology selection D) manufacturing system design E) marketing plan design Answer: B 2) During the ________ stage of the project development process, external and internal sources brainstorm new concepts. A) product marketing and supply chain preparation B) technology development for process selection C) customer future needs projection D) product idea generation E) technology selection for product development Answer: D 3) Which of the following is an internal source for product ideas? A) management B) industry experts C) competitors D) inventors E) customers Answer: A 4) Which of the following is an external source for product ideas? A) marketing B) employee suggestions C) research and development D) management E) industry experts Answer: E 5) R&D-generated ideas can be differentiated from marketing-generated ideas in that the latter ________. A) tend to be risky B) are less aligned with customer needs C) build on existing designs D) tend to be groundbreaking E) tend to be technologically innovative Answer: C

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6) During ________ stage of the product development process, preliminary work can be performed to identify key quality characteristics and potential for variability with each of the different materials. A) product marketing and supply chain preparation B) technology selection for product development C) technology development for process selection D) final product definition E) manufacturing system design Answer: B

7) The ________ stage of the product development process often requires the design of aftersales processes such as maintenance, warranties, and repair processes that occur after the customer owns the product. A) final product definition B) product design and evaluation C) manufacturing system design D) technology selection for product development E) product marketing and supply chain preparation Answer: E 8) The ________ stage of the product development process requires definition of the product architecture, the design, production, testing of subassemblies, and testing of the system for production. A) manufacturing system design B) final product definition C) product design and evaluation D) technology development for process selection E) technology selection for product development Answer: C 9) In the product development process, the acronym PDS stands for ________. A) Product Development System B) Product Distribution System C) Product Design and Selection D) Product Design Specification E) Product Definition and Specification Answer: D 10) The ________ stage of the product development process involves the selection of the process technologies that will result in a low-cost, high-quality product. A) final product definition B) technology selection for product development C) technology development for process selection D) product design and evaluation E) manufacturing system design Answer: E 7-2

11) What is the final step in the product development process? A) project customer needs B) manufacture, delivery, and use C) final product definition D) product evaluation E) manufacturing system design Answer: B 12) The acronym QFD stands for ________. A) Quality Function Deployment B) Quality Feasibility Development C) Quality Function Design D) Quality Factors for Development E) Quality Feasibility Data Answer: A 13) ________ describes a method for translating customer requirements into functional design. A) Manufacturing system design B) Final product definition C) Quality function deployment D) Product design specification E) Customer future projection Answer: C

14) What is the first step in performing quality function deployment? A) prioritize technical requirements B) identify the correlations between design elements in the roof of the house C) prioritize customer requirements D) develop a listing of technical design elements along the roof of the house E) develop a list of customer requirements Answer: E 15) A particular customer requirement has a strong association with a technical requirement, an importance of 6, a target value of 3, and a sales point value of 2. The absolute weight of this customer requirement is ________. A) 1 B) 6 C) 9 D) 18 E) 36 Answer: E

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16) A particular customer requirement is associated with a technical requirement, has an importance of 3, a target value of 5, and a sales point value of 2. The absolute weight of this customer requirement is ________. A) 15 B) 30 C) 6 D) 10 E) 25 Answer: B 17) A particular customer requirement is associated with a technical requirement, has an importance of 3, a target value of 1, and a sales point value of 3. The absolute weight of this customer requirement is ________. A) 9 B) 45 C) 6 D) 90 E) 81 Answer: A 18) A particular customer requirement has a strong association with a technical requirement, an importance of 9, a target value of 3, and a sales point value of 1. The absolute weight of this customer requirement is ________. A) 1 B) 3 C) 9 D) 27 E) 243 Answer: D 19) ________ is used to develop a computer compatible mathematical description of a part. A) Geometric modeling B) Engineering analysis C) Multilevel prototyping D) Process modeling E) Concurrent engineering Answer: A 20) ________ involves the usage of heat-transfer calculations, stress calculations, or differential equations to determine the dynamic behavior of the system being designed. A) Process modeling B) Geometric modeling C) Concurrent engineering D) Engineering analysis E) Multilevel prototyping Answer: D 7-4

21) Examining a design to see if different components in a product occupy the same space is called ________. A) process evaluation B) design analysis C) interference checking D) multilevel evaluation E) product testing Answer: C

22) The ________ component of a CAD system allows for the cataloging and standardization of parts and components for complex products. A) group technology B) geometric modeling C) multilevel prototyping D) product testing E) concurrent engineering Answer: A

23) ________ refers to the performance of all the design process steps simultaneously. A) Just-in-time engineering B) Lean engineering C) Concurrent engineering D) Reengineering E) Reverse engineering Answer: C 24) ________ refers to the differences in products that are produced and marketed by a single firm at any given time. A) Change B) Criticality C) Nonuniformity D) Variety E) Differentiation Answer: D 25) ________ is the magnitude of the differences in a product when measured at two different times. A) Criticality B) Variety C) Differentiation D) Nonuniformity E) Change Answer: E

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26) ________ products are new products using similar technologies that can coexist in a family of products. A) Contiguous B) Complementary C) Differentiated D) Concurrent E) Variable Answer: B 27) ________ means to design products so that they are cost-effective and simple to build. A) Design for maintenance B) Design for control C) Design for reliability D) Design for engineering E) Design for manufacture Answer: E 28) ________ means standardizing parts, modularizing, and using as few parts as possible in a design. A) Designing for engineering B) Designing for reliability C) Designing for manufacture D) Designing for simplicity E) Designing for control Answer: D 29) Over-the-wall syndrome refers to the difficulties that arise when ________. A) different types of engineers work in totally different departments B) firms integrate financial, planning, and control systems into a single architecture C) translating customer requirements into functional design D) environmental issues become key considerations for companies designing products E) the design products become complicated to build Answer: A

30) ________ systems are used to integrate financial, planning, and control systems into a single architecture. A) Product data management B) Enterprise resource planning C) Computer-aided design D) Business process management E) Information technology management Answer: B

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31) ________ reliability is defined as the propensity for a part to fail over a given time. A) System B) Concurrent C) Component D) Process E) Perpetual Answer: C 32) What is the first step in failure modes and effects analysis? A) assign each component an identifier B) list functions for each part C) identify highest risks D) list one or two failure modes for each function E) estimate likelihood of failure Answer: A 33) What is the final step in failure modes and effects analysis? A) describe effects of each failure mode B) estimate likelihood of failure C) eliminate or reduce highest risks D) estimate failure detection E) determine hazard likelihood and categorize Answer: C

34) ________ refers to how often a failure will occur, how easy it is to diagnose, and whether it can be fixed. A) Reliability B) Criticality C) Traceability D) Feasibility E) Maintainability Answer: B

35) A method of manufacturing that minimizes waste and pollution is referred to as ________. A) renewable manufacturing B) clean manufacturing C) green manufacturing D) ecofriendly manufacturing E) sustainable manufacturing Answer: C

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36) The life-cycle approach to product design has led to practices known as ________. A) design for aesthetics, design for performance, and design for quality B) design for ease of manufacture, design for optimal pricing, and design for quality C) design for cost containment, design for quality, and design for conformance D) design for reuse, design for disassembly, and design for remanufacture E) design for reliability, design for dependability, and design for conformance Answer: D 37) The principles for ________ include using fewer parts and fewer materials, and using snapfits instead of screws. A) design for disassembly B) design for conformance C) design for reuse D) design for remanufacturing E) design for performance Answer: A 76) State the nine phases of a product development process. Answer: The design process includes nine phases that are interrelated: • Product idea generation • Customer future needs projection • Technology selection for product development • Technology development for process selection • Final product definition • Product marketing and supply chain preparation • Product design and evaluation • Manufacturing system design • Product manufacture, delivery, and use 77) What is quality function deployment (QFD)? Answer: Quality function deployment (QFD) describes a method for translating customer requirements into functional design. Sometimes this process of translation is referred to as the voice of the customer. The quality function deployment approach was developed by Dr. S. Mizuno, a former professor of the Tokyo Institute of Technology. 78) What are the steps in performing quality function deployment? Answer: Following are the steps in performing quality function deployment: • Develop a list of customer requirements. • Develop a listing of technical design elements along the roof of the house. • Demonstrate the relationships between the customer requirements and technical design elements. • Identify the correlations between design elements in the roof of the house. • Perform a competitive assessment of the customer requirements. • Prioritize customer requirements. • Prioritize technical requirements. • Final evaluation. 7-8

79) How are the values for absolute and relative weights established? Answer: The value for the absolute weight is the sum of the products of the relationship between customer and technical requirements and the importance to the customer columns. The value for relative weight is the sum of the products of the relationship between customer requirements and technical requirements and the customer requirements absolute weights. 80) What are multi-user CAD systems? Answer: An important advance in CAD systems has been the advent of multi-user CAD systems. Using a common database in a network, multiple designers in locations worldwide can work on a design simultaneously around the clock. Consider a multinational corporation developing a new product. When the U.S. designers sleep, Asian and European designers work. When the U.S. designers return to work, they can see the progress that has been made overnight. 81) Explain the use of CAD systems in geometric design and engineering analysis. Answer: CAD systems are used in geometric design and engineering analysis. Geometric modeling is used to develop a computer-compatible mathematical description of a part. The image developed is typically a wire-frame drawing of a component. This part may appear in two dimensions, as a two-dimensional drawing of a three-dimensional object, or in full three-dimensional view with complex geometry. Engineering analysis may involve many different engineering tests such as heat-transfer calculations, stress calculations, or differential equations to determine the dynamic behavior of the system being designed. Analysis-of-mass-properties features in CAD systems automatically identify properties of a designed object such as weight, area, volume, center of gravity, and moment of inertia. CAD systems allow for the automatic calculation of these properties. 82) Define interference checking with an example. Answer: Examining a design to see if different components in a product occupy the same space is called interference checking. Interference checking is of major importance in design of airplanes. Hundreds of pipes and thousands of wires occupy the walls of the aircraft. Interference checking in design review ensures that designs are feasible. This is especially important for airplane makers because so many engineers are participating in the design. 83) What is the group technology component of a CAD system? Answer: An important component of a CAD system is the group technology component that allows for the cataloging and standardization of parts and components for complex products. Standard parts can result in fewer suppliers, simpler inventory, and less variability in processes.

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84) Explain concurrent engineering and state its benefits. Answer: If the design process steps are performed sequentially, the design process will be very time-consuming. Therefore, the steps are performed simultaneously as often as possible. This approach is called concurrent engineering and has been very helpful in speeding up the design life cycle. The benefits of concurrent engineering primarily include communication among group members and speed. By working on products and processes simultaneously, the group makes fewer mistakes, and the time to get the concept to market is reduced drastically. The team concept joins people from various disciplines, which enhance communication and the cross-fertilization of ideas. Another benefit of concurrent engineering is increased interaction with the customer. Often customers are included in concurrent engineering teams to give immediate feedback on product designs. 85) State the importance of complementary products. Answer: Complementary products are new products using similar technologies that can coexist in a family of products. Complementary products are needed for two reasons. First, product obsolescence requires that products be updated. Second, some products have seasonal demand necessitating counter seasonal products. 86) State any three considerations in a design. Answer: There are many things to consider when designing products. One of the biggest considerations is design for manufacture (DFM). Design for manufacture means to design products so that they are cost-effective and simple to build. Another aspect is designing for reliability. It makes little sense to design a product that is capable and stable but not reliable. Product designs must be simple. Designing for simplicity means standardizing parts, modularizing, and using as few parts as possible in a design. 87) Explain the over-the-wall syndrome. Answer: In the old world of designing products, there existed a hierarchy of engineers. At the top of this hierarchy was the product design engineer. Lower down the hierarchy were the process design engineers. Often these different engineers worked in totally different departments. The fact that they were in different departments often impeded communication. This organizational problem has been referred to as the over-the-wall syndrome. 88) State the importance of the product data management (PDM) tool? Answer: An important component of design software is the product data management (PDM) tool. PDM is a general extension of techniques commonly known as engineering data management, document management, and other similar names. PDM helps manage both product data and the product development process by tracking the masses of data needed to design, manufacture, support, and maintain products.

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89) Differentiate between component reliability and system reliability. Answer: Component reliability is defined as the propensity for a part to fail over a given time. System reliability refers to the probability that a system of components will perform the intended function over a specified product life. It is important to recognize the difference between component reliability and system reliability. The levels of measurement are different for system and component reliability. When we talk of component reliability, we refer to a finite aspect of the overall product. System reliability is computed from the aggregation of multiple components. 90) What are the benefits of using failure modes and effects analysis (FMEA)? Answer: Failure modes and effects analysis (FMEA) systematically considers each component of a system, identifying, analyzing, and documenting the possible failure modes within a system and the effects of each failure on the system. Some benefits that can be derived through the use of FMEA include: • Improvement of the safety, quality, and the reliability of products • Improvement of a company's image and its competitiveness • Increased satisfaction from a user standpoint • Reduction in product development cost • Record of actions taken to reduce a product risk

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91) State the nine-step process of failure modes and effects analysis (FMEA). Answer: Failure modes and effects analysis (FMEA) uses a nine-step process: • Assign each component an identifier. • List functions for each part. • List one or two failure modes for each function. • Describe effects of each failure mode. • Determine hazard likelihood and categorize. • Estimate likelihood of failure. • Estimate failure detection. • Identify highest risks. • Eliminate or reduce highest risks. 92) Describe the failure modes, effects, and criticality analysis (FMECA). Answer: Failure modes, effects, and criticality analysis (FMECA) is an extensive but simple method for identifying ways in which an engineered system could fail. As in FMEA, failures, effects, and causes are identified. FMECA rates failure modes by ranking each possible mode according to both the probabilities of its occurrence and the severity of its effects. The primary goal of FMECA is to develop priorities for corrective action based on estimated risk. FMECA is used to analyze a probable cause of a product failure, to determine how the problem affects a customer, to identify the probable manufacturing or assembly processes responsible, to identify which process control variable to focus on for prevention detection, and to quantify the effects on the customer. 93) Differentiate between design for reuse and design for disassembly. Answer: Design for reuse refers to designing products so they can be used in later generations of products. The principles for design for disassembly include using fewer parts and fewer materials, using snap-fits instead of screws, making assembly efficient and improving disposal, using design for disassembly experts in concurrent design teams, and eliminating waste through better design.

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