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business
total quality management

Questions and Answers of Total Quality Management

Define the role of the project manager in the enterprise and how he or she fits into the prevailing hierarchies, particularly if you have a personal example.
Write an essay that defends a management approach: project-based, matrix, weak matrix, and pyramid.
Create a protocol for capturing “lessons learned.”
Why are lessons learned so easy to speak about and so difficult to do? Come up with an explanation for this anomaly.
Difficult: brainstorm 100 ways to capture lessons learned and choose 20 of these for future assessment.
What is the objective of product testing?
Create a map of a hardware test bench.
Create a map of a software test bench.
Create a map of a hardware-in-the-loop (real subsystems) software test bench.
Define how much subsystem simulation you consider to be appropriate.
List the types of simulation available (for example, discrete-event) and define for each one the most applicable scenario.
As a PM, when would you start testing? What tools allow you to do this? List your assumptions and probable tool use. How would you know when you are finished with testing?
Summarize the main goals of testing.
Explain how you would test a process.
Pick a process for simulation and summarize how this approach could help with process analysis and improvement.
Explain how you would determine which metrics are significant.
Make a case for a specific number (count) of metrics.
How many are too few?
How many are too many?
What is the goal?
How do you consolidate metrics for presentation to management?
Write a protocol that defines how the various developmental, product integrity, and order fulfillment teams will report to you.
Which metrics do you need?
How do you avoid becoming overwhelmed?
Explain in a well-reasoned essay which tools seem to be the most useful for the TQM project manager.
Explain the relationship between the project manager and the line manager in a matrix organization.
Describe how TQM tools allow the project manager to understand and mitigate risks to the project.
When would you use a Pareto diagram?
Create an Ishikawa diagram for an effect you wish to understand the cause.
Create a checklist for the quality activities for a product with which you are familiar.
Explain the difference between checklists, and check sheets.
Draw flow chart for a project change management process.
Provide two examples of tampering. Show how tampering is not always a physical event.Create a level three Work Breakdown Structure for an embedded product.
How does task variation impact the critical path of a project schedule? Provide a strategy for handling the critical path tasks versus the non-critical path tasks in terms of accounting for variation.
What tasks are least impacted by task duration variation?
What happens when non-critical path items show up on the critical path due to schedule changes and execution? How can this be anticipated?
List 2 duration estimating techniques?
Define a project with a number of gates. Identify the key deliverables and what each gate should address. You can use your industry’s project life cycle model if needed.
What is the reason behind a project white book? What level of team participation is appropriate? What happens when team members are excluded? What happens when the content of the white book is
List three brainstorming techniques? When is this approach least effective?
What are the prerequisites to employing Earned Value Management tools?
What are the obstacles to developing a time phased budget?
What happens when you can’t get the information you need to be successful in your project activity?
What are the prerequisites to employing Earned Value Management tools?
Use any collected data and group through time in subgroups of five to ten items and take the mean of these values—you will see a normal distribution.
Use the R statistical tool and any of the following packages: IQCC, qat (quality assurance toolkit), or qcc (quality control charts). Perform the same grouping as above but use the tool to plot the
Try any other statistical package: Minitab, Statistica, SAS, SPSS, or other.
Follow a stock price value with a CuSum chart.
Follow a stock price value with an EWMA chart.
Plot your weight over a period of time.
Compare and contrast attribute data and variable data.
Pick a part of your organization’s process, identify the relevant data needed to acquire to understand that capability. Gather this information. Perform statistical analysis on that data.
Describe what a running average is.
Provide one example how understanding the project processes via T QM is valuable.
Create a process control plan for the main thread of the project time line with special attention paid to the reaction plan.
Create a process FMEA for the main thread of the project time line.
Create a process for project change management including stakeholders.
Show a time line that looks “sewn” because the main thread bounces between product development and process development.
What would a short version of the statement of work look like?
Discuss the level of detail used in a statement of work. What is important?
Build a work breakdown structure for a wooden pencil.
Build a work breakdown structure for a mechanical pencil.
Build a work breakdown structure for a ballpoint pen.
Link responsibility to the above work breakdown structure.
Search the world wide web for Microsoft Excel examples that support various control charts and try them with the data we have already used.
Map your process and create a process FMEA (PFMEA) for this process.
Make an argument for significant value part numbers (these are the part numbers where you can tell what it is by looking at the part numbers).
Make an argument for random value part numbers (you can’t tell what it is from the part number).
Develop an efficient protocol for configuration identification.
Read MIL-STD-973 and summarize the approach of the Department of Defense to configuration management.
Read MIL-HDBK-61 and summarize the approach of the Department of Defense to configuration management.
Create an efficient approach to MIL-STD-973 style configuration management.
Explain why you want software development to fall under a software configuration management tool.
Determine if you have a manufacturing resource planning (MRP) system or something like it and see if you can manage prototype part numbers in this system (many can’t do this at all or very well).
Create a protocol for shifting from MRO (maintenance, repair, and operations)purchased parts to MRP purchased parts (we often see a discontinuity in parts ordering during this shift).
Evaluate the comparative and contrasting benefits/costs of using MRO purchasing or MRP buying.
Difficult: compile a taxonomy of parts numeration schemes (a least five, with ten more desirable) and summarize the costs and benefits of each type.
Difficult: choose a project time line that you already have for a small- to medium-sized project and restate the sequence of events in process control plan format (you may use the AIAG format).
Contrast and compare the typical FMEA approach with FMECA (Failure Mode, Effects, and Criticality Analysis [MIL–STD–1629A]) and then HACCP(Hazard Analysis and Critical Control Point [ISO 22000
Merge the concept of the FMEA with that of a process control plan and synthesize a new super-document.
List probable documentation requirements for a typical project.
Produce a protocol that specifies how much say a purchasing/procurement department or organization should have regarding acceptance of new products.
Produce a specification that defines the steps necessary to avoid bad parts or bad designs when accepting a new product. Define whether you see a difference between commodity parts and
Compile a protocol that balances risk management with speed for incoming new components.
Difficult: produce a complete program for reducing risk with new components, component changes, and other supplier changes.
Difficult: produce a complete program for reducing risk with product releases, product changes, and customer demands and interference.
Difficult: define an efficient method for tying an enterprise configuration management system on the supplier side with a different enterprise configuration management system on the customer side.
Medium: if release of bad material to a customer is an “escape,” what is the best way to prevent an escape? Define how you would do this improvement without simply adding more controls.
Come up with some reasonable explanation why we don’t have every component“mistake-proofed” (poka-yoke) and what recommendation you would make to improve this situation.
Design a system that does not need quality inspections.
Explain why you would do 100% visual inspection when it appears to have so little real value.
If you have inspection standards available (Z1.4 or Z1.9 or even MIL-STD-109), select an inspection mode and explain your selection.
Construct a method for preventing type 2 failures.
Explain (compare and contrast) the difference between quality assurance and quality control.
State a well-reasoned argument for why we do not inspect every piece.
Generate an essay explaining your approach to inspecting small commodity parts (for example, surface-mount resistors).
Categorize the types of inspection (see if you can find some which we did not elucidate in this chapter) and explain in tabular format the benefits and costs of each approach.
Analyze your own situation and determine when it is advisable to tighten up or loosen the inspection requirements (note that the standards provide for this situation).
Justify using an attribute sampling plan instead of a variables-based sampling plan.
Analyze a mass production situation (for example, surface mount soldering of printed circuit boards) and justify the cost of an automated optical inspection system.

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