TQM TOOLS & TECHNIQUES-Unit III

TQM TOOLS & TECHNIQUES-Unit III

PART A (2 MARKS): 

1. Give the seven tools of quality?

i. Pareto Diagram

ii. Process Flow Diagram

iii.Cause-and-Effect Diagram

iv. Check Sheets

v. Histogram

vi. Control Charts

vii. Scatter Diagrams

2. Define Statistics?

Statistics is defined as the science that deals with the collection, tabulation, analysis, interpretation, and presentation of quantitative data.

3. What is a measure of central tendency?

A measure of central tendency of a distribution is a numerical value that describes the central position of the data or how the data tend to build up in the center. There are three measures in common in use in quality viz, the average, the median and the mode.

4. What is Measures of dispersion?

Measures of dispersion describe how the data are spread out or scattered on each side of the central value. The measures of dispersion used are range and standard deviation.

5. What is a normal curve?

The normal curve is a symmetrical, unimodal, bell-shaped distribution with the mean, median and mode having the same value.

6. What is the use of the control chart?

The control chart is used to keep a continuing record of a particular quality characteristic. It is a picture of process over time.

7. Give the objectives of the attribute charts?

i. Determine the average quality level.

ii. Bring to the attention of management any changes in the average.

iii. Improve the product quality.

iv. Evaluate the quality performance of operating and management personnel.

v. Determine acceptance criteria of a product before shipment to the customer.

8. Define Six Sigma Problem Solving Method?

Define - improvement opportunity with an emphasis on increasing customer satisfaction.

Measure - determine process capability (Cp/ Cpk) & dpmo (defects per million

opportunities).

Analyze - identify the vital few process input variables that affect key product output

variables (“Finding the knobs”).

Improve - Make changes to process settings, redesign processes, etc. to reduce the number of defects of key output variables.

Control - Implement process control plans, install real-time process monitoring tools, standardize processes to maintain levels.

9. What are the new seven management tools?

i. Affinity Diagram

ii. Interrelationship Digraph

iii. Tree Diagram

iv. Matrix Diagram

v. Prioritization Matrices

vi. Process Decision Program Chart

vii. Activity Network diagram

10. Define Benchmarking?

Benchmarking is a systematic method by which organizations can measure themselves against the best industry practices. The essence of benchmarking is the process of borrowing ideas and adapting them to gain competitive advantage. It is a tool for continuous improvement.

11. Enumerate the steps to benchmark?

a) Decide what to benchmark

b) Understand current performance

c) Plan

d) Study others

e) Learn from the data

f) Use the findings

12. What are the types of benchmarking?

i. Internal

ii. Competitive

iii. Process

13.What are the four basic steps included in SPC?

The four basic steps included in SPC are

a. Measuring the process

b. Eliminating variances in the process to make it consistent.

c. Monitoring the process.

d. Improving the process to its best target value.

14. Mention the seven basic tools involved in statistic quality control.

The seven tools involved in statistical quality control. They are,

a. Pareto diagram

b. Check sheet

c. Cause and effect diagrams

d. Scatter diagram

e. Histogram

f. Control charts

g. Graphs

15. What is Pareto chart?

A Pareto chart is a special form of a bar graph and is used to display the relative importance of problems or conditions.

16. Give some applications of Pareto chart.

The applications of Pareto chart are,

a. Focusing on critical issues by ranking them in terms of importance and

frequency (Example: which course causes the most difficulty for students?; which problem with product X is most significant to out customers?)

b. Prioritizing problems or causes to efficiently initiate problem solving (Example: which discipline problems should be tackled first? or what is the most frequent complaint by parents, regarding the school? solution of what production problem will improve quality most?)

17.What is the use of SPC?

SPC is used to monitor the consistency of processes used to manufacture a product as designed.

18. Define check sheet. Mention its uses.

The check sheet is a data gathering and interpretation tool.

A check sheet is used for,

a. Distinguishing between fact and opinion (Example: How does the community perceive the effectiveness of the school in preparing students for the world of work?)

b. Gathering data about how often a problem is occurring? (Example: How often are students missing classes?)

c. Gathering data about the type of problem occurring. (Example: What is the most common type of word processing error created by the students-grammar, punctuation, transposing letter etc.?)

19.What are the uses of cause and effect diagram?

A cause and effect diagram is used for,

a. Identifying potential causes of a problem or issue in an orderly way.

(Example: why has membership in the band decreased? Why isn’t the phone4 being answered on time? Why is the production process suddenly producing so many defects?)

b. Summarizing major causes under four categories. (Example: People, machines, methods and materials or policies, procedures, people and plant.)

20.What is scatter diagram?

A scatter diagram is used to interpret data by graphically displaying the relationship between two variables.

21. Lsit some applications of scatter diagram.

The applications of scatter diagram

a. Validating ‘hunches’ about a cause-and-effect relationship between types of variables (examples: I wonder if students who spend more time watching TV having higher or lower average GPA’s? IS there a relationship between the production speed of an n operator and the number of defective parts made? Is there relationship between typing speed in WPM and errors made?)

b. Displaying the direction of the relationship (positive negative, etc).

(Examples: will test scores increase or decrease if the students spend more time in study hall? Will increasing assembly line speed, increase or decrease the number of defective parts made? Do faster typists make more or fewer typing errors?)

c. defective parts produced? How strong is the relationship between typing

faster and the number of typing errors made?).

22. Define histogram.

A histogram is used to display in bar graph format measurement data distributed by categories.

23. What are the problems that can be interpreted by the histogram?

The problems that can be interpreted by the histogram are,

a. Skew problems

b. Clustering problems.

24.Define control chart.

Control chart is defined as a display of data in the order that they occur with statistically determined upper and lower limits of expected common cause variations. It is used to indicate special causes of process variations to monitor a process for maintenance and to determine if process changes have has the desired effect.

25. What is line graph?

A line graph is a way to summaries how two pieces of information are related

and how they vary depending on one another. The numbers along a side of the

line graph are called the scale.

26. What is an arrow diagram?

An arrow diagram is another term for a PERT or CPM chart. It is graphic

descriptions of the sequential steps that must be completed before a project can

completed.

27. Give some applications of arrow diagram.

The applications of arrow diagram are,

a. Understanding and managing complex project or task.

b. Understanding and managing a project that is of major importance to the

organization, and the consequences of late completion are sever.

c. Understanding and managing a project in which multiple activities must take

place and be managed simultaneously.

d. Explaining the project status to others.

28.How is an arrow diagram constructed?

Steps in constructing an arrow diagram are,

a. Select a team that is knowledgeable about the project, its task and subtasks.

b. Record all of the tasks and subtasks necessary to the completion of the

project.

c. Sequence the tasks.

d. Assign a time duration to each task.

e. Calculate the shortest possible implementation time schedule using the

critical path method.

f. Calculate the earliest starting and finishing times for each task.

g. Locate tasks with slack (extra) time and calculate total slack.

h. Update the schedule as the project is being completed.

29. What is nominal group technique?

The nominal group technique is a structured process, which identifies and ranks

the major problems or issues that need addressing.

30. Give the seven tools of quality?

•Pareto Diagram

•Process Flow Diagram

•Cause-and-Effect Diagram

               •Check Sheets

31. Give the usage of C&E diagrams?

•Analyze actual conditions for the purpose of product or service quality improvement, more efficient use of resources, and reduced costs.

•Eliminate conditions causing nonconformities and customer complaints.

•Standardize existing and proposed operations.

               •Educate and train personnel in decision-making and corrective-action activities

32. Define Six Sigma?

Six-Sigma is a business process that allows organizations to drastically improve their bottom line by designing and monitoring every day business activities in ways that minimize waste and resources while increasing customer satisfaction. It is achieved through continuous process measurement, analysis & improvement

33. What are the various histogram shapes?

* Symmetrical * Skewed right * Skewed left * Peaked * Flat * Bimodal * Plateau distribution * Comb distribution * Double peaked distribution

34. Differentiate Population & Sample?

Population represents the mathematical world and Sample represents the real world. A population frequency distribution is represented by a smooth curve whereas a sample frequency distribution is represented by a histogram.

35. Give the sources of variation?

Equipment,

 Material,

 Environment Operator

36. Define Run chart?

A  run chart is a very simple technique for analyzing the process in the development stage or, for that matter, when other charting techniques are not applicable.

37. What are the various patterns of scatter diagrams?

• Positive correlation

• Negative correlation

• No correlation

   • Negative correlation may exist

38. What is the procedure for constructing the tree diagram?

Choose an action oriented objective  statement from  the interrelationship diagram, affinity diagram, brainstorming, team mission statement, and so forth.

   Using brainstorming, choose the major headings. Generate the next level by analyzing      the major headings.

39. Give at least five standard formats of matrix diagram?

            L-shaped

            T-shaped

            Y-shaped

            C-shaped

            X-shaped

40. What are the benefits of an activity network diagram?

A realistic timetable determined by the users.

            Team members understand the role in the overall plan. Bottlenecks can be discovered and corrective action taken. Members focus on the critical tasks.

41.  What are the benefits of an activity network diagram?
1. A realistic timetable determined by the users.
2. Team members understand the role in the overall plan.
3. Bottlenecks can be discovered and corrective action taken.
4. Members focus on the critical tasks

.

 42. What are the categories in piece part production? (Nov/ Dec’08)

1. Change causes of variations

2. Assignable causes of variation.

43. Difference between control charts for variables and attributes. (Nov/ Dec’05)

The control charts for variables restrict the chance causes of variation by detecting & eliminating the Assignable causes.

The control charts for attributes monitor the no. of defects in the sample.

44. Mention the ways to reduce variability. (Nov/ Dec’09)

 The ways to reduce variability are to control variations in the equipment, material, environment,etc.

45.  Define Process capability. (Nov/ Dec’06) (Nov/ Dec’09)

Process capability may be defined as the “minimum spread of a specific measurement variation which will include 99.7% of the measurements from the given process.”

46. Define Process capability ratio. (Nov/ Dec’09)

Process capability index Cp = (USL – LSL)/6б

47. What are the control charts for attributes? (Nov/ Dec’06)

p-chart: The chart for fraction rejected as non-conforming to specifications

np chart: The control chart for no. of non-conforming items.

C chart : The control chart for no. of defects

U chart: The control chart for no. of defects per unit.

48. What are the five phases in six sigma process? (Nov/ Dec’05)

1. Define        2. Measure     3. Analysis     4. Improve     5. Control

49. When np chart is preferred over p chart?

When subgroup size is constant the np chart is preferred over p chart

50. When U chart is used?

When subgroup size varies from sample to sample then U chart is used.

PART B (16 Marks)

1. Explain the detail about the 7 SPC tools of quality.

2. Explain the term “process capability”.

3. Discuss in detail about the concept of Six-Sigma.

4. List out the new 7 management tools and explain each one.

5. Discuss briefly the various tools of statistical fundamentals.

6.Explain the QC or SPC tools?

7. Explain the Seven Management Tools?

8. Plot the control chart for variables and attributes

9. Explain the concepts of Six Sigma?

10.Explain the different steps involved in FMEA with an examples.

11.problems in control charts and process capability