TQM TOOLS -Unit IV

 TQM TOOLS -Unit IV 

PART A (2 MARKS):

 1.What is a QFD?

Quality Function Deployment is a planning tool used to fulfill

customer expectations. It is a disciplined approach to product design, engineering, and

production and provides in-depth evaluation of a product.

2.. What are the benefits of QFD?

i. Customer driven

ii. Reduces implementation time

iii. Promotes teamwork

iv. Provides documentation

3. What are the steps required to construct an affinity diagram?

i. Phrase the objective

ii. Record all responses

iii. Group the responses

iv. Organize groups in an affinity diagram

4.What are the goals of TPM?

The overall goals of Total Productive Maintenance, which is an

extension of TQM are

i. Maintaining and improving equipment capacity

ii. Maintaining equipment for life

iii. Using support from all areas of the operation

iv. Encouraging input from all employees

v. Using teams for continuous improvement

5. Give the seven basic steps to get an organization started toward TPM?

a) Management learns the new philosophy

b) Management promotes the new philosophy

c) Training is funded and developed for everyone in the organization

d) Areas of needed improvement are identified

e) Performance goals are formulated

f) An implementation plan is developed

g) Autonomous work groups are established

6. What are the major loss areas?

i. Planned downtime

ii. Unplanned downtime

iii. Idling and minor stoppages

iv. Slow-downs

v. Process nonconformities

vi. Scrap

7.Define TPM?

T : Total = All encompassing by maintenance and production individuals working

together.

P : Productive = Production of goods and services that meet or exceed customer’s

expectations.

M : Maintenance = Keeping equipment and plant in as good as or better than te

original condition at all times.

8.Define quality cost.

Quality cost is defined as the cost associated with the non-achievement of

product/service quality as defined by the requirements established by the

organisation and its contracts with customers and society.

9.List the categories of quality costs.

The categories of quality cost are

1. Cost of prevention

2. Cost of appraisal

3. Cost of internal failures and

4. Cost of external failures.

10.What is meant by cost of prevention?

Prevention costs are the costs that are incurred on preventing a quality problem

from arising.

11.List the elements of cost of prevention.

The elements of cost of prevention are

1. Cost of quality planning

2. Cost of documenting

3. Process control cost

4. Cost of training

5. Costs associated with preventing recurring defects.

12.What is cost appraisal?

Appraisal costs are the cost that are incurred in assessing that the

products/services conform to the requirements

13. What are the cost of appraisal?

The cost of appraisal are

1. Cost of receiving test and equipment

2. Cost of Laboratory acceptance testing

3. Cost of installation testing

4. Cost of installation and commissioning

5. Cost of maintenance and calibration of testing and inspecting

equipments.

14. What is meant by cost of internal failures?

The costs associated with defective products, components and materials

that fail to meet quality requirements and result in manufacturing losses are called

as costs of internal failures. These costs are linked to correcting mistakes before

delivery of the product

15. List the components cost of internal failures.

The cost of internal failures are

1. Cost associate with scrap and rejects.

2. Cost of repair and rework.

3. Cost of design changes.

4. Cost of trouble shooting

5. Cost of reinspection and retesting., etc;

16. What is meant by cost of external failures?

It consist of the cost which are generated because of defective products

being shipped to customers. These cost are associated with the adjustments of

malfunctions after delivery of the product.

17.Give the sub-elements of Preventive cost category?

i. Marketing/Customer/User

ii. Product/Service/Design development

iii. Purchasing

iv. Operations/

v. Quality Administration

vi. Other Prevention Costs

18. Give the sub-elements of Appraisal cost category?

i. Purchasing appraisal cost

ii. Operations appraisal cost

iii. External appraisal cost

iv. Review of test and application data

v. Miscellaneous quality evaluations

19. Give the sub-elements of Internal failure cost category?

i. Product or Service Design costs (Internal)

ii. Purchasing failure costs

iii. Operations failure costs

20. Give the sub-elements of External failure cost category?

i. Complaint investigations of customer or user service

ii. Returned goods

iii. Retrofit and recall costs

iv. Warranty claims

v. Liability costs

vi. Penalties

vii. Customer or user goodwill

viii. Lost sales

ix. Other external failure costs

21. Give the typical cost bases?

i. Labor

ii. Production

iii. Unit

iv. Sales

22. How will you determine the optimum cost?

a. Make comparison with other organizations

b. Optimize the individual categories

c. Analyze the relationships among the cost categories

24. 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.

25. 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

26. What are the types of benchmarking?

i. Internal

ii. Competitive

iii. Process

27. What are the objectives for benchmarking?

The objectives for benchmarking are

1.  Benchmarking aims at a goal setting process to facilitate comparison with best.

2.  It aims at motivating and stimulating company employees towards the goal of continuous quality improvement.

3.  It aims at external orientation of the company.

4.  It aims at identifying a technological breakthrough.

5.  It aims at searching for industry best practices.

28. What are the different types of benchmarking in relation to objects being benchmarked?

The different types of benchmarking in relation to objects being benchmarked are

1. Product benchmarking

2. Performance benchmarking

3. Process benchmarking and

4. Strategic benchmarking.

5. Relationship benchmarking

29. List out any four benefits of benchmarking.

The benefits of competitive benchmarking include:

1. Creating a culture that values continuous improvement to achieve excellence.

2. Sharing the best practices between benchmarking partners.

3. Prioritizing the areas that need improvement.

4. Enhancing creativity by d evaluating the not-invented-here syndrome.

30. What is a QFD?

Quality Function Deployment is a planning tool used to fulfill

customer expectations. It is a disciplined approach to product design, engineering, and production and provides in-depth evaluation of a product.

31. What are the benefits of QFD?

The benefits of QFD are i. Customer driven

ii. Reduces implementation time

iii. Promotes teamwork

iv. Provides documentation

32. What are the steps required to construct an affinity diagram?

The steps required to construct an affinity diagram are i. Phrase the objective

ii. Record all responses iii. Group the responses

iv. Organize groups in an affinity diagram

33. What are the parts of house of quality?

The parts of house of quality are i. Customer requirements

ii. Prioritized customer requirements iii. Technical descriptors

iv. Prioritized technical descriptors

v. Relationship between requirements and descriptors vi. Interrelationship between technical descriptors

34. How will you build a house of quality?

a) List customer requirements b) List technical descriptors

c) Develop a relationship matrix between WHATs and HOWs d) Develop an interrelationship matrix between HOWs

e) Competitive assessments

f) Develop prioritized customer requirements g) Develop prioritized technical descriptors

35.Define FMEA? (Au Nov 05 ,)

Failure Mode Effect Analysis is an analytical technique that combines the technology and experience of people in identifying foreseeable failure modes of a product or process and planning for its elimination

36. What are the stages of FMEA?

The stages of FMEA are

1. Specifying possibilities

a. Functions

b. Possible failure modes c. Root causes

d. Effects

e. Detection/Prevention

2. Quantifying risk

a. Probability of cause b. Severity of effect

c. Effectiveness of control to prevent cause d. Risk priority number

3. Correcting high risk causes

a. Prioritizing work b. Detailed action

c. Assigning action responsibility

d. Check points on completion

4. Revaluation of risk

a. Recalculation of risk priority number

37. What are the several types of FMEA?

Design FMEA Process FMEA Equipment FMEA Maintenance FMEA Concept FMEA Service FMEA System FMEA

              Environment FMEA etc.

38. What are the phases of QFD process?

I. Product planning

ii. Part development

 iii. Process planning

               iv. Production planning

39. What are the major loss areas?

i. Planned downtime

ii. Unplanned downtime

iii. Idling and minor stoppages iv. Slow-downs

v. Process nonconformities

               vi. Scrap

  40. What are the generic steps for the development and execution of action    plans in benchmarking?

 Specify tasks.

               Sequence tasks

Determine resource needs.

 Establish task schedule.

 Assign responsibility for each task.

 Describe expected results.

               Specify methods for monitoring results

41. What are the goals of TPM?
The overall goals of Total Productive Maintenance, which is an extension of TQM are i. Maintaining and improving equipment capacity ii. Maintaining equipment for life iii. Using support from all areas of the operation iv. Encouraging input from all employees v. Using teams for continuous improvement

42. Give the seven basic steps to get an organization started toward TPM?
a) Management learns the new philosophy b) Management promotes the new philosophy c) Training is funded and developed for everyone in the organization d) Areas of needed improvement are identified e) Performance goals are formulated f) An implementation plan is developed g) Autonomous work groups are established

43.  When is QFD used? (Nov/Dec ‘06)

QFD is used when the true voice of customer needs to be identified for designing new products and services.

44. What do you mean by House of Quality? (Nov/Dec ‘09)

The primary planning tool used in QFD is House of Quality. The House of Quality converts the voice of the customer into product design characteristics.

45. Write the philosophy of quality loss function? (Nov/Dec ‘06)

The loss function philosophy says that “For a manufacturer the best strategy is to produce products as close to the target as possible rather than aiming at being within specifications”.

46. Differentiate between Taguchi’s approach and traditional approach. (Nov/Dec ‘10)

In traditional approach the product within the specification limit is considered as a good product while the outside are as bad.

In Taguchi’s approach when a product move from its target value that move causes a loss no matter if the move falls inside or outside the specified limits.

47. List out the various techniques adopted for JIT. (Nov/Dec ‘09)

Pull system, Kanban, Waste reduction, TPM, Continuous improvement, Flexible work force, etc.

48. What are objectives/ benefits of TPM? Or Why TPM is required?  (Nov/Dec ‘05)

1. To improve equipment effectiveness

2. To achieve autonomous maintenance

3. To plan maintenance

4. To train all staff in relevant maintenance skills.

5. To achieve early equipment management.

49. Define Failure rate. (Nov/Dec ‘09)

It is the probability of failure per unit time of items in operation; sometimes estimated as a ratio of the no. of failures to the accumulated operating time for the items.

50. Differentiate failure mode and failure effects. (Nov/Dec ‘10)

 A failure mode is defines as the manner in which a component, subsystem, process,etc., could potentially fail to meet the design purpose.

A failure effect is defined as the result of a failure mode on the function of process as perceived by the customer.

PART B (16 Marks)

1.Explain QFD with a suitable example. What are its advantages and Limitations.

2. Write short notes on: (a) Taguchi’s Quality Loss Function  (b) TPM

3.Explain quality costs.

4.What are the barriers for implementing TQM in an industry?

Explain.

5.What are the six major loss areas need to be measured for implementing TPM?

6.Discuss the QFD process with new chart and flow diagram.

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