SOLVING A MAINTENANCE PROBLEM - SCDL C …scdlpgdba.weebly.com/uploads/4/6/5/9/4659319/techniques_for... · INTRODUCTION: Systematic problem solving provides a structured approach

Vikas Choudhary 200323811

Techniques for Operation Efficiency

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1) What are the basics steps in the problem solving process? Explain them briefly. Ans: INTRODUCTION: Systematic problem solving provides a structured approach to problem solving. Depending upon the nature of problem (i.e. maintenance or improvement problem), some steps may be different. SOLVING A MAINTENANCE PROBLEM: Maintenance problems as mentioned earlier, surface when the status quo is distributed and decision make needs to recommend/take measures to restore and maintain the status quo.

Fig: Steps to solve a maintenance problem.

(a) Diagnose (define) the problem: Sound diagnosis is the crucial step in the problem solving process. Defining the problem sets the boundaries for that follows. Decision maker, like a doctor, must take into account all symptoms before prescribing the medicines (i.e. recommending the

Identify a maintenance problem

Collect data on “causes”

Perform Pareto Analysis

Identify root causes

Evolve alternatives & select (Brain storming)

Implement best alternative

Monitor effect

Is the problem resolved?

End

No



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decision). Peter Drucker rightly states, “The books and articles on leadership are full of advice on how to make fast, forceful and useful decisions, but there is no more foolish and no more time wasting advice than to decide quickly what a problem really is. Defining the problem in most instances is a time-consuming task, but it is time well spent.” Sound diagnosis requires

(i) Measurement of the gap between the desired performance and the actual

performance. (ii) Identification of the root cause for the gap.

(iii) Identification of the restraints in the decision making process.

(b) Secure and analyse pertinent facts: Once the problem has been diagnosed (defined), the next step is to collect data. Data collection implies collecting background material, pertinent facts, decision taken in the past and their outcome, previous solutions to similar problems etc. General rules are:

(i) The information should be collected from the most reliable source. (ii) All relevant facts, regardless of how disorganized or unrelated they seem

at the time of data gathering, should be recorded. (iii) The information should be subjected to checks and cross checks. The

conflicting data must be resolved. The temptation to accept first response to inquiries should be avoided.

(iv) The facts wherever possible should be supported by tangible evidence in

the form of copies of the appropriate documents. Facts when cannot be supported by documentary evidence (i.e. facts which are bases on opinion of the individuals) should carry the names of the contributors so that they (individuals) can be contacted later if required.

Facts are next analysed to establish:

(i) The length of time to which the decision should apply. (ii) Effect of the decision on other functional areas. (iii) Qualitative considerations to take overall view of the business.

(c) Develop alternative solutions: This step concerns looking for the possible solutions and listing them down. Most common sources of collecting and listing of alternatives include experience, superiors, juniors, consultants, research, creativity, brain storming, critical examination, literature etc.



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It is also the most important step and therefore good amount of time, effort and money should be spent /invested to get good alternative solutions. Generally, for every problem, alternative solutions exist and efforts need to put to unearth these alternatives. Usually, a brain storming or interaction session with those, concerned with the problem can highlight several alternatives. For example, the company was considering purchase of a CNC machine. The general manager held a series of brain storming session of his engineers and following alternatives got identified:

(a) continue to make the part by present method, or (b) buy the proposed CNC machine, or

(c) buy a machine other than the proposed one, or

(d) improvise the current method of making part (e.g retrofitting the

existing machine improves tooling and gauging method etc.), or

(e) subcontract CNC – compatible operations to a good quality vendor, or (f) discontinue manufacturing the part at company’s own plant and buy

the part from an outside source. After evaluating all the alternatives for their merits and demerits, the general manager opted for alternatives ‘d’, ‘e’ and ‘f’ and got the best results. (d) Evaluate alternatives: Once all the alternative solutions have been enumerated, they are next evaluated. This is usually done by testing each alternative against a set of objectives or specified criteria which the solution must meet. The steps involved are:

(i) Each alternative is analysed to see whether or not it meets the “must” objectives. An alternative which does not meet the “must” objective is immediately removed from further study.

(ii) Alternatives which meet the “must” objectives are next checked for “want”

objectives and those which are good in terms of “want” objectives are examined for adverse consequences. Since each alternative usually entails some risk, the decision maker next assesses the risk, the probability of risk, the probability or risk, and /or seriousness of the risk.

(iii) Every attempt is made to eliminate or minimize risk (or disadvantages). T

chart analysis is usually helpful.

(iv) Alternatives are next weighed for their effectiveness by identifying their long term and short term consequences. The advantages of the alternatives are quantified in terms of common denominator, usually the money.



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(e) Select the best alternative: The alternative cleared at the evaluation stage are ranked according to their worth. Final selection is then made of the alternative which provides the maximum advantages while entailing acceptance risk (i.e. the alternative that best meets the solution criteria is selected) (f) Implement the selected decision: Once the final choice has been made the next step is to implement the decision and follow up for verification of the consequences (or effect of the decision) Though the steps mentioned above are sequential and separate but usually there is recycling among the steps. For example, while trying to evaluate alternatives, the decision maker may have to ho back to data collection step if he finds that he does not have all the information. STEPS FOR SOLVING AN IMPROVEMENT PROBLEM: The Japanese have provided a structured methodology for solving “improvement” problem. The methodology is also known as QC story and it comprises of the following six steps based on famous Deming Plan-Do-Check-Act (PDCA) cycle.



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Fig: Steps to solve an improvement problem



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Define improvement problem

Measure current status

Decide on desired level

Find gap in performance

Set Target

Prepare action plan (counter measure)

Implement counter measure

Measure /analyse achievement

Satisfactory performance?

New target

Stabilize/standardize (SDCA)

Maintain status quo

End

Plan (P)

Do (D)

Check (C)

No

Yes

No

Yes



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2. (a) What is “Cause and effect” diagram? How is it useful in analyzing a problem? How is it constructed? Ans: INTRODUCTION: Every organization has contributory causes. The causes need to be identified to eliminate problems or minimize the effect of the problems. All causes including probable causes (i.e. which have not occurred earlier) should be identified so that preventive action can be taken (After all, prevention is better than cure) After the causes have been identified, they should be put into a systematic form that facilitates presentation and analysis. Cause and effect diagram is also called as “Ishikawa Diagram” or a fishbone diagram (due to its shape) – an effective tool for diagnosis to a problem – was developed by Dr. Kaoru Ishikawa, a professor of Tokyo University. The diagram lists out in a classified and systematic manner all causes which are responsible for the problem (called effect). The diagram consists of a main line to represent the actual problem and few lines to represent the major causes – materials, men, methods and machines – and horizontal or slanting arrows to represent sub-causes und relying each main cause. Procedure: Step1 : Specify the problem to be solved For eg:

(i) Accidents (ii) Process defectives (iii) Employer – employee relations (iv) Delayed delivery (v) Defective bills (vi) Labour efficiency

Step2: Brain storm to find all possible causes of the problem. Step3: Organize/ arrange these causes in few major themes (i.e. rational categories) Step4: Construct a cause and effect diagram that accurately displays the relationship of all data in each category. Steps in the construction of the diagram are as follows:

(a) Draw a box on the far right hand side of a large sheet of paper and write inside the box the description of the problem to be solved. Also draw a thick arrow that points to the box and look up on this as a main trunk of a tree.

(b) Enter the titles of the categories (also called themes) above and below the

horizontal line and connect them to horizontal line by vertical or standing arrows. Think of these as branches of the main truck of the tree.

Problem



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(c) Enter the detailed cause data for each category / theme by arrows meeting the horizontal or slanting lines (i.e. lines representing the main theme). Look upon these as limbs or twigs of the branches.

(d) Review diagram drawn above to ensure that no cause has been missed.

Problem

Man Machine

Method Materials

Cause A

Cause B

Cause B

Cause D

Cause A

Cause C

Cause A Cause C

Cause ACause C

Cause C

Cause B Cause B

Cause D

Problem

Man Machine

Materials Method



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A cross function team constituted to study problem of employees’ poor morale have conducted on following probable causes. Draw a “cause and effect” diagram from the given data… Ans:

Poor Management selection

Lack of communication

Improper management training

EMPLOYEE

HIRING REWARD/RECOGNITION

MANAGEMENT WORKING CONDITIONS

Poor selection

Incomplete job description

Recruiting errors


Low pay level

Wage differentials

Poor benefits

Favoritism

Lack of discipline methods

Public reprimands

Unclear company goals

Faulty working assignment Bad Lighting

Noise

Temperature

Long working hours

Excessive Criticism



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3. a) What is Pie-Chart? How is it constructed? Ans: INTRODUCTION: Pie chart is also called an angular diagram. It is the graph of percentage breakdown of data. Steps in Construction of a PIE CHART:

i. Express value of each category of component group as a percentage of total of all categories or components or groups.

ii. Calculate degree of the angle formed by each category/component/group as under

Degree of particular category = Value of the group X 360 Total Value

iii. Draw a circle of a suitable diameter (say diameter of 3”) iv. Segment the circle into angles calculated in step 2 with the help of a

protractor v. Shade or color different segments suitable to make distinction between

different categories.

vi. Enter the percentage of each category in to the pie chart. b) Draw a Pie Chart to represent the following population in a village. Males Females Girls Boys Total 2000 1800 4200 2000 10000 Sol: S.No Gender Population Population % Degree 1. Males 2000 20% 72o 2. Females 1800 18% 64.8o 3. Girls 4200 42% 151.2o 4. Boys 2000 20% 72o Total 10000 100%



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POPULATION

Girls42%

Females18%

Males20%

Boys20%

Males Females Girls Boys

4. a) What is Pareto’s analysis? How is it used for problem solving? Ans: Introduction: Every problem is the result of few causes and all causes are not equally important. Some causes are more significant than others. Pareto’s analysis underlines and operates his philosophy of “vital few: trivial many”. It is a technique of identifying vital causes by arranging the data according to the descending order of their frequency of occurrence. Pareto’s diagram is the outcome of the study conducted by Vilfredo Pareto to study the phenomenon of wealth in his country. Pareto observed that in his native country 80% of the wealth was held by 20% of the population. He eventually realized that he had discovered a universal law – around 20% of the activity causes 80% of the effect. For Example:

• 80% to 90% of the Italy’s wealth lay in the hands of 10% to 20% of the population.

• 80% of the accidents occur on 20% of the roads (i.e. some roads are more dangerous than others)

• 80% of the shopping that takes place is done in 20% of the time of the store are open.(i.e. people try to shop at the same time).

• 80% of the absenteeism in a company is generally on account of 20% of the work force.

• 20% of the machines are responsible for 80% of the total down time. • 20% of the end products generate 80% of sales revenue. • 20% of the clerks make 80% of the clerical errors. • 20% of the employees create 80% of the troubles. • 20% of the customers are responsible for 80% of the bad debts. • 20% of the total items in the stock account for 80% of the annual expenditure

on materials.



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U.S Economist M.C. Lorenz presented this lop sided distribution in the form of theoretical curve, called Lorenz’s curve. Dr. J. M. Juran observed similar phenomenon in many other fields including quality. He names this phenomenon as Pareto Analysis in honor of the originator of the concept. We need to follow few steps in order to solve the problems using Pareto’s Chart. They are listed as follows:

1) Select the problem and identify causes into a handful of categories. For example, for a problem of “late coming to works”, possible categories of causes may be heavy traffic oversleeping, sickness, vehicle problem, family problem etc.

2) Select the standard unit for measurement (e.g. frequency, cost, sales etc.) 3) Select the time period over which data will be collected (e.g. 8 hours, 5 days, 2

weeks, etc.) 4) Collect necessary data on each category and summarize results.

It is generally convenient to create a three-column-table having heading as “error category”. “frequency (or cost)”, and “percentage of total”. This information can be directly taken from the check sheet.

5) Rearrange the data in the descending order of the frequency or cost. 6) Organize the Pareto’s chart

(a) Draw two vertical axis, one on either side of a horizontal side axis (leaving enough space on the horizontal axis to list the problem categories). Mark the frequency of occurrence of the problem along left vertical axis and percentage along right vertical axis.

(b) Divide the horizontal axis into intervals equal to the number of categories.

(c) List down the categories from left to right in their order of decreasing frequency or cost.

(d) Construct a bar or rectangle above each category with height equal to frequency or cost.

7) Draw the cumulative line /curve (Pareto’s curve) by plotting each point at the

right hand corner of each bar and them connecting these points. 8) Write all necessary information concerning the diagram.



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b) Shrivastive, an administrative officer, working with Dattatreya Chemicals Ltd. has been receiving frequent complaints from internal customers regarding late and wrong receipt of mail delivered by his department. In order to correct the problem, he called a meeting of a small group of his internal customers and with their help identified five error categories, namely mail behind schedule, wrong deliveries, and late delivery of outgoing mail to post office, rude clerks and incorrect charges. The administrative officer then started tracking complaints. The data collected by him in a 30-day span in the form of a check-sheet reproduced below. Error Category Tally Mark Frequency Behind schedule mail lllll ll 7 Wrong delivery of mail lllll lllll lllll 20 Late delivery of outgoing mail to P.O lllll lllll ll 12 Rude clerks l 1 Incorrect charges lllll 5 Total 45 Draw a Pareto’s Chart. Sol:

1. Collect the data concerning the problem under study. 2. Rearrange the data in the descending order.

Error Category Frequency %of Error to total Cumulative% Wrong delivery of mail 20 44.44 44.44 Late delivery… 12 26.67 72.1 Behind schedule mail 7 15.55 86.65 Incorrect charges 5 11.11 97.76 Rude clerks 1 2.22 100.00



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PARETO's DIAGRAM

2012 7 5 1

44.44

26.6715.55 11.11

2.22

44.44

72.186.65

97.76 100

0

20

40

60

80

100

120

0 2 4 6

Frequency%of Error to total Cumulative%Log. (Cumulative%)

5. What are the quality circles? How are they formed? Explain briefly the organization of quality circles. Ans: Introduction: Quality circle is basically a small group of employees – who volunteer to meet regularly to undertake work related projects – quality, productivity, safety, efficiency, cost, working conditions, etc., - and evolve recommendations to improve effectiveness in the selected functional area. The size of quality circle is important. Too big a size 9 (too many members) may not provide enough time to each member to effectively participate and too small a size may make a circle dormant. An ideal size of the circle is eight to ten members but in any case it should not exceed fifteen members. More than one circle may be formed if too many employees in a particular work area are willing to participate in the quality circle activities. For example, if there are 25 clerks in the organization doing identical jobs, 2 to 3 circles may be formed. Participation in the circle activities is absolutely voluntary. Members are not selected /nominated. They are not elected or rotated either. Employees, however, are encouraged to form circles. Ideally, members of a particular circle should be from the same area or who do similar work so that problems that they select /analyse / discuss will be familiar to all of them. Brief History: Japanese Union of Scientists and Engineers (JUSE) was established in 1946 after the World War II in which Japanese industries were completely destroyed. JUSE worked for growth and development of quality and in 1950 it invited Dr. Edward Deming, a renowned American expert on quality to visit Japan. Dr. Deming delivered a series of lectures on various aspects of quality control to the top management of several companies of Japan. These circles have lifted war-ravaged Japan to its present dominant position and have endangered even the very existence of American industry. A quality circle in Japan on the average saves $56, 000. All this is achieved without any monetary incentives.



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Around 25% of the profitability of the Japanese industries is attributed to the quality circles. Nissan motor, for example works with 57,000 employees, has 4,200 quality circles which have helped the company to double its productivity in ten years. Quality circles in India were first launched in the Hyderabad unit of BHEL in 1980 which has now around 100 quality circles in its various branches throughout India. Quality circles forum of India was formed in 1982 to propagate concept. The concept of quality circles is gaining momentum and quite a few firms in the private and public sector – Kirloskars, Alwayns, Tata’s, H.A., Bharat Forge, Balaji Auto, Vulcan Laval, Rourkela Steel plant etc., have instituted quality circles. Organization for quality circles: The Organization of circles consists of:

i. Steering Committee: Steering committee is the apex body at the highest level of the plant which is made up of heads of the major departments like Production, Finance, Materials, Marketing, Engineering, Quality Assurance, etc, and is headed by the Chief Executive of the plant. The committee meet periodically and it- o Evolves policies and guidelines for the formation, functioning and

growth of quality circles. o Appoints facilitators and a co-coordinator. o Identifies overall quality and productivity problems in the

organization. o Authorizes budget for quality circle activities o Takes part in top management presentation and annual get-togethers o Demonstrates, in visible manner, management commitment and

support o Reviews performance of the quality circles regularly on the basis of

reports from the coordinator and facilitators. o Evolves guidelines for recognizing the good performance of quality

circles. The head of the Quality Assurance department takes the responsibility of convening the meeting of the committee.

ii. Facilitators: The facilitators are selected by the steering committee to supervise the activities of two, three or more circles. Facilitator is usually a senior officer nominated by the management who is incharge of shop or department. The facilitator acts as a teacher, a promoter, a catalyst, and a guide to the quality circles. The responsibilities of the facilitators include: o To co-ordinate the activities of quality circles under their supervision

and guidance o To train QC leaders and lend help in training QC members. o To interface between circles o To render support and assistance to the circles under his control. o To encourage employees to form more QC’s o To demonstrate support of the management.

iii. Leaders: A leader acts as an integral part of the quality circle. The leaders

should have good knowledge of statistical methods and approaches to be



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used to identify and analysis problems. The leaders also, like other regular members, participate in the discussions. The leader should preferably be the first line supervisor but it not essential. Supervisors taking over the task of leaders ensure some leadership quality inputs are already available.

Responsibilities of the leader are: o To conduct training of members of the circle with the help of facilitator

and other agencies. o To prepare agenda for the meetings. o To organize and conduct meeting o To evolve action plans and milestone charts to compare actual progress

with targets by periodic reviews and take mid-course correction. o To assign roles to members and to guide them for effective

contribution towards the achievement of goals. o To ensure participation and involvement of all members in the

activities of the circle. o To ensure records and liaison with other agencies to obtain help in

solving the problem o To catalyse attitudinal changes in his own and other related areas. o To make management presentations o To take sincere interest individually by active involvement in the

progress of quality circle movement. o To endeavour to promote quality circles as a way of life in the

organization.

iv. Members: Members form hard core of the quality circles; Members are selected on “purely voluntarily basis” and are from the same or similar functional areas. The group should basically be small, between 8 to 10 members. The members should have adequate education and experience in the concerned field and should have the ability to express clearly and freely.

v. Co-ordinator: In a large manufacturing organization, some agency –

usually Quality Assurance – is required to co-ordinate the activities of the quality circles. The responsibility of the coordinating department includes: o Rendering assistance as request by circles o Disseminating literature relating to circle activities elsewhere o Organizing training programmes o Publishing newsletter to communicate circle activities o Providing circles with necessary facilities for the meeting o Organizing social get-together for circle members and senior

executives



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6. “5-S is an excellent technique to achieve good house-keeping”. Discuss. Ans: Introduction: Good housekeeping is the foundation for and first step towards quality achievement in a manufacturing organization. It boosts employee morale and inspires customer confidence. Good quality of work place is essential as –

1. Good environment has a strong influence on the people and the quality of product they produce.

2. A customer visiting the plant sees in a quality work place a guarantee for the product quality.

3. Good housekeeping helps to eliminate waste by identifying non-value added activities, such as searching for tools, time lost in reaching out to retrieve items, over production, etc.

4. Housekeeping reflects management’s general attitude towards work in the organization.



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Housekeeping is measured the way - Factory floor are swept and machines are cleaned - Tools are stored - Scarp and chips from machines are handled - Work tables are organized - Personal items are stored - Records are maintained - Targets and achievements are displayed or communicated to

employees. Good housekeeping is simply the basic to a better workplace and to –

- Reduce cost of products and service - Achieve discipline in manufacturing - Bring improvement in quality and productivity

5-S (Seiri, Seiton, Seiso, Seiketsu and Shitsuke) are considered in Japan the basics of any job. 5-S principles have been practiced in Japan the basics of any job. 5-S principles have been practiced in Japan to establish and maintain quality environment in the organization. Japanese managements are of the view that if the housekeeping in a plant is weak, no further diagnosis is needed to know as to why that plant produces poor quality products. 5-S technique has been defined as – “A systematic and rational approach to work place organization and methodical housekeeping with a sense of purpose”

Japanese English Meaning How to apply it to the work place?

Seiri Structurise Sorting Classify items into necessary and unnecessary, retain only those which are required and dispose off others. (i.e. those not needed)

Seiton Systematise Re-organise Store things systematically to ensure safety, quality and efficiency. Storage methods must permit efficient use of space-accident free stage, long shelf and easy retrievability of items within pre-fixed target retrieval time.

Seiso Sanitise Cleanup Maintain work place free of dirt/ dust and garbage by fixing individuals’ cleaning responsibility.

Seiketsu Standardize Standardization Maintain cleanliness through Seiri, Seiton and Seiso by ensuring transparency and uniformly of everything that is done in the organization.

Shitsuke Self-discipline Sustain Make a habit of doing things the way they are supposed to be done (i.e. developing habit of following rules/ practices) including 5-S practices.



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Relationship between 5-S’s:

SEIRI (Organisation

SEIKETSU (Standardisation)

SHITSUKE (Discipline)

SEITON (Maintenance)

SEISO (Clean Up)



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7. What is SMED? How is it used to reduce setup time of an operation? Ans: Introduction: Every organization must increase line of its products, accept low volume orders, shorten delivery lead time, and keep its cost low to maintain its market share in a competitive market. The organization must cut production lead time and decrease production batch sizes. It should also reduce inventory levels in the production and inventory systems. Since small batches require frequent changeovers, production capacity is expected to shrink unless setup times are reduced. Set up time reduction, therefore, is the key to developing or monitoring a company’s competitiveness in today’s market where more diversified products are desired at short production lead time. Quick Die/ set up change is not restricted to set-up reduction of press shop alone, it can be extended to all areas of manufacturing wherever there is requirement of tool change/ set up on a machine prior to manufacturing.

i. Presses ii. Multi-spindle automats iii. Lathes, turret lathes iv. Milling machines v. Drilling machines vi. Broaching machines. vii. Forging machines viii. Paint manufacturing equipment ix. Powder coating machines x. Oil extracting mill

Meaning: Set up time is the time required to prepare a machine or a group of machines to changeover from one job to another. Time of a conventional set up consists of following tasks.

(a) The time to study blue print , including time spent on receiving instructions from supervisor or foreman.

(b) The time to go to tool crib to get necessary tools and gauges, etc and to return the tools used to previous job.

(c) The time to select fixture (Vice, mandrel, suitable sized collets, face plate, etc) and secure it to the bed of the machines.

(d) The time to install/ mount necessary tools on to the machine, make adjustments, set longitudinal or traverse feed stoppers wherever necessary to ensure that each tool cuts properly and to dimensions.

(e) The time to call the inspector and get inspection done (pilot piece inspection). Alternatively it is the time necessary to deliver the part to the inspection booth for inspection. Inspection time, however, does not include time to manufacture the part.

(f) The time spent by the operative, over and above the unit standard time, to produce first few pieces.

(g) The time to physically count the jobs produced, including time to sign the completed work-order.

(h) The time to remove tools from their tool-holders after required quantity has been manufactured, clean each tool and put it away in proper place.



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(i) The time to clean measuring instruments and put them away in proper places. (j) The time to release and remove fixture blow or brush it clean and keep it

aside. (k) The time to remove borings, turning, drilling etc, from the bed of the machine.

Normally, turnings/ drillings/ borings should be removed by a helper (even when the production is in progress) when these gather in large quantity. However, burns removal, would have to be considered part of set up operation if different material is required on the next job (e.g. Steel for the job just completed and brass for the job to be loaded).

Traditional set up operations involve several kinds of waste and SMED technique was developed to eliminate waste and to reduce set up time from hours to minutes. SMED also has interesting history of development. Reduction in set up time results in the following benefits:

o Reduction in batch sizes o Lowering of manufacturing lead times o Drop in inventory levels o Reduction in set-up scrap o Increase in machine efficiency o Increased flexibility to respond to changes.

The firm desiring to reduce change-over time may not achieve its target figure in one attempt, but after a series of improvements. From its current level of set up time of double digit on a particular machine, it may be able to reduce to single digit hours. And subsequently on the same machine from single digit hours to double digit minutes, still later from double digit minutes to single-digit ones and finally in to few extreme situations one touch change over.

Step-by-step reduction of set-up time

Elimination of sample runs, inspection, adjustments

Comp. A run

Study blue print

Remove existing

Replace too at the crib store

Install tools for the new job

Sample run

Adjust

Run for component A

SETUP Run for component B

Component B

Component A

Setup

Sample run



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8 a) What is meaning of MUDA? What are the various types of MUDAS? Ans: Introduction: MUDA is a Japanese word for waste and waste means anything (or any activity) which does not add value to the product.

o A worker looking, even though affectionately, at an automatic machine does not add any value while machine does (MUDA of Waiting)

o A maintenance engineer who walks over a long distance with tool in his hand, does not add any value (value is added when he uses the tool to fix the machine) ( MUDA of Transport)

o Piles of material lying in racks in the stores don’t add any value but add to cost (MUDA of Stock)

o A material handler while pushing a heavy trolley full of parts, even though perspiring, adds no value (MUDA of Transport)

o An assembly operator, overstretching his hand to pick up parts for assembly, adds no value but causes fatigue to himself (MUDA of Motion)

o A welding operation, performed to join metal parts of assembly constituent, does add value but the welding operation performed to repair weld a blowhole in job is a non-value added activity (MUDA of Processing)

Waste (MUDA) is the major element of company’s product cost and must be continually identified and eliminated from its processes to stay competitive. Since labour cost is hardly 8-10% of total cost (which also is on the decline due to recent advances in manufacturing technologies), we also need to look at various other hidden wastages, besides human waste, to improve productivity. Types of MUDA: There are seven types of MUDA in manufacturing: 1. MUDA of Over Production. 2. MUDA of Stock (inventory)

3. MUDA of Waiting 4. MUDA of Transport

5. MUDA of Defects

6. MUDA of Motion

7. MUDA of Processing



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b) What Causes MUDA of “Motions”? How can it be eliminated? Ans: Introduction: A workman while performing a task makes use of a number of motions. The scrutiny of these motions may reveal that some of these motions –

o Are unnecessary and can be eliminated o Can be combined / modified by changing their sequence o Can be simplified by effecting changes in work bench layout o Can be performed efficiently by other members of the body.

In the absence of the above mentioned actions, the workman makes motions which don’t add any value. Typical examples are –

o Walking to reach objects/ parts. Tools o Lifting or carrying objects o Picking up and putting down a work piece o Transferring objects from one hand to another o Searching to find the required object

While dealing with MUDA of motion it is recommended to get rid of operations that are difficult dirty and / or dangerous (3D’s). such actions include –

o Work that makes and employee move over long distances o Work that causes physical strain (i.e. use of undue physical effort) o Work that causes mental strain (e.g. work that needs memorizing lot of details) o Work that involves search or unnecessary sorting.

Tools and techniques to eliminate MUDA of Motion:

i) Improvement in layout: Lifting or carrying a heavy object is undesirable on two counts, firstly because it represents MUDA and secondly it causes physical exertion. The need for the operator to carry a heavy object can be eliminated by rearranging the work place.

ii) Motion economy principles: Motions of the hands/ legs can be shortened and some of them can be eliminated by rearranging the parts on work table and development of tools and jigs.

iii) Effective supervision: Finding workmen busy with their jobs may give supervisor satisfaction but it may do no good to the company. A supervisor must watch closely his people to find as to – - What are they doing? - How are they doing? - Do they need to do what they are doing? - Are they doing the right way? - Are they doing work which adds value? - Are they using motions of the lowest classification?



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List down different kinds of human errors. How can they be eliminated? How is PokaYoke technique useful to eliminate human errors?

Ans:

“Poka-Yoke” is a combination of two Japanese words, “Poka” meaning “inadvertent errors” and “Yoke” (derived from Japanese word Yokerie) meaning “to avoid” and

Description of the error

Typical examples Remedial action

Forgetting to do a thing

3. Operator skipping an operation.

4. Operator forgetting to tighten bolts

5. station master forgetting to lower the crossing gate

Misunderstanding

Jumping to the wrong conclusion due to poor familiarity with the situation

1. Putting foot on clutch thinking it is brake

1. Training 2. Checking in advance 3. Standardizing work

procedures.

Mistaken identity

Misjudging a situation

1. Mistaking Rs.500 note as Rs.100 note

1. Improving attentiveness.

Errors by amateurs

Lack of experience 1. Improper welding 2. Wrong measurements

1. On-the-job training 2. Work Standardisation

Willful errors Ignoring rules/ deliberate wrong actions

1. Ignoring safety rules2. Crossing a street against

a red light just because there are no vehicles in sight at the moment.

3. Not replacing blunt tool on time

1. Attitude change. 2. Education

Inadvertent errors

Absent mindedness i.e. not knowing how the problem / error has occurred

1. Removing job before completing drilling of all holes

2. Crossing street without noticing that the light is red

1. Improving attentiveness 2. Work standardization

Judgmental errors

Errors due to absence of instructions of work standards

1. Difference in method of measurement used by vendor and by buyer’s inspection

2. Operator deciding his own

1. Works instructions 2. Work standardization.

Errors due to absence of standards

Lack of instructions or absence of work instructions

Measurements left to the discretion of the workman

1. Works instructions 2. Work standardization.

Type of Error

Forgetfulness 1. Altering operator in advance 2. Checking at regular intervals 3. Verification by another

employee



25

together they translate as “Error/ mistake proofing” or “Fool proofing” or “Failsafing” a work process system to eliminate inadvertent errors.

Poka-Yoke is a powerful and comprehensive tool for identification, measurement and analysis of mistakes/ defects at the Gemba (real piece of work) and implementation of measure that prevent the activity from being incorrectly performed, thereby ensuring production of quality goods and services. Errors are inevitable but can be eliminated, using Poka-Yoke technique. This is the technique that can help to analyse the kinds of mistakes employees make and to eliminate these mistakes by implementing / installing simple Poka-Yoke devices. Poka-Yoke Devices: Poka-Yoke may be designed either to help the operator to recognize the defect before it is about to occur called “Prevention type Poka-Yoke” or to help the operator to know immediately on occurrence of the defect called “Detection type Poka-Yoke”. Some of the Poka-Yoke devices which can help to avoid defects are – 1. Guide Pins / locators 2. Error detection buzzers/ alarms and blinking lights 3. Limit switches 4. Counters 5. Color coding 6. Checklist 9.a) What is Kaizen? What are different types of Kaizen? Ans: Introduction: Kaizen is a combination of two Japanese words, “Kai” and “Zen”, Kai means “to change or modify” and Zen means “to improve or make better” and together they translate as “improvement”. Kaizen when used in the context of a management process, has come to mean as continual and slow improvement in every aspect of management (i.e. improvement in whatever company does and the way it does things) through the active involvement of all company’s employees. Kaizen does not just merely mean doing things better but it is an unending process to eliminate muda, improve quality, cost and delivery, thereby creating more and more customers. Few Definitions: Kaizen is a management supported, employee driven process, where employees seek development of their own capabilities by challenging existing system and finding improvement in them - R.R. Asawa & Dr. D. R. Baheti Kaizen is a program, a philosophy and a strategy to improve quality of goods and services or an organization - Samuel KHO Kaizen means making a great number of continuous lasting improvements by discovering small problems and eliminating them permanently (attacking root causes of the problems) thereby helping the organization in setting and reaching higher standards of performance. - Surindra Narang



26

The Spirit of kaizen is that whatever you are doing, you can do better. Kaizen thus helps in setting and reaching higher standards of performance. The word “Kaizen” was used for the first time by Maasaki Imai, who wrote a look of same name. although a registered name of Kaizen Institute, the work is now widely used and understood all over the world to mean “continuous improvement”. The word “Kaizen” also now appears in the English dictionary. Recently, Imai has elaborated on Kaizen in his book titled “Gemba Kaizen” Types of Kaizen: Kaizen depending upon the complexity and level, can be placed into one of three categories

1) Management Kaizen 2) Group Kaizen 3) Individual Kaizen

1) Management oriented Kaizen: Concentrates on strategic issues and often

involves people from different departments working together on cross-functional problems as project teams. Typical examples of management oriented Kaizen are:

♦ Identification and elimination of waste in workers motions ♦ Charges in plant layout for better efficienvy ♦ Reduction in buffer stocks ♦ Just-in-time production ♦ System improvement

2) Group oriented Kaizen: Concentrates on improvement within the same

workplace or department brought about by employees working in small groups, called quality circles. Typical areas of group Kaizen generally include –

♦ Productivity improvement ♦ Defect prevention ♦ Accident prevention ♦ Absenteeism

3) Individual oriented Kaizen: Concentrates on issues concerning worker’s own

work area and improvements are brought about through worker’s own suggestions. Problems solved through individual Kaizen generally include –

♦ Improvement in machines and processes ♦ Improvement in jigs and fixtures ♦ Reduction in defect level ♦ Customer service and customer complaints ♦ Improvements in working environment.



27

b) Discuss in brief the Kaizen process and its steps. Ans: Introduction: Kaizen process provides a disciplined and analytical approach, sometimes called the kaizen story to problems solving. It consists of a series of sequential steps that can be used to guide a group (say an improvement team) for the process of identifying and fixing problems. The Kaizen story (or Kaizen process) is built on PDCA mnemonic – Plan, Do, Check and Act. The Kaizen process is a seven step basic procedure which allows any individual or team to solve problems scientifically, rationally, effectively and efficiently. These seven steps are –

1. Defining the problem 2. Understanding/ assessing the current status 3. Finding the root cause. 4. Planning counter measures 5. Implementing counter measure 6. Verifying results 7. Standardising and establishing control.

A brief of each of the steps in the Kaizen process is given.

Fig: Problem definition phase



28

When Deming cycle is used as a tool for systematic problem solving (improvement), the PDCA activities take the form as shown below…

Poka-yoke for failsafing

Model machine exercises in TPM

Exercises to identify MURA, MUDA and MURI

Spotting abnormalities at Gemba

Internal customer’s complaints

External customer’s complaints

Cost of Quality

SMED/ JIT Targets

5-S Audits

ISO-9000, QS-9000 and ISO-14000 non-conformities

Problems

Define Problems

Enlist problems

Prioritize problems

Select topics for Kaizen

Assign themes to Kaizen teams

Conduct PDCA-SDCA improvement cycles



29

Process Steps Objective Element of PDCA

Defining the problem Identification of the problem The “PLAN” element

Understanding / Assessing Current status

Establishing the base from which you are trying to improve

The “PLAN” element

Finding the root cause Identifying underlying causes of the problem


The “PLAN” element Planning counter measures

Preparing action plan to fix the problem

The “DO” element Implementing counter measures

Verifying results

Standardizing and establishing control

Implementing the action plan

Confirming the effect of implementation

Consolidating the change

The “CHECK” element

The “ACT” element of PDCA and / or + the STANDARDIZE element of SDCA

Sem – 3rd Techniques for Operations Efficiency 2

Staff attitudemeasurement

Employee satisfactionindex


Select The BlankQuestion ________ is an effect due to the muda of defect.

Correct Answer Wear & tear of parts while disassembling

Your Answer Poor production planning & control

Select The BlankQuestion If some defective parts are discovered by the subsequent

process they should be returned to the ________ to preventreoccurrence.

Correct Answer Preceding process

Your Answer Return to stores

Multiple Choice Multiple AnswerQuestion The results oriented efforts of the quality circle should also

include :-Correct Answer Efforts to avoid the problem permanently , Ultimate aim of the

customers satisfaction , Attacking the real root causes & allpossibilities

Your Answer Efforts to avoid the problem permanently , Publication oradvertisement of your contribution , Attacking the real rootcauses & all possibilities

Match The FollowingQuestion Correct Answer Your Answer

Parato diagram alwaysindicates

Magnitude of defects Philosophy of 20% of theactivity causes 80% of theeffect

Parato analysis underlines& operates on

Philosophy of "vitalfew:trivial many"


Parato analysis istechnique of identifyingvital causes by

Arranging data accordingto the descending order oftheir frequency ofoccurrence


Parato diagram is a Bargraph with height or valuedrawn by

Arranging data indescending order

Magnitude of defects

Multiple Choice Multiple AnswerQuestion Few steps in construction in Radar chart are :-

Correct Answer Brainstorming to enlist characteristics which require to beevaluated & draw the circle & divide it into 'slices' equal tonumber of characteristics , The first slice begins at 12 noon.Then draw vertical line & calibrate it equal to the number of


levels required , Draw concentric circles from each gradiationusing 'o' point as centre

Your Answer Brainstorming to enlist characteristics which require to beevaluated & draw the circle & divide it into 'slices' equal tonumber of characteristics , The first slice begins at 12 noon.Then draw vertical line & calibrate it equal to the number oflevels required , Draw concentric circles from each gradiationusing 'o' point as centre

Select The BlankQuestion 5 S audit result is discussed in ________ meeting.

Correct Answer Monthly

Your Answer Monthly

True/FalseQuestion Fishbone analysis is used both in analysis & planning.

Correct Answer True

Your Answer False

Multiple Choice Single AnswerQuestion One Green Belt may head a team of :-

Correct Answer 20 employees

Your Answer 20 employees

Multiple Choice Multiple AnswerQuestion Role of champions are :-

Correct Answer Approve six sigma projects , Remove road block in the path ofsix sigma implementation , Monitor progress of six sigmaprojects

Your Answer Monitor progress of six sigma projects , Approve six sigmaprojects , Remove road block in the path of six sigmaimplementation

Multiple Choice Multiple AnswerQuestion To draw control charts, sample must be representative of

homogeneous segment of production for which :-Correct Answer The items of the sample should be from the same machine

setting , The items should be of the same batch , Items shouldbe made from the same raw material batch

Your Answer The items of the sample should be from the same machinesetting , The items should be of the same batch , Items shouldbe made from the same raw material batch

Multiple Choice Single Answer


Question Failure mode and effect analysis (FMEA) establish

Correct Answer Process failure and minimize frequency

Your Answer Process failure and minimize frequency

Multiple Choice Multiple AnswerQuestion What are the steps in deciding the benchmarking partner?

Correct Answer Decide level of benchmarking , List down a few prospectivecandidates of partnership , Collect information of short listedpartners

Your Answer Decide level of benchmarking , List down a few prospectivecandidates of partnership , Collect information of short listedpartners

Multiple Choice Single AnswerQuestion One Master Black Belt may head a team of :-

Correct Answer 15-20 Black Belts

Your Answer 15-20 Black Belts

Multiple Choice Single AnswerQuestion Competitive benchmarking involves identifying key competitive

product, services or processes & comparing with those of :-Correct Answer Main competitor

Your Answer Main competitor

Multiple Choice Single AnswerQuestion Implication of Quality problem is:-

Correct Answer Gap in performance

Your Answer Gap in performance

Select The BlankQuestion Number of defects in an individual component, like gear, shaft,

wheel etc can be monitored through ________ type of controlchart.

Correct Answer c-chart

Your Answer c-chart

True/FalseQuestion Non-availability of files /document in time is a problem to be

addressed by office TPM.Correct Answer True


Your Answer True

Multiple Choice Single AnswerQuestion Check sheet is easy to use because it is :-

Correct Answer Simplest tool

Your Answer Simplest tool

Multiple Choice Single AnswerQuestion Benchmarking helps to identify the gap between the current

performance of the organization and the :-Correct Answer Performance of the best organization

Your Answer Performance of the best organization

True/FalseQuestion Flow chart is pictorial representation of the steps in production

control.Correct Answer False

Your Answer True

Multiple Choice Multiple AnswerQuestion Breakdown problem may be stratified by :-

Correct Answer Sections , Machines , Type of breakdown (e.g mech. Orelectrical)

Your Answer Sections , Machines , Type of breakdown (e.g mech. Orelectrical)

Select The BlankQuestion A control chart to exhibit counted data on number of defect is

called ________.Correct Answer c-chart

Your Answer c-chart

Select The BlankQuestion Procedure for implementation of TPM consists of ________

numbers of steps.Correct Answer 12

Your Answer 8

Select The BlankQuestion Capability index Cp = ________

Correct Answer Specification width/process width


Your Answer Specification width/process width

Multiple Choice Single AnswerQuestion Pareto's analysis underlines & operates philosophy of :-

Correct Answer Vital few = trivial many

Your Answer Vital few = trivial many

True/FalseQuestion Kanban signals are required when assembly work, subassembly

work and manufacturing at parts is carried out at differentlocations.

Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion To reduce clamping & declamping time, following actions are

desirable :-Correct Answer Standardize clamping bolts / screws , Cut off unnecessary

threads , Use quick clamping deviceYour Answer Standardize clamping bolts / screws , Cut off unnecessary

threads , Use quick clamping device

Select The BlankQuestion Benchmarking allows exchange of ________ between the

benchmarking partners.Correct Answer Information

Your Answer Information

Multiple Choice Multiple AnswerQuestion TQM can never flourish if the staff are:-

Correct Answer Worried about losing jobs , Afraid of being reprimanded if thereare mistakes , Scared of their bosses

Your Answer Worried about losing jobs , Afraid of being reprimanded if thereare mistakes , Scared of their bosses

True/FalseQuestion In bar graph each bar is of same height.

Correct Answer False

Your Answer False

Multiple Choice Multiple AnswerQuestion During SMED implementation, primary study consists of :-


Correct Answer Equipment analysis , Setup change analysis , Preparation items(storage place , method) analysis

Your Answer Equipment analysis , Setup change analysis , Preparation items(storage place , method) analysis

True/FalseQuestion Daily work management can also be extended to non

manufacturing areas like procurement, QA, HRD etc.Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion Types of Poka-Yoke are :-

Correct Answer Prevention type Poka-Yoke , Detection type Poka-Yoke

Your Answer Prevention type Poka-Yoke , Detection type Poka-Yoke

Multiple Choice Single AnswerQuestion Quality problem solving tool is used to :-

Correct Answer Improve quality

Your Answer Save time

True/FalseQuestion Along with problem solving tools experience and judgment is

also used.Correct Answer True

Your Answer False

Select The BlankQuestion JIT advocates the philosophy at elimination of waste from

system which occurs due to ________.Correct Answer Over Production

Your Answer Over Production

True/FalseQuestion Without measuring initial performance, target can't be set.

Correct Answer True

Your Answer False

Multiple Choice Multiple AnswerQuestion An erratic patterns falling above & below the control limits

indicates :-


Correct Answer Defect in materials , Frequent adjustment of machines , Poorlytrained operators

Your Answer Defect in materials , Frequent adjustment of machines , Poorlytrained operators

True/FalseQuestion Sample size for the construction of p-chart are larger than X bar-

R chart.Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of the

histogram gives :-Correct Answer It shows cause which affects the process , An idea of what is

happening to the process , Whether the process is capable ofmeeting process or not i.e. around correct average & withinspecific limits

Your Answer An idea of what is happening to the process , Whether theprocess is capable of meeting process or not i.e. around correctaverage & within specific limits , A bird's eye view of the variation

Multiple Choice Single AnswerQuestion Productivity improves by :-

Correct Answer Voluntary participants of everyone

Your Answer Voluntary participants of everyone

TechniquesForOperationsEfficiency

ASSIGNMENTS

LIST OF ATTEMPTED QUESTIONS AND ANSWERS

Select The BlankQuestion Cp for six sigma process is ________

Correct Answer 2

Your Answer 2

True/FalseQuestion Operator monitoring a machine while machine works on auto

cycle is an example of muda of waiting.Correct Answer True

Your Answer False

Select The BlankQuestion ________ PDCA cycle is the systematic approach towards

meeting the target.Correct Answer Kaoishikawa

Your Answer Deming

Multiple Choice Multiple AnswerQuestion As benchmark in Japan seiso activities means :-

Correct Answer Everyone, clerk to officer does cleaning his area , No sweeper orcleaner employees , Every family does cleaning of pavement oftheir residence

Your Answer Everyone, clerk to officer does cleaning his area , No sweeper orcleaner employees , Every family does cleaning of pavement oftheir residence




Multiple Choice Multiple AnswerQuestion After finding out the solution & working on it, the equally

important job is :-Correct Answer Prepare for the presentation of your work , Explain the progress

by presentation to steering committee , Convince committee forfinancial help for running the project

Your Answer Prepare for the presentation of your work , Explain the progressby presentation to steering committee , Convince committee for

financial help for running the project

Select The BlankQuestion A ________ is an excellent device to condense & present large

mass of data in an elegant form.Correct Answer Frequency distribution

Your Answer Frequency distribution


Hidden faults come outwhile implementing.

Cleaning yourself yourequipments

shitsuke

Fix the place of items,tools as per frequency ofuse

Seiri Seiton

Responsibility same fromtop to bottom

Seiso Cleaning yourself yourequipments

Evolve standard operatingprocedure & implement.

Seiketsu Seiketsu

Multiple Choice Single AnswerQuestion Seiton means

Correct Answer Code Numbers to item as well as racks & drawers

Your Answer Code Numbers to item as well as racks & drawers

True/FalseQuestion np chart unlike P chart records the 'number of defective' instead

of "fraction or proportion of defectives".Correct Answer True

Your Answer False




Select The BlankQuestion ________ is the critical element of TQM.

Correct Answer Focus on customer

Your Answer Focus on customer

Multiple Choice Single AnswerQuestion Requirement of more machines, is an example of :-

Correct Answer Muda of overproduction

Your Answer Muda of overproduction

Multiple Choice Single AnswerQuestion Accountability means :-

Correct Answer Responsibility of Business Results

Your Answer Responsibility Execution or Action




Multiple Choice Multiple AnswerQuestion Actions that can be thought for the process having process

capability is higher than specification tolerance areCorrect Answer 100 % inspection is required , Reduce variability , Possibility of

squeezing tolerancesYour Answer 100 % inspection is required , Reduce variability

Multiple Choice Single AnswerQuestion To provide flexibility to supervisors in allocation of task, JIT

emphasizes :-Correct Answer Multiskilled operators

Your Answer Multiskilled operators

Multiple Choice Multiple AnswerQuestion The aim of education & training under TPM is :-

Correct Answer To develop abilities to respond quickly to abnormalities , Todevelop abilities to discover analyze malfunction

Your Answer To develop abilities to respond quickly to abnormalities , Todevelop abilities to discover analyze malfunction , To havemultiskilled employees in all departments

Multiple Choice Multiple AnswerQuestion Typical examples of process benchmark are :-

Correct Answer Procurement procedures , Budgeting , Recruitment

Your Answer Procurement procedures , Budgeting , Recruitment



Your Answer True

Select The BlankQuestion A 'Radar chart' is used to portray ________ strength or

weakness of the activity.Correct Answer Relative

Your Answer Relative

True/FalseQuestion Exercise to identify MURA, MUDA & MURI is not helpful to

identify problems.Correct Answer False

Your Answer False

Select The BlankQuestion In traditional purchasing ________ inventory is required.

Correct Answer Plenty of

Your Answer Minimum

Multiple Choice Single AnswerQuestion Control chart can be used as :-

Correct Answer Process monitoring tool

Your Answer Process monitoring tool




Multiple Choice Multiple AnswerQuestion Tools and techniques for six sigma are :-

Correct Answer Process mapping , FMEA , QFD

Your Answer Process mapping , FMEA , QFD

Select The BlankQuestion World class benchmarking candidate in 'Quality' is ________.

Correct Answer Motorola

Your Answer Motorola

True/FalseQuestion Seiso prevents the potential problems by discovering

abnormalities while cleaning your own area.Correct Answer True

Your Answer True



Your Answer Wear & tear of parts while disassembling

Multiple Choice Single AnswerQuestion Quality circle should consist adequate experienced members

between :-Correct Answer 8 to 10

Your Answer 8 to 10

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when

value of 'y' decreases as the value of 'x' increases.Correct Answer Strong negative

Your Answer Strong negative

Multiple Choice Single AnswerQuestion POP is :-

Correct Answer Process Oriented Management

Your Answer Process Oriented Management

True/FalseQuestion TQM improves the quality by improving processes.

Correct Answer True

Your Answer True

True/FalseQuestion Generally time interval should be proportional to the average

frequency of out of control conditions.Correct Answer True

Your Answer False

Multiple Choice Multiple AnswerQuestion Problem solving tools used for Root cause analysis are :-

Correct Answer Check sheet , Pareto analysis , Fish bone analysis

Your Answer Check sheet , Pareto analysis , Fish bone analysis

Select The BlankQuestion Good ________ is the asset to acquire the success of quality

circle.Correct Answer Teamwork

Your Answer Teamwork




Your Answer Efforts to avoid the problem permanently , Ultimate aim of thecustomers satisfaction , Attacking the real root causes & allpossibilities

True/FalseQuestion Process capability index Cp is a measure of capability of the

process to meet the specification limits.Correct Answer True

Your Answer True




Your Answer It shows cause which affects the process , An idea of what ishappening to the process , Whether the process is capable ofmeeting process or not i.e. around correct average & withinspecific limits

True/FalseQuestion Any withdrawal without C-kanban is not permitted.

Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion During the steps of Deming cycle of PDCA what is important?

Correct Answer Plan unitedly for the target within reach , Make plan active by"doing it" i.e. everyone working , After some time check theresults for success

Your Answer Plan unitedly for the target within reach , Make plan active by"doing it" i.e. everyone working , After some time check theresults for success

Multiple Choice Single AnswerQuestion Discussion on people, problem & role play exercise helps to

develop :-Correct Answer Counseling skill

Your Answer Counseling skill


LCLnp n p - 3 ( sq.root( n p( 1- p)))

n p - 3 ( sq.root( n p( 1- p)))

UCLp p + 3 ( sq.root( p ( 1 - p ) /n ))

p + 3 ( sq.root( p ( 1 - p ) /n ))

LCLp p - 3 ( sq.root( p ( 1- p ) /n))

p - 3 ( sq.root( p ( 1- p ) /n))

UCLnp n p + 3 ( sq.root( n p ( 1- p n p + 3 ( sq.root( n p ( 1- p

))) )))

Multiple Choice Single AnswerQuestion TPM implementation is done through:-

Correct Answer Small group

Your Answer Small group

Multiple Choice Single AnswerQuestion To hold the customer to do business with you :-

Correct Answer Reduce the amount of time, the customer spend till he receiveservice

Your Answer Increase the amount of time, the customer spend till he receiveservice



Your Answer Equipment analysis , Setup change analysis , Convertinginternal setup into external setup

True/FalseQuestion Everyone in the team of quality should target his own benefits

i.e. promotion, etc.Correct Answer False

Your Answer False

1

Techniques for Operations Efficiency assgn :01: NareshMultiple Choice Multiple AnswerQuestion Advantages of JIT :-

CorrectAnswer

Reduce incoming inspection , Reduce inventory , Lower per unit cost

Your Answer Reduce incoming inspection , Reduce inventory , Lower per unit cost

Multiple Choice Multiple AnswerQuestion Benefits from the standardized containers are

CorrectAnswer

Minimization of transit damages , Ease in verification of quantity of parts , Automaticsignal to supplier to replenish stock

Your Answer Minimization of transit damages , Ease in verification of quantity of parts , Automaticsignal to supplier to replenish stock

Multiple Choice Multiple AnswerQuestion Benefits from SMED are :-

CorrectAnswer

Reduce work in process , Better average daily production , Increase capacity

Your Answer Reduce work in process , Increase capacity

Multiple Choice Single AnswerQuestion Competitive benchmarking involves identifying key competitive product, services or

processes & comparing with those of :-Correct

AnswerMain competitor


Multiple Choice Multiple AnswerQuestion Benefits of stratification are :-

CorrectAnswer

It helps to separate data into groups so that you can draw connect & meaningfulinference , It helps to diagnose & localize problem , It helps to identify the influencingfactors

Your Answer It helps to separate data into groups so that you can draw connect & meaningfulinference , It helps to diagnose & localize problem , Finding out different reasons

Multiple Choice Multiple AnswerQuestion Quality maintenance & pillar focuses on following production inputs :-

CorrectAnswer

Men , Machine , Material

Your Answer Men , Machine , Management

Multiple Choice Single AnswerQuestion The success indicators in quality, cost, delivery & product development are :-

CorrectAnswer

Managing points

Your Answer Accountability

Multiple Choice Multiple AnswerQuestion Steps in setup time reduction are :-

2

CorrectAnswer

Team formation , Training , Recoding of activities on multiple activity charts

Your Answer Team formation , Recoding of activities on multiple activity charts , Convert externalsetups in to internal setups

Multiple Choice Multiple AnswerQuestion POM essentially consists of :-

CorrectAnswer

Time management , Team participation and performance , Moral boosting

Your Answer Time management , Team participation and performance , Cost Management

Multiple Choice Single AnswerQuestion Activity under quality management is :-

CorrectAnswer

Use team approach to track down root causes of the problem

Your Answer Maintenance of equipment condition by eliminating lubricant leakage.

True/FalseQuestion Every department should make their own rules of standardization.

CorrectAnswer

False

Your Answer True

Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of the histogram gives :-

CorrectAnswer

It shows cause which affects the process , An idea of what is happening to the process, Whether the process is capable of meeting process or not i.e. around correct average& within specific limits

Your Answer It shows cause which affects the process , An idea of what is happening to the process, Whether the process is capable of meeting process or not i.e. around correct average& within specific limits


Productivity performancemeasurement

Turnover employee Sales of the months

Financial performancemeasurement

Sales of the months Cash saving per department

Customer satisfactionmeasurement

Customer complaints per period Customer complaints per period

Staff attitude measurement Employee satisfaction index Employee satisfaction index

Multiple Choice Single AnswerQuestion TPM helps to reduce down time due to:-

CorrectAnswer

Breakdown of machine

Your Answer Breakdown of machine

3

Multiple Choice Single AnswerQuestion Kaizen emphasizes :-

CorrectAnswer

Implementation of ideas

Your Answer Collection of ideas

Select The BlankQuestion Create as many ________ system as possible for better Seiketsu.

CorrectAnswer

Visual control

Your Answer Visual control

True/FalseQuestion Inadequate maintenance of machine leads to muda of defects

CorrectAnswer

True

Your Answer False

Select The BlankQuestion The shape of histogram can provide a clue about the ________ of the lot.

CorrectAnswer

Quality

Your Answer Distribution

Multiple Choice Single AnswerQuestion Customer's return is an indicators of the MUDA of :-

CorrectAnswer

Defect

Your Answer Defect

Multiple Choice Single AnswerQuestion In bar graph the interval (gap) between the bars is :-

CorrectAnswer

Equal

Your Answer Symmetrical

True/FalseQuestion Inspection is poor method of assuring 100% quality.

CorrectAnswer

True

Your Answer False

True/FalseQuestion A radar chart is combination of a circle & line graph

CorrectAnswer

True

4

Your Answer True

Multiple Choice Single AnswerQuestion A workshop is to be treated as :-

CorrectAnswer

Place where one's creativity can be applied

Your Answer Place where one's creativity can be applied

True/FalseQuestion Customer wise outstanding is discussed in daily work management meeting by

operations head.Correct

AnswerFalse

Your Answer True

True/FalseQuestion Number of operation can change according to production requirement in U-Line

arrangement.Correct

AnswerFalse

Your Answer True

True/FalseQuestion Automation can correct the basic faults of a improper setup process.

CorrectAnswer

False

Your Answer True


CorrectAnswer

2

Your Answer 1.66

Select The BlankQuestion Range ( R ) is obtained as the difference between the highest and ________

measurement of a sample.Correct

AnswerLowest

Your Answer Second highest

Select The BlankQuestion ________is an important step toward successful JIT purchasing.

CorrectAnswer

JIT Contract

Your Answer JIT Contract

True/False

5

Question U-Line layout is better than straight lime layout.

CorrectAnswer

True

Your Answer True

Multiple Choice Single AnswerQuestion TQM applicable to :-

CorrectAnswer

Marketing, design & manufacturing

Your Answer Quality Control department

Select The BlankQuestion Bar graph is display of data that facilitates ________ of quality.

CorrectAnswer

Comparison

Your Answer Performance

Multiple Choice Single AnswerQuestion Production kanban is presented by :-

CorrectAnswer

P-kanban

Your Answer R-kanban

Multiple Choice Single AnswerQuestion Check sheet are also used as :-

CorrectAnswer

Data gathering & interpretation tool

Your Answer Cause finding & effect finding tool

Select The BlankQuestion Japanese believe that when they are ________ they are cleaning there minds too.

CorrectAnswer

Cleaning

Your Answer Repairing machines

Select The BlankQuestion Poka-Yoke devices under category use ________ to distinguish between similar parts

which may be assembled in wrong position.Correct

AnswerColor coding

Your Answer Counting device

Select The BlankQuestion Shitsuke means ________ all the previous 4-S throughout the month/year.

CorrectAnswer

Sustaining

6

Your Answer Implementing

Multiple Choice Multiple AnswerQuestion Types of meetings held in DWM are :-

CorrectAnswer

Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCA meeting

Your Answer Weekly PDCA meeting , Monthly PDCA meeting , Yearly PDCA meeting

True/FalseQuestion By TPM, consumption of electrical energy can be reduced.

CorrectAnswer

True

Your Answer True

Multiple Choice Multiple AnswerQuestion According to Seiketsu Standardization means :-

CorrectAnswer

To develop easy to follow standards , Evolve standard operating procedure , Bettervisual management

Your Answer To develop easy to follow standards , Evolve standard operating procedure , Reductionof wastage

True/FalseQuestion Flow chart helps to stop an old process.

CorrectAnswer

False

Your Answer True

Multiple Choice Multiple AnswerQuestion Training related to Quality includes:-

CorrectAnswer

Quality measures , Quality failure

Your Answer Quality measures , Quality failure , Goal of business

Multiple Choice Single AnswerQuestion Total area under the normal curve is

CorrectAnswer

Unity

Your Answer Six

Multiple Choice Multiple AnswerQuestion Cpk =

CorrectAnswer

(x - USL)/3 sigma , (x - LSL)/3 sigma

Your Answer (x - USL)/6 sigma

Select The Blank

7

Question A histogram is a graphical display of distribution of measurements & reveals theamounts of ________ within the process.

CorrectAnswer

Variation

Your Answer Percentage defects


Value analysis / valueengineering

To eliminate MUDA of processing To eliminate MUDA of overproduction

SMED To eliminate MUDA of overproduction

To eliminate MUDA of defect

VMI ( Vendor ManagementInventory) system

To eliminate MUDA of stock To eliminate MUDA of stock

Flow / string diagram To eliminate MUDA of transport To eliminate MUDA of processing

Select The BlankQuestion A 'Radar chart' is used to portray ________ strength or weakness of the activity.

CorrectAnswer

Relative

Your Answer Comparative

2nd assignmentTechniques for Operations Efficiency assgn :02: Naresh

True/FalseQuestion Performance benchmarking does not involves comparison of financial ratios at the

aggregate level.Correct

AnswerFalse

Your Answer False

Multiple Choice Multiple AnswerQuestion Few steps to construct a flow chart are :-

CorrectAnswer

Decide on the objective of flowchart & define boundaries of the process , Identifysteps in the process & construct a draft of the flowchart , Review the draft & connectthe changes as per review & name it & put the data & use it as 'Record'

Your Answer Decide on the objective of flowchart & define boundaries of the process , Identifysteps in the process & construct a draft of the flowchart , Review the draft & connectthe changes as per review & name it & put the data & use it as 'Record'

Select The BlankQuestion In PDCA cycle for benchmarking 'Identification of performance gap' is done in

________.Correct

AnswerChecking

Your Answer Checking


8

CorrectAnswer

Monthly

Your Answer Shift beginning

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when value of 'y' decreases

as the value of 'x' increases.Correct

AnswerStrong negative


Select The BlankQuestion Kaizen projects are managed by ________

CorrectAnswer

Cross functional team

Your Answer Management

Multiple Choice Single AnswerQuestion Poka-yoke for employee not performing work as per established method is :-

CorrectAnswer

Implement work standard

Your Answer Implement work standard


CorrectAnswer

Procurement procedures , Budgeting , Recruitment



CorrectAnswer

Decide level of benchmarking , List down a few prospective candidates of partnership ,Collect information of short listed partners

Your Answer Decide level of benchmarking , Collect information of short listed partners

Multiple Choice Single AnswerQuestion Errors by armatures is :-

CorrectAnswer

Lack of experience

Your Answer Absent mindedness

True/FalseQuestion Control chart is also called as run-chart.

CorrectAnswer

True

Your Answer True

9


Reduce clamping & declampingtime

Use U-shaped washer Use U-shaped washer

Reduce time of external setup Improve work aids positioningmethod

Improve work aids positioningmethod

Convert internal setup intoexternal setup

Preparation of tools / dies as offline activity


Eliminate adjustment Pre setting of tool Pre setting of tool

Multiple Choice Single AnswerQuestion Muda of defect is very serious in case of:-

CorrectAnswer

High speed automatic machines

Your Answer High speed automatic machines

Multiple Choice Multiple AnswerQuestion To reduce clamping & declamping time, following actions are desirable :-

CorrectAnswer

Standardize clamping bolts / screws , Cut off unnecessary threads , Use quickclamping device

Your Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quickclamping device


CorrectAnswer

Muda of overproduction

Your Answer Muda of waiting

Multiple Choice Single AnswerQuestion In India quality circle was first launched by :-

CorrectAnswer

Hyderabad unit of BHEL

Your Answer Hyderabad unit of BHEL

Multiple Choice Multiple AnswerQuestion 3M' is world class benchmarking ' candidates in the field of :-

CorrectAnswer

Product development , Technology transfer , Environmental Management

Your Answer Product development , Technology transfer , Environmental Management

Multiple Choice Single AnswerQuestion Responsibility for Quality should rest on:-

CorrectAnswer

Who produce the product

Your Answer Quality control department

10

True/FalseQuestion Increase in defect rate is an example of 'Deviation from an established norms'

CorrectAnswer

True

Your Answer True

Select The BlankQuestion ________ are implemented for defect detection & prevention.

CorrectAnswer

Poka-Yokes

Your Answer Poka-Yokes


CorrectAnswer

Improve quality

Your Answer Improve quality


CorrectAnswer

Gap in performance

Your Answer Lower efficiency

True/FalseQuestion Presentation of graphs in pictorial form of data collection are for easy understanding.

CorrectAnswer

True

Your Answer True

Select The BlankQuestion ________ waste is probably the biggest waste in most of the organizations.

CorrectAnswer

Time

Your Answer Labor

True/FalseQuestion Globalization of trade and industrial operations have forced Indian companies to

become more & more competitive and customer driven.Correct

AnswerTrue

Your Answer True


11

CorrectAnswer

True

Your Answer True

Multiple Choice Multiple AnswerQuestion An erratic patterns falling above & below the control limits indicates :-

CorrectAnswer

Poorly trained operators , Defect in materials , Frequent adjustment of machines

Your Answer Defect in materials , Frequent adjustment of machines , Poorly trained operators

Multiple Choice Single AnswerQuestion Defects per million for the process at six sigma level are :-

CorrectAnswer

3.4

Your Answer 6210

Multiple Choice Single AnswerQuestion To provide flexibility to supervisors in allocation of task, JIT emphasizes :-

CorrectAnswer

Multiskilled operators


Multiple Choice Single AnswerQuestion To maintain smoothness in production :-

CorrectAnswer

Elimination of buffer stock is recommended

Your Answer Maintenance of buffer stock is recommended.

Select The BlankQuestion ________ should be used to exercise control on the process.

CorrectAnswer

Control chart

Your Answer Latest checking instruments


Ideally the histogram will have abell shape

Tapering away on the both sidesfrom average value


Histogram is a graphical displayof distribution of measurementsand

Reveals the amount of variationwithin the process


Histogram is a diagrammaticpresentation of

The frequency distribution of acharacteristics


The shape of histogram can Provide a clue about the qualityof the lot

Provide a clue about the quality ofthe lot

True/False

12

Question In single card kanban system production greater than quantity withdrawn ispermitted.

CorrectAnswer

False

Your Answer False

True/FalseQuestion Flow chart are drawn to document a process charting the tasks performed & the

sequence in which tasks are performed.Correct

AnswerTrue

Your Answer True

Select The BlankQuestion Cpk for six sigma process is ________

CorrectAnswer

1.5

Your Answer 1.5

True/FalseQuestion Seiso prevents the potential problems by discovering abnormalities while cleaning

your own area.Correct

AnswerTrue

Your Answer True

Multiple Choice Multiple AnswerQuestion Some steps for stratification are :-

CorrectAnswer

Define the problem & identify the stratification variables , Sort out data intocategories & summarise information in each category , Present the information ingraphical form & study, decide if further stratification is required?

Your Answer Define the problem & identify the stratification variables , Sort out data intocategories & summarise information in each category , Present the information ingraphical form & study, decide if further stratification is required?

True/FalseQuestion Processing cost of a product is mainly decided by conversion process.

CorrectAnswer

True

Your Answer True

Multiple Choice Multiple AnswerQuestion Work standards enable management to minimize variation in :-

CorrectAnswer

Output , Quality , Cost

Your Answer Output , Quality , Cost

Multiple Choice Multiple AnswerQuestion Process can be made capable by :-

13

CorrectAnswer

Reducing process variability , Bringing target & average to fall at the same point ,Examine possibility of relaxing specification

Your Answer Reducing process variability , Bringing target & average to fall at the same point , Useof less precision machine

Multiple Choice Multiple AnswerQuestion Few steps in construction of Pie chart are :-

CorrectAnswer

Express value of each category as percentage of total of all categories & calculate thedegree of angle form by each category by equation degree = Value of groups/Totalvalue * 360 , Draw the circle & segment the circle into angles calculated in step one ,Colour different segments & enter the percentage of each category into pie chart

Your Answer Express value of each category as percentage of total of all categories & calculate thedegree of angle form by each category by equation degree = Value of groups/Totalvalue * 360 , Draw the circle & segment the circle into angles calculated in step one ,Colour different segments & enter the percentage of each category into pie chart


CorrectAnswer

Everyone, clerk to officer does cleaning his area , No sweeper or cleaner employees ,Every family does cleaning of pavement of their residence

Your Answer Everyone, clerk to officer does cleaning his area , No sweeper or cleaner employees ,Every family does cleaning of pavement of their residence

Select The BlankQuestion Poka Yoke designed to help operators to know immediately ________ of the defeat

called detection type Poka-Yoke.Correct

AnswerOn occurrence

Your Answer Before Occurrence

Select The BlankQuestion Flow chart helps to dissect a process for better understanding & ________ of process.

CorrectAnswer

Analysis

Your Answer Analysis

Multiple Choice Single AnswerQuestion Small groups forming a circle should consist of :-

CorrectAnswer

Employees of different department related to the problem

Your Answer Employees of same department

Select The BlankQuestion Graphs convey a situation more ________ than summary of data or figures.

CorrectAnswer

Effectively & clearly

Your Answer Effectively & clearly

Multiple Choice Single AnswerQuestion Number of Kaizen projects suggested and implemented is checking point for :-

14

CorrectAnswer

Continual Improvement

Your Answer Continual Improvement

3rd assignmentTechniques for Operations Efficiency assgn :03: Senthil N


Correct Answer Material , Men , Machine

Your Answer Material , Men , Machine

Multiple Choice Multiple AnswerQuestion Histograms are useful to :-

Correct Answer Measure the current pattern & extent of variation , Assess current conformanceto specification & scope of improvement , Determine whether or not the processis in the state of control

Your Answer Measure the current pattern & extent of variation , Assess current conformanceto specification & scope of improvement , Determine whether or not the processis in the state of control

Multiple Choice Single AnswerQuestion In problem solving the best alternative is that :-

Correct Answer Which best meets the criteria

Your Answer Which best meets the criteria

Multiple Choice Single AnswerQuestion "Cause & effect" diagram was developed by :-

Correct Answer DR.Kaoru Ishikawa

Your Answer DR.Kaoru Ishikawa

Multiple Choice Single AnswerQuestion Identifying key preventive operational functions and comparing these

operational functions within the firm's own division & branches comes under :-Correct Answer Internal benchmarking

Your Answer Internal benchmarking

Select The BlankQuestion JIT advocates the philosophy at elimination of waste from system which occurs

due to ________.Correct Answer Over Production


Select The BlankQuestion In scatter diagram "________" relationship is said to exist when there is

positive relationship upto certain level & negative thereafter or negativerelationship upto certain level & positive thereafter.

15

Correct Answer Curvilinear

Your Answer Curvilinear

True/FalseQuestion Kanban signals are required when assembly work, subassembly work and

manufacturing at parts is carried out at different locations.Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion Customers complaints may be segregated by :-

Correct Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excessquantity

Your Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excessquantity

True/FalseQuestion In case of more than one quality characteristics, separate chart is made for

each quality characteristics.Correct Answer True

Your Answer True

True/FalseQuestion Safety, hygiene and environment control is one of the pillar of TPM.

Correct Answer True

Your Answer True

Multiple Choice Single AnswerQuestion 5-S technique is useful to:

Correct Answer To all places including homes

Your Answer To all places including homes










Multiple Choice Single AnswerQuestion The facilitator should be normally :-

16

Correct Answer Senior officer /Shop incharge

Your Answer Senior officer /Shop incharge


Parato diagram always indicates Magnitude of defects Philosophy of 20% of the activitycauses 80% of the effect

Parato analysis underlines &operates on

Philosophy of "vital few:trivialmany"


Parato analysis is technique ofidentifying vital causes by

Arranging data according to thedescending order of theirfrequency of occurrence


Parato diagram is a Bar graphwith height or value drawn by

Arranging data in descendingorder




Your Answer Make work easy

True/FalseQuestion Pie chart is also called as angular diagram.

Correct Answer True

Your Answer True

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when value of 'y'

somewhat decreases as the value of 'x' increases.Correct Answer Weak negative

Your Answer Weak negative

Multiple Choice Single AnswerQuestion From scatter diagram the strength of relationship between two variables or

associated set of data can be inferred from the examination of the shape of :-Correct Answer Cloud

Your Answer Cloud

Multiple Choice Multiple AnswerQuestion Product benchmarking requires, comparison of product :-

Correct Answer Performance , Features , Cost

Your Answer Performance , Features , Cost

Multiple Choice Multiple Answer

17

Question Steps in construction of scatter diagram :-

Correct Answer Collect paired data (X,Y) from two variables who's relationship is to be studied ,Find out max & min values for both X & Y and these values to scale X & Y axis &plot the paired data , Examine the shape of the cloud of points & discover type& strength of relationship

Your Answer Collect paired data (X,Y) from two variables who's relationship is to be studied ,Find out max & min values for both X & Y and these values to scale X & Y axis &plot the paired data , Examine the shape of the cloud of points & discover type& strength of relationship




Select The BlankQuestion Each quality characteristic has permitted variation & is equal to ________.

Correct Answer USL - LSL

Your Answer USL - LSL

Select The BlankQuestion Kaizen is ________ supported process.

Correct Answer Management


True/FalseQuestion The flow charts are prepared to enhance the employees understanding of the

process by indicating interrelationship within the process.Correct Answer True

Your Answer False

True/FalseQuestion Gap analysis for production & dispatches is discussed in monthly meeting.


Your Answer False

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when value of 'y'

decreases as the value of 'x' increases.Correct Answer Strong negative


Select The Blank

18

Question ________ is most difficult 'S' to implement & achieve.

Correct Answer Shitsuke

Your Answer Shitsuke

True/FalseQuestion Presentation of graphs in pictorial form of data collection are for easy

understanding.Correct Answer True

Your Answer True


Correct Answer Effectively & clearly



Correct Answer Lack of experience

Your Answer Lack of experience

Multiple Choice Multiple AnswerQuestion While preparing scatter diagram following precautions are to be taken :-

Correct Answer Data should be properly stratified & should be collected for full range , Scaleselected should be right to avoid wrong conclusions , Data should be free frombias or undue importance

Your Answer Data should be properly stratified & should be collected for full range , Scaleselected should be right to avoid wrong conclusions , Data should be free frombias or undue importance


become more & more competitive and customer driven.Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion If 'Annual saving in procurement expenses is managing point', then checking

points will be :-Correct Answer Price revision , Credit period , Transport expenses

Your Answer Price revision , Credit period , Transport expenses

Multiple Choice Single AnswerQuestion Number of kaizen in Group kaizen categories are :-

Correct Answer Two to three per year

19

Your Answer Two to three per year

True/FalseQuestion Flow chart is pictorial representation of the steps in production control.


Your Answer False

Multiple Choice Single AnswerQuestion It is essential to convey customer's expectations to :-

Correct Answer Top Management

Your Answer Supervisors & workmen




Select The BlankQuestion Identification of non-value added operations & their elimination is the first step

to eliminate muda of ________.Correct Answer Processing

Your Answer Processing

Select The BlankQuestion A 'Radar chart' is used to portray ________ strength or weakness of the

activity.Correct Answer Relative





True/FalseQuestion In single card kanban system production greater than quantity withdrawn is

permitted.Correct Answer False

Your Answer False

Multiple Choice Multiple AnswerQuestion Benefits of planned maintenance are :-

20

Correct Answer Improved reliability mean time between failures , Improved maintainabilitymean time to repair , Improvement in breakdown

Your Answer Improved reliability mean time between failures , Improved maintainabilitymean time to repair

Multiple Choice Multiple AnswerQuestion Gap analysis & problem identification is done during converting internal setups

into external setups in the areas like :-Correct Answer Equipment , Method , Human

Your Answer Equipment , Method , Human

Multiple Choice Single AnswerQuestion Some quantity in stock of item, is desirable if :-

Correct Answer Manufacturing lead time is more

Your Answer Manufacturing lead time is more

Multiple Choice Single AnswerQuestion Sorting of usable items should be

Correct Answer Planned storage based on frequency of use

Your Answer Within visual reach method

Multiple Choice Multiple AnswerQuestion Benefits of Quality maintenance are :-

Correct Answer Reduction in customer quality complaints , Reduction in inspection time

Your Answer Reduction in customer quality complaints , Reduction in inspection time

4th assignmentTechniques for Operations Efficiency assgn :04: Sameer

Multiple Choice Multiple AnswerQuestion Training related to Quality includes:-Correct Answer Quality measures , Quality failureYour Answer Negotiation skill , Goal of business , Quality measures , Quality failure

Multiple Choice Single AnswerQuestion If defects found at own process, the cost to the company is :-Correct Answer Very littleYour Answer Very high

Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of the histogram gives :-Correct Answer It shows cause which affects the process , An idea of what is happening to the

process , Whether the process is capable of meeting process or not i.e. around correct average &within specific limitsYour Answer It shows cause which affects the process , An idea of what is happening to the process

, Whether the process is capable of meeting process or not i.e. around correct average & within specificlimits , A bird's eye view of the variation


21

Correct Answer FalseYour Answer False

Select The BlankQuestion Basic objective of control chart is to ________ the variation due to chance & assignable

cause.Correct Answer Separate outYour Answer Separate out

Multiple Choice Multiple AnswerQuestion Benefits of stratification are :-Correct Answer It helps to separate data into groups so that you can draw connect & meaningful

inference , It helps to diagnose & localize problem , It helps to identify the influencing factorsYour Answer It helps to separate data into groups so that you can draw connect & meaningful

inference , It helps to diagnose & localize problem , It helps to identify the influencing factors , Findingout different reasons

Multiple Choice Single AnswerQuestion For 'Timely clearance of GRR's', checking point will be :-Correct Answer Number of GRRs pending beyond 1 dayYour Answer Number of GRRs pending beyond 1 day

Multiple Choice Single AnswerQuestion Organizing the place is not enough , what is required is :Correct Answer Planning storage based on Frequency of useYour Answer Planning storage based on Frequency of use

Select The BlankQuestion JIT helps to ________ the waste in the purchasing process.Correct Answer EliminatesYour Answer Eliminates

Multiple Choice Single AnswerQuestion In cellular manufacturing system, the cells are designed so that the material flow within

the cell and between the cells are :-Correct Answer MinimizedYour Answer Minimized

True/FalseQuestion Kanban signals are required when assembly work, subassembly work and manufacturing

at parts is carried out at different locations.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Causes of Muda of transport are :-Correct Answer Faulty layout , Over productionYour Answer Faulty layout , Over production , Proper material handling equipment , Low rejection /

rework

Multiple Choice Multiple AnswerQuestion Types of meetings held in DWM are :-Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCA meetingYour Answer Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA meeting

Multiple Choice Multiple AnswerQuestion Customers complaints may be segregated by :-Correct Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantityYour Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity ,

Payment problem

22

Multiple Choice Multiple AnswerQuestion Cleaning your own area/equipments gives benefits of :-Correct Answer You know your self how to avoid dust , When you touch while cleaning you may find

a fault , Saving of further failure due to dustYour Answer You know your self how to avoid dust , When you touch while cleaning you may find a

fault , Saving of further failure due to dust , Utilization of spare time

Multiple Choice Multiple AnswerQuestion Role of champions are :-Correct Answer Approve six sigma projects , Remove road block in the path of six sigma

implementation , Monitor progress of six sigma projectsYour Answer Approve six sigma projects , Remove road block in the path of six sigma

implementation , Monitor progress of six sigma projects , Deliver presentation to teams on six sigmaprojects

Select The BlankQuestion Benchmarking shows how an organization is ________ in comparison to its competitors.Correct Answer PerformingYour Answer Performing

True/FalseQuestion Inspection is poor method of assuring 100% quality.Correct Answer TrueYour Answer False

Multiple Choice Multiple AnswerQuestion Benefits of TQM are :-Correct Answer Greater customer satisfaction , Lower manufacturing costYour Answer Greater customer satisfaction , Lower manufacturing cost

Select The BlankQuestion ________ ensures that communication is simple & effective.Correct Answer Visual ManagementYour Answer Visual Management

True/FalseQuestion Daily work management develops problem finding & solving attitude.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Key principles of TQM :-Correct Answer Continuous improvement , People involvement , Cost of qualityYour Answer Continuous improvement , People involvement , Cost of quality , Competitor focus

Select The BlankQuestion A histogram is a graphical display of distribution of measurements & reveals the amounts

of ________ within the process.Correct Answer VariationYour Answer Variation

Select The BlankQuestion To assess effectiveness of training ________ is essential.Correct Answer EvaluationYour Answer Evaluation

Select The BlankQuestion ________ are implemented for defect detection & prevention.Correct Answer Poka-YokesYour Answer TPM

23

True/FalseQuestion To achieve quality, it has to be designed into the product.Correct Answer TrueYour Answer True

Multiple Choice Single AnswerQuestion Setting & maintaining optimal process condition to get quality product is the aim of :-Correct Answer Quality maintenanceYour Answer Quality maintenance


Productivity performance measurement Turnover employee Cost of quality

Financial performance measurement Sales of the months Sales of the months

Customer satisfaction measurement Customer complaints per period Customer complaints per period


Multiple Choice Single AnswerQuestion Recording of the entire setup operators focusing on hand, eye and body movements of the

person doing the setting is done through :-Correct Answer Video recordingYour Answer Video recording


In scatter diagram, the strength of relationship can be determined By "correlation coefficient" By"correlation coefficient"

The scatter diagram provides the technique to establish The possible relationship between a pair ofvariables The possible dependency between a pair of variables

The scatter diagram displays The pair of data as a cloud of points The possible relationship between apair of variables

The scatter is also known as Correlation diagram Correlation diagram

Multiple Choice Single AnswerQuestion What is to be done before selecting benchmarking partner?Correct Answer level of benchmarking is to be decidedYour Answer level of benchmarking is to be decided

True/FalseQuestion Flow chart helps to stop an old process.Correct Answer FalseYour Answer False

Select The BlankQuestion Create as many ________ system as possible for better Seiketsu.Correct Answer Visual controlYour Answer Labeling

Multiple Choice Single AnswerQuestion Allowing worker's to stop machine / assembly line if they believe that product quality is

below standard' is an example of :-

24

Correct Answer EmpowermentYour Answer Empowerment

Multiple Choice Single AnswerQuestion Kanban Signals are required when :-Correct Answer Set up time on the feeding operation is higher then the receiving operation.Your Answer Set up time on the feeding operation is higher then the receiving operation.

Multiple Choice Single AnswerQuestion Kanban system isCorrect Answer 1. Pull SystemYour Answer 1. Pull System

Multiple Choice Single AnswerQuestion Quality problem solving tool is used to :-Correct Answer Improve qualityYour Answer Improve quality

Multiple Choice Single AnswerQuestion To avoid short receipt of items to customers, provide the dispatch clerk with :Correct Answer The check list for verificationYour Answer The check list for verification

True/FalseQuestion Control chart is also called as 'Mean -Range or X-chart'.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Flow chart is required :-Correct Answer When trying to improve the process , At the time of review of the process , To

understand steps in a process by pictorial presentationYour Answer When trying to improve the process , At the time of review of the process , To

understand steps in a process by pictorial presentation , For defects finding of the products

Select The BlankQuestion ________ is the critical element of TQM.Correct Answer Focus on customerYour Answer Focus on customer

Multiple Choice Multiple AnswerQuestion Management skill includes :-Correct Answer Leadership , Motivation , Performance appraisalsYour Answer Leadership , Motivation , Performance appraisals , Quality measurement

Multiple Choice Single AnswerQuestion 5-S technique is useful to:Correct Answer To all places including homesYour Answer To all places including homes

True/FalseQuestion Safety, hygiene and environment control is one of the pillar of TPM.Correct Answer TrueYour Answer True

Select The BlankQuestion Inspection activity for semi finished & finished component should be ________ to reduce

muda of transport .Correct Answer DecentralizedYour Answer Decentralized

25

True/FalseQuestion Flow chart is pictorial representation of the steps in production control.Correct Answer FalseYour Answer True

Select The BlankQuestion Good ________ is the asset to acquire the success of quality circle.Correct Answer TeamworkYour Answer Teamwork

5th assignment

True/FalseQuestion Performance benchmarking does not involves comparison of financial ratios at the aggregate

level.Correct Answer False

Your Answer False

Multiple Choice Single AnswerQuestion Setup time includes :-

Correct Answer Internal setup time & External setup time

Your Answer Internal setup time & External setup time

Multiple Choice Single AnswerQuestion Participants of the groups for quality circles should be decided by :-

Correct Answer Employees coming together by their own enthusiasm

Your Answer Employees coming together by their own enthusiasm


Correct Answer Data gathering & interpretation tool

Your Answer Data gathering & interpretation tool

Multiple Choice Single AnswerQuestion SMED means :-

Correct Answer Single minute exchange of dies

Your Answer Single minute exchange of dies



Turnover employee Cost of quality


Sales of the months Sales of the months

26






Select The BlankQuestion If some defective parts are discovered by the subsequent process they should be returned to

the ________ to prevent reoccurrence.Correct Answer Preceding process


Multiple Choice Multiple AnswerQuestion The results oriented efforts of the quality circle should also include :-

Correct Answer Efforts to avoid the problem permanently , Ultimate aim of the customers satisfaction ,Attacking the real root causes & all possibilities

Your Answer Efforts to avoid the problem permanently , Publication or advertisement of your contribution ,Attacking the real root causes & all possibilities




Philosophy of "vital few:trivial many" Philosophy of "vital few:trivial many"


Arranging data according to thedescending order of their frequencyof occurrence


Parato diagram is a Bar graph withheight or value drawn by

Arranging data in descending order Magnitude of defects


Correct Answer Brainstorming to enlist characteristics which require to be evaluated & draw the circle & divideit into 'slices' equal to number of characteristics , The first slice begins at 12 noon. Then drawvertical line & calibrate it equal to the number of levels required , Draw concentric circles fromeach gradiation using 'o' point as centre

Your Answer Brainstorming to enlist characteristics which require to be evaluated & draw the circle & divideit into 'slices' equal to number of characteristics , The first slice begins at 12 noon. Then drawvertical line & calibrate it equal to the number of levels required , Draw concentric circles fromeach gradiation using 'o' point as centre



27

Your Answer Monthly


Correct Answer True

Your Answer False





Correct Answer Approve six sigma projects , Remove road block in the path of six sigma implementation ,Monitor progress of six sigma projects

Your Answer Monitor progress of six sigma projects , Approve six sigma projects , Remove road block in thepath of six sigma implementation

Multiple Choice Multiple AnswerQuestion To draw control charts, sample must be representative of homogeneous segment of

production for which :-Correct Answer The items of the sample should be from the same machine setting , The items should be of

the same batch , Items should be made from the same raw material batchYour Answer The items of the sample should be from the same machine setting , The items should be of

the same batch , Items should be made from the same raw material batch

Multiple Choice Single AnswerQuestion Failure mode and effect analysis (FMEA) establish




Correct Answer Decide level of benchmarking , List down a few prospective candidates of partnership , Collectinformation of short listed partners

Your Answer Decide level of benchmarking , List down a few prospective candidates of partnership , Collectinformation of short listed partners





28

Question Competitive benchmarking involves identifying key competitive product, services or processes& comparing with those of :-

Correct Answer Main competitor





Select The BlankQuestion Number of defects in an individual component, like gear, shaft, wheel etc can be monitored

through ________ type of control chart.Correct Answer c-chart

Your Answer c-chart

True/FalseQuestion Non-availability of files /document in time is a problem to be addressed by office TPM.

Correct Answer True

Your Answer True




Multiple Choice Single AnswerQuestion Benchmarking helps to identify the gap between the current performance of the organization

and the :-Correct Answer Performance of the best organization




Your Answer True


Correct Answer Sections , Machines , Type of breakdown (e.g mech. Or electrical)

Your Answer Sections , Machines , Type of breakdown (e.g mech. Or electrical)

29

Select The BlankQuestion A control chart to exhibit counted data on number of defect is called ________.


Your Answer c-chart

Select The BlankQuestion Procedure for implementation of TPM consists of ________ numbers of steps.

Correct Answer 12

Your Answer 8







True/FalseQuestion Kanban signals are required when assembly work, subassembly work and manufacturing at

parts is carried out at different locations.Correct Answer True

Your Answer True


Correct Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quick clampingdevice

Your Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quick clampingdevice

Select The BlankQuestion Benchmarking allows exchange of ________ between the benchmarking partners.

Correct Answer Information



Correct Answer Worried about losing jobs , Afraid of being reprimanded if there are mistakes , Scared of theirbosses

30

Your Answer Worried about losing jobs , Afraid of being reprimanded if there are mistakes , Scared of theirbosses



Your Answer False


Correct Answer Equipment analysis , Setup change analysis , Preparation items (storage place , method)analysis

Your Answer Equipment analysis , Setup change analysis , Preparation items (storage place , method)analysis

True/FalseQuestion Daily work management can also be extended to non manufacturing areas like procurement,

QA, HRD etc.Correct Answer True

Your Answer True







True/FalseQuestion Along with problem solving tools experience and judgment is also used.

Correct Answer True

Your Answer False

Select The BlankQuestion JIT advocates the philosophy at elimination of waste from system which occurs due to

________.Correct Answer Over Production



31

Correct Answer True

Your Answer False


Correct Answer Defect in materials , Frequent adjustment of machines , Poorly trained operators


True/FalseQuestion Sample size for the construction of p-chart are larger than X bar-R chart.

Correct Answer True

Your Answer True


Correct Answer It shows cause which affects the process , An idea of what is happening to the process ,Whether the process is capable of meeting process or not i.e. around correct average & withinspecific limits

Your Answer An idea of what is happening to the process , Whether the process is capable of meetingprocess or not i.e. around correct average & within specific limits , A bird's eye view of thevariation




6th assignments

Multiple Choice Multiple AnswerQuestion Steps to six sigma process consists of :-Correct

AnswerIdentify the work you do , Identify your customers , Map the process

True/FalseQuestion Member giving suggestion in his quality circle may not concern for the work

related problem.Correct

AnswerFalse


Review your efforts & successachieved

Check Check

Act about the causes found out Do Act

Collect the initial data for the Plan Control

32

problem

Actions further after reviewingthe progress

Act Repeat

True/FalseQuestion Seiso means cleaning the workplace, is the responsibility of sweeper or cleaning

person.Correct

AnswerFalse

Multiple Choice Multiple AnswerQuestion The purpose of Shitsuke is especially for :-Correct

AnswerMaintaining the 4-S consistently , Develop discipline attitude in everyone , Anyday throughout the year sustain the discipline

Multiple Choice Single AnswerQuestion Chronic problems of poor quality, bad quality delivery, absentism etc, all gets

hide if inventory isCorrect

AnswerHigh

Multiple Choice Single AnswerQuestion Quality is the responsibility of :-Correct

AnswerEveryone in the organization

Multiple Choice Single AnswerQuestion "DOW chemical' is world class benchmarking candidate in :-

CorrectAnswer

Environmental Management

True/FalseQuestion Benefits of DWN is faster response to customer needs.

CorrectAnswer

True

Multiple Choice Single AnswerQuestion Control chart is a graphical method of ascertaining / checking :-

CorrectAnswer

Stability of the process

Select The BlankQuestion Poka-Yoke devices under category 'locating pins' to eliminate cause of ________Correct

AnswerIncorrect positioning


In scatter diagram, the strengthof relationship can bedetermined

By "correlation coefficient" By "correlation coefficient"

The scatter diagram provides The possible relationship The possible dependency

33

the technique to establish between a pair of variables between a pair of variables

The scatter diagram displays The pair of data as a cloud ofpoints

The pair of data as a cloud ofpoints

The scatter is also known as Correlation diagram By "correlation ratio"

Multiple Choice Single AnswerQuestion Time required to prepare machine to change over from one job to another is

called :-Correct

AnswerSetup time

Select The BlankQuestion ________ % of quality problems are due to individual errors.

CorrectAnswer

15


CorrectAnswer

It helps to separate data into groups so that you can draw connect & meaningfulinference , It helps to diagnose & localize problem , It helps to identify theinfluencing factors


CorrectAnswer

Performance , Features , Cost

Multiple Choice Single AnswerQuestion To help operators to recognize the defect before it occurs :-

CorrectAnswer

Build up low cost automated detection method for each process

Multiple Choice Multiple AnswerQuestion Interrupted flow of work from the preceeding operation which may be due to :-

CorrectAnswer

Lack of parts , Machine breakdown , Operator temporarily absent from place ofwork

True/FalseQuestion Daily work management develops problem finding & solving attitude.

CorrectAnswer

True


CorrectAnswer

Procurement procedures , Budgeting , Recruitment

Select The BlankQuestion Suppliers may________ their prices to cover for cost of delivery, small production

run etc.

34

CorrectAnswer

Raise

Multiple Choice Single AnswerQuestion Benefits of Seiton means

CorrectAnswer

Easy irretrievability of material

True/FalseQuestion New benchmarking projects are initiated after reviewing competitive position

periodically.Correct

AnswerTrue


CorrectAnswer

Effectively & clearly


CorrectAnswer

True

Multiple Choice Multiple AnswerQuestion Scatter diagram is used :-

CorrectAnswer

To discover relationship between two associated sets of data , To display therelationship between two variables , To confirm anticipated relationship betweentwo variables / associated sets of data

Select The BlankQuestion Basic objective of control chart is to ________ the variation due to chance &

assignable cause.Correct

AnswerSeparate out

True/FalseQuestion TQM improves manufacturing as well as clerical activities.

CorrectAnswer

True

Select The BlankQuestion Poka Yoke designed to help operators to know immediately ________ of the

defeat called detection type Poka-Yoke.Correct

AnswerOn occurrence

True/FalseQuestion A control chart is a chart with UCL & LCL placed at 6 Sigma distance on either

side of the process average.Correct

AnswerFalse


35

Question Cleaning your own area/equipments gives benefits of :-

CorrectAnswer

You know your self how to avoid dust , When you touch while cleaning you mayfind a fault , Saving of further failure due to dust

Multiple Choice Single AnswerQuestion For 'Analysis of non conformance' checking point will be :-

CorrectAnswer

Find out root cause and take corrective & preventive action

Multiple Choice Single AnswerQuestion Assignable causes :-

CorrectAnswer

Can be eliminated

Select The BlankQuestion ________ used to detect drop in air pressure.

CorrectAnswer

Buzzers / alarms

Multiple Choice Single AnswerQuestion Statistical process control is application of statistical technique to control :-Correct

AnswerProcess

Multiple Choice Multiple AnswerQuestion Benefits from SMED are :-Correct

AnswerReduce work in process , Better average daily production , Increase capacity


CorrectAnswer

To develop easy to follow standards , Evolve standard operating procedure ,Better visual management

Select The BlankQuestion ________ PDCA cycle is the systematic approach towards meeting the target.

CorrectAnswer

Kaoishikawa

Multiple Choice Multiple AnswerQuestion To draw control charts, sample must be representative of homogeneous segment

of production for which :-Correct

AnswerThe items of the sample should be from the same machine setting , The itemsshould be of the same batch , Items should be made from the same raw materialbatch

Multiple Choice Single AnswerQuestion Withdrawal kanban is presented by :-Correct

AnswerC- kanban

Multiple Choice Multiple AnswerQuestion Steps in construction of scatter diagram :-

36

CorrectAnswer

Collect paired data (X,Y) from two variables who's relationship is to be studied ,Find out max & min values for both X & Y and these values to scale X & Y axis &plot the paired data , Examine the shape of the cloud of points & discover type &strength of relationship


CorrectAnswer

Employees of different department related to the problem

Select The BlankQuestion A ________ is an excellent device to condense & present large mass of data in an

elegant form.Correct

AnswerFrequency distribution


________.Correct

AnswerChecking

True/FalseQuestion Low level of delegation is an example of muda in office.Correct

AnswerTrue

True/FalseQuestion Change of job titles can help to raise employee's morale.Correct

AnswerTrue

Select The BlankQuestion ________ is benefit of TPM.Correct

AnswerLow production cost

My assignment attempt 2nd

True/FalseQuestion The flow charts are prepared to enhance the employees understanding of the process by

indicating interrelationship within the process.Correct Answer True

Your Answer True





37



Multiple Choice Multiple AnswerQuestion Flow chart is prepared when :-

Correct Answer Defining the problem , Trying to know the activities involved in the process , Identifying theroot causes

Your Answer Defining the problem , Trying to know the activities involved in the process , Identifying theroot causes


Correct Answer It helps to separate data into groups so that you can draw connect & meaningful inference , Ithelps to diagnose & localize problem , It helps to identify the influencing factors

Your Answer It helps to separate data into groups so that you can draw connect & meaningful inference , Ithelps to diagnose & localize problem , It helps to identify the influencing factors


World class benchmarking companyin assembly automation

Ford Ford

World class benchmarking companyin marketing

Microsoft Microsoft

World class benchmarking companyin quality

Motorola Motorola

World class benchmarking companyin training

General Electric General Electric


Correct Answer Product development , Technology transfer , Environmental Management



Correct Answer True

Your Answer True

Multiple Choice Single AnswerQuestion Statistical process control (SPC) is the application of statistical technique for the purpose of :-

Correct Answer Process control

Your Answer Process control

Multiple Choice Single AnswerQuestion The area enclosed under normal distribution curve between mean +1standard deviation is :-

38

Correct Answer 0.6826

Your Answer 1

Multiple Choice Single AnswerQuestion Quality maintenance means :-

Correct Answer Incorporating quality into product

Your Answer Incorporating quality into product



Your Answer True


Correct Answer True

Your Answer True

Multiple Choice Single AnswerQuestion A drive for people involved should start with the :-

Correct Answer Study of staff attitudes

Your Answer Developing basic skill


Ideally the histogram will have a bellshape



Histogram is a graphical display ofdistribution of measurements and






The shape of histogram can Provide a clue about the quality ofthe lot



Correct Answer Define the problem & identify the stratification variables , Sort out data into categories &summarise information in each category , Present the information in graphical form & study,decide if further stratification is required?

Your Answer Define the problem & identify the stratification variables , Sort out data into categories &summarise information in each category , Present the information in graphical form & study,decide if further stratification is required?

Select The Blank

39

Question Capability index Cp = ________



Select The BlankQuestion Pie chart is the graph of ________ data.

Correct Answer Percentage breakdown

Your Answer Percentage breakdown

Select The BlankQuestion ________feel that quality circle cause erosion of their control over workmen.

Correct Answer Supervisors

Your Answer Supervisors

True/FalseQuestion Globalization of trade and industrial operations have forced Indian companies to become more

& more competitive and customer driven.Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion For 'Control on PPM and rework level;, checking points' will be :-

Correct Answer PPM level , Initiate corrective actions on rejection/rework , Initiate preventive action onrejection / rework

Your Answer PPM level , Initiate preventive action on rejection / rework , 100% inspection


Correct Answer Measure the current pattern & extent of variation , Assess current conformance tospecification & scope of improvement , Determine whether or not the process is in the state ofcontrol

Your Answer Measure the current pattern & extent of variation , Assess current conformance tospecification & scope of improvement , Determine whether or not the process is in the state ofcontrol


Correct Answer Quality measures , Quality failure

Your Answer Quality measures , Quality failure



40


Select The BlankQuestion Good ________ is the asset to acquire the success of quality circle.

Correct Answer Teamwork

Your Answer Teamwork

Select The BlankQuestion Ideally the histogram will have a symmetrical ( i.e. also called as bell) shape tapering away on

both sides from ________ value.Correct Answer Average

Your Answer Average


Correct Answer Cleaning

Your Answer Cleaning

True/FalseQuestion Key element of JIT is continuous improvement.

Correct Answer True

Your Answer True

True/FalseQuestion Statistical limits are calculated from averages of samples, instead of a single sample of large

size.Correct Answer True

Your Answer True

Select The BlankQuestion World class benchmarking candidate in 'Quality' is ________.

Correct Answer Motorola

Your Answer DOW chemical


Correct Answer Elimination of buffer stock is recommended

Your Answer Elimination of buffer stock is recommended


41

Correct Answer Poka-Yokes



Correct Answer High speed automatic machines



Correct Answer Data should be properly stratified & should be collected for full range , Scale selected shouldbe right to avoid wrong conclusions , Data should be free from bias or undue importance

Your Answer Data should be properly stratified & should be collected for full range , Scale selected shouldbe right to avoid wrong conclusions , Data should be free from bias or undue importance

Multiple Choice Multiple AnswerQuestion The purpose of Shitsuke is especially for :-

Correct Answer Maintaining the 4-S consistently , Develop discipline attitude in everyone , Any day throughoutthe year sustain the discipline

Your Answer Maintaining the 4-S consistently , Develop discipline attitude in everyone , Any day throughoutthe year sustain the discipline




Select The BlankQuestion Range ( R ) is obtained as the difference between the highest and ________ measurement of

a sample.Correct Answer Lowest

Your Answer Lowest



Your Answer False

Multiple Choice Single AnswerQuestion What is to be done before selecting benchmarking partner?

Correct Answer level of benchmarking is to be decided

Your Answer level of benchmarking is to be decided

True/False

42

Question Operator monitoring a machine while machine works on auto cycle is an example of muda ofwaiting.

Correct Answer True

Your Answer False

Multiple Choice Single AnswerQuestion Frequencies, values, tabulated in the frequency table, can be represented pictorially in the

form of bar graph & this graph of frequency is called as :-Correct Answer Histogram

Your Answer Histogram

Select The BlankQuestion To assess effectiveness of training ________ is essential.

Correct Answer Evaluation

Your Answer Evaluation


Correct Answer Reduce work in process , Better average daily production , Increase capacity

Your Answer Reduce work in process , Better average daily production , Increase capacity

Multiple Choice Single AnswerQuestion Line graph is also called as :-

Correct Answer Run chart

Your Answer Radar chart

Multiple Choice Single AnswerQuestion In bar graph each bar is of same :-

Correct Answer Width

Your Answer Width

Multiple Choice Multiple AnswerQuestion The alternate meaning of seiso is

Correct Answer Sanities , Cleanup , Dust free / scrab

Your Answer Cleanup , Dust free / scrab , Neatness

True/FalseQuestion In P-chart, the value of P can never be negative.

Correct Answer True

Your Answer True

43

My skipped qustions

1. Control chart is a graphicalmethod of checking

1. As process monitoring tool

2. Control chart can be used todetermine

2. At 6 Sigma distance on either side of the process average

3. Control chart is a chart withUCL & LCL placed

3. For quality monitoring

4. Control chart can be used 4. Stability of the process

5. How much variability in the process is due to random causes& how much is due to assignable causes

6. At 3 Sigma distance on either side of the process average

Quality circle should consists employees ofLow er levels

who are not usually considered capablecontributing

Shitsuke is most difficult out of all 5-S because it means to sustain all the first 4-S throughout the year.

After choosing the problem area, to go ahead further what is required?

a)

b)

c)

d)

Regular meeting plan to follow

Discuss on the root cause bybrainstorming

Study individually for the problem

Follow the Deming PDCA circle

Mechanization &Discipline

are the two constituents of streamlining

29.is serve as a stepping stone to TQM

Actions that can be thought for the process having process capability is approximately equal tothe specification tolerance are :-

a)

b)

c)

d)

Greaterattention tocentering ofthe process

Keepmean &standarddeviationunder strictcontrol

Putefforts toreducevariability

44

Use oflessprecisionmachine

Technique involved in listing of setup task, establishing technological relationship between tasks, drawing

arrow diagram is called as

36. .

True

False


Multiple Choice Multiple AnswerQuestion Advantages of JIT :-

Correct Answer Reduce incoming inspection , Reduce inventory , Lower per unit cost



Correct Answer Minimization of transit damages , Ease in verification of quantity ofparts , Automatic signal to supplier to replenish stock

Your Answer Minimization of transit damages , Ease in verification of quantity ofparts , Automatic signal to supplier to replenish stock


Correct Answer Reduce work in process , Better average daily production , Increasecapacity






Correct Answer It helps to separate data into groups so that you can draw connect &meaningful inference , It helps to diagnose & localize problem , Ithelps to identify the influencing factors

Your Answer It helps to separate data into groups so that you can draw connect &meaningful inference , It helps to diagnose & localize problem ,Finding out different reasons

Multiple Choice Multiple AnswerQuestion Quality maintenance & pillar focuses on following production inputs

:-Correct Answer Men , Machine , Material


Multiple Choice Single AnswerQuestion The success indicators in quality, cost, delivery & product

development are :-

Correct Answer Managing points



Correct Answer Team formation , Training , Recoding of activities on multiple activitycharts

Your Answer Team formation , Recoding of activities on multiple activity charts ,Convert external setups in to internal setups


Correct Answer Time management , Team participation and performance , Moralboosting

Your Answer Time management , Team participation and performance , CostManagement


Correct Answer Use team approach to track down root causes of the problem

Your Answer Maintenance of equipment condition by eliminating lubricantleakage.



Your Answer True

Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of the histogram

gives :-Correct Answer It shows cause which affects the process , An idea of what is

happening to the process , Whether the process is capable ofmeeting process or not i.e. around correct average & within specificlimits

Your Answer It shows cause which affects the process , An idea of what ishappening to the process , Whether the process is capable ofmeeting process or not i.e. around correct average & within specificlimits







Customer complaints perperiod


Staff attitude measurement Employee satisfactionindex

Employee satisfaction index


Correct Answer Breakdown of machine



Correct Answer Implementation of ideas



Correct Answer Visual control



Correct Answer True

Your Answer False

Select The BlankQuestion The shape of histogram can provide a clue about the ________ of

the lot.Correct Answer Quality



Correct Answer Defect

Your Answer Defect


Correct Answer Equal



Correct Answer True

Your Answer False


Correct Answer True

Your Answer True


Correct Answer Place where one's creativity can be applied


True/FalseQuestion Customer wise outstanding is discussed in daily work management

meeting by operations head.Correct Answer False

Your Answer True

True/FalseQuestion Number of operation can change according to production

requirement in U-Line arrangement.Correct Answer False

Your Answer True



Your Answer True


Correct Answer 2

Your Answer 1.66

Select The BlankQuestion Range ( R ) is obtained as the difference between the highest and

________ measurement of a sample.Correct Answer Lowest



Correct Answer JIT Contract


True/FalseQuestion U-Line layout is better than straight lime layout.

Correct Answer True

Your Answer True


Correct Answer Marketing, design & manufacturing


Select The BlankQuestion Bar graph is display of data that facilitates ________ of quality.

Correct Answer Comparison



Correct Answer P-kanban





Select The BlankQuestion Japanese believe that when they are ________ they are cleaning

there minds too.Correct Answer Cleaning


Select The BlankQuestion Poka-Yoke devices under category use ________ to distinguish

between similar parts which may be assembled in wrong position.Correct Answer Color coding


Select The BlankQuestion Shitsuke means ________ all the previous 4-S throughout the

month/year.Correct Answer Sustaining



Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCAmeeting

Your Answer Weekly PDCA meeting , Monthly PDCA meeting , Yearly PDCAmeeting


Correct Answer True

Your Answer True


Correct Answer To develop easy to follow standards , Evolve standard operatingprocedure , Better visual management

Your Answer To develop easy to follow standards , Evolve standard operatingprocedure , Reduction of wastage



Your Answer True





Correct Answer Unity

Your Answer Six


Correct Answer (x - USL)/3 sigma , (x - LSL)/3 sigma


Select The BlankQuestion A histogram is a graphical display of distribution of measurements &

reveals the amounts of ________ within the process.Correct Answer Variation




To eliminate MUDA ofprocessing

To eliminate MUDA of overproduction


To eliminate MUDA ofdefect


To eliminate MUDA ofstock

To eliminate MUDA of stock

Flow / string diagram To eliminate MUDA oftransport

To eliminate MUDA ofprocessing

Select The BlankQuestion A 'Radar chart' is used to portray ________ strength or weakness of

the activity.Correct Answer Relative


1. TPM 1. Waste elimination

2. JIT 2. Visual management

3. Kanban 3. Best way of doing job

4. Work standards 4. Reducing breakdown of machines

5. Pull system6. Statistical process control

1. Parato analysis underlines &operates on

1. Arranging data according to thedescending order of their frequency ofoccurrence

2. Parato analysis is technique ofidentifying vital causes by

2. Philosophy of 20% of the activity causes80% of the effect

3. Parato diagram is a Bar graphwith height or value drawn by

3. Magnitude of defects

4. Parato diagram alwaysindicates

4. Arranging data in ascending order

5. Arranging data in descending order

6. Philosophy of "vital few:trivial many"

27. Total area under the normal curve is

a)

b)

c)

d)

Unity

Zero

Infinity

Six

U shape arrangement of layout provides the operator degree of mobility.

48. Quality problems may be segregated by & regrouped by :-

a)

b)

c)

Machines

Workers

Materials

d)Suggestion



Correct Answer Scared of their bosses , Worried about losing jobs , Afraid ofbeing reprimanded if there are mistakes

Your Answer Scared of their bosses , Worried about losing jobs , Afraid ofbeing reprimanded if there are mistakes




Multiple Choice Single AnswerQuestion The concept of quality circle was mooted by :-

Correct Answer Prof. Kaoishikawa

Your Answer Prof. Kaoishikawa


SMED Setup time reduction Setup time reduction

5 'S Cleanliness Total productivemaintenance

Muda elimination Waste elimination Waste elimination

Poka-Yoke Error proofing Error proofing

Multiple Choice Single AnswerQuestion Allowing worker's to stop machine / assembly line if they believe

that product quality is below standard' is an example of :-Correct Answer Empowerment

Your Answer Involvement



Your Answer Workmen

Select The BlankQuestion Ratio of ________ to the number of pieces inspected is called

fraction defectives.Correct Answer Number of item rejected

Your Answer Number of item rejected

Multiple Choice Single AnswerQuestion Histogram always indicates :-

Correct Answer Only height

Your Answer Percentage defect

Multiple Choice Single AnswerQuestion List of customers, to carry out parato analysis to identify

customers who gives business includes :-Correct Answer Present & past customers

Your Answer Present & past customers




Multiple Choice Multiple AnswerQuestion Steps to six sigma process consists of :-

Correct Answer Identify the work you do , Identify your customers , Map theprocess

Your Answer Identify the work you do , Identify your customers , Map theprocess

Multiple Choice Single AnswerQuestion From scatter diagram the strength of relationship between two

variables or associated set of data can be inferred from theexamination of the shape of :-

Correct Answer Cloud

Your Answer Cloud



Your Answer True


Correct Answer Buzzers / alarms

Your Answer Locators

Multiple Choice Single AnswerQuestion TQM is a way to improve quality of product and service :-

Correct Answer Continuously

Your Answer Continuously





In scatter diagram, thestrength of relationshipcan be determined


The scatter diagramprovides the technique toestablish

The possible relationshipbetween a pair ofvariables

The possible relationshipbetween a pair of variables

The scatter diagramdisplays

The pair of data as acloud of points

The pair of data as a cloudof points

The scatter is also knownas

Correlation diagram Correlation diagram



Your Answer True




Multiple Choice Single AnswerQuestion Pareto diagram always indicate magnitude of :-


Your Answer Influence of defect

True/FalseQuestion By cutting the cost of quality, profitability decreases.


Your Answer False




True/FalseQuestion The flow charts are prepared to enhance the employees

understanding of the process by indicating interrelationshipwithin the process.

Correct Answer True

Your Answer True

Multiple Choice Single AnswerQuestion Abnormal variations can occur if :-

Correct Answer There are assignable causes

Your Answer There are assignable causes



Your Answer Prevention type Poka-Yoke , Detection type Poka-Yoke ,Standards type Poka-Yoke

True/FalseQuestion Control limits of control charts should be revised from time to

time as additional data is accumulated.Correct Answer True

Your Answer True

Select The BlankQuestion Kaizen is an excellent method to involve ________ to unearth &

eliminate hidden waste.Correct Answer Employees

Your Answer Employers

Multiple Choice Multiple AnswerQuestion To reduce Muda of transport, techniques used are :-

Correct Answer Cellular layout , Method study , 5 'S

Your Answer Cellular layout , Method study , 5 'S


Correct Answer 2

Your Answer 2

Select The BlankQuestion ________ participants in monthly meeting(MRM)

Correct Answer GM, operation heads, corporate functional heads

Your Answer Department heads & supervisors

True/False

Question Processing cost of a product is mainly decided by conversionprocess.

Correct Answer True

Your Answer True

Select The BlankQuestion Production in last shift & production plan for next shift is

discussed during ________.Correct Answer Shift beginning & shift end/change meeting

Your Answer Shift beginning & shift end/change meeting

Multiple Choice Multiple AnswerQuestion Material Supply on DSL basis helps :-

Correct Answer To eliminate handling , To reduce transporting , To reduceinspection

Your Answer To eliminate handling , To reduce transporting , To reduceinspection


Correct Answer True

Your Answer True

True/FalseQuestion Most of the external setups are treated as internal setup.

Correct Answer True

Your Answer False


Correct Answer Reduce work in process , Better average daily production ,Increase capacity

Your Answer Reduce work in process , Better average daily production ,Increase capacity




True/FalseQuestion Low level of delegation is an example of muda in office.

Correct Answer True

Your Answer False


Correct Answer Measure the current pattern & extent of variation , Assesscurrent conformance to specification & scope of improvement ,Determine whether or not the process is in the state of control

Your Answer Measure the current pattern & extent of variation , Assesscurrent conformance to specification & scope of improvement ,Determine whether or not the process is in the state of control

Multiple Choice Multiple AnswerQuestion While preparing scatter diagram following precautions are to be

taken :-Correct Answer Data should be properly stratified & should be collected for full

range , Scale selected should be right to avoid wrongconclusions , Data should be free from bias or undue importance

Your Answer Data should be properly stratified & should be collected for fullrange , Scale selected should be right to avoid wrongconclusions , Data should be free from bias or undue importance

Multiple Choice Single AnswerQuestion Through continuous improvement in the process & procedures,

kobetsu-kaizen is continuously improve utilization of :-Correct Answer Worker, equipment & material

Your Answer Workers & materials

True/FalseQuestion Every department should make their own rules of

standardization.Correct Answer False

Your Answer False



Your Answer 8 to 10



Your Answer As many as management decides

Select The BlankQuestion Flow chart helps to provide clarity of the ________ without

visiting actual spot.Correct Answer Process

Your Answer Process

Multiple Choice Single AnswerQuestion Gap in performance = Ideal situation minus :-

Correct Answer Current situation

Your Answer Current situation

Select The BlankQuestion Seminar talks and video show are organized to introduce TPM

concept to ________Correct Answer General employees

Your Answer General employees


True/FalseQuestion Performance benchmarking does not involves comparison of

financial ratios at the aggregate level.Correct Answer False

Your Answer False


Correct Answer Decide on the objective of flowchart & define boundaries of theprocess , Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes as per review &name it & put the data & use it as 'Record'

Your Answer Decide on the objective of flowchart & define boundaries of theprocess , Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes as per review &name it & put the data & use it as 'Record'

Select The BlankQuestion In PDCA cycle for benchmarking 'Identification of performance gap'

is done in ________.Correct Answer Checking









Correct Answer Cross functional team



Question Poka-yoke for employee not performing work as per establishedmethod is :-

Correct Answer Implement work standard







Your Answer Decide level of benchmarking , Collect information of short listedpartners





Correct Answer True

Your Answer True


Reduce clamping &declamping time


Reduce time of externalsetup

Improve work aidspositioning method



Preparation of tools / diesas off line activity

Preparation of tools / dies asoff line activity






desirable :-Correct Answer Standardize clamping bolts / screws , Cut off unnecessary threads ,

Use quick clamping deviceYour Answer Standardize clamping bolts / screws , Cut off unnecessary threads ,

Use quick clamping device





Correct Answer Hyderabad unit of BHEL



Correct Answer Product development , Technology transfer , EnvironmentalManagement

Your Answer Product development , Technology transfer , EnvironmentalManagement


Correct Answer Who produce the product


True/FalseQuestion Increase in defect rate is an example of 'Deviation from an

established norms'Correct Answer True

Your Answer True










True/FalseQuestion Presentation of graphs in pictorial form of data collection are for

easy understanding.Correct Answer True

Your Answer True

Select The BlankQuestion ________ waste is probably the biggest waste in most of the

organizations.Correct Answer Time

Your Answer Labor

True/FalseQuestion Globalization of trade and industrial operations have forced Indian

companies to become more & more competitive and customerdriven.

Correct Answer True

Your Answer True


Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion An erratic patterns falling above & below the control limits indicates

:-Correct Answer Poorly trained operators , Defect in materials , Frequent adjustment

of machines



Correct Answer 3.4

Your Answer 6210

Multiple Choice Single AnswerQuestion To provide flexibility to supervisors in allocation of task, JIT

emphasizes :-Correct Answer Multiskilled operators






Correct Answer Control chart



Ideally the histogram willhave a bell shape

Tapering away on the bothsides from average value

Tapering away on the bothsides from average value

Histogram is a graphicaldisplay of distribution ofmeasurements and

Reveals the amount ofvariation within the process

Reveals the amount ofvariation within the process

Histogram is adiagrammatic presentationof

The frequency distributionof a characteristics

The frequency distribution ofa characteristics

The shape of histogramcan

Provide a clue about thequality of the lot

Provide a clue about thequality of the lot

True/FalseQuestion In single card kanban system production greater than quantity

withdrawn is permitted.Correct Answer False

Your Answer False

True/FalseQuestion Flow chart are drawn to document a process charting the tasks

performed & the sequence in which tasks are performed.Correct Answer True

Your Answer True


Correct Answer 1.5

Your Answer 1.5

True/FalseQuestion Seiso prevents the potential problems by discovering abnormalities

while cleaning your own area.Correct Answer True

Your Answer True


Correct Answer Define the problem & identify the stratification variables , Sort outdata into categories & summarise information in each category ,Present the information in graphical form & study, decide if furtherstratification is required?

Your Answer Define the problem & identify the stratification variables , Sort outdata into categories & summarise information in each category ,Present the information in graphical form & study, decide if furtherstratification is required?

True/FalseQuestion Processing cost of a product is mainly decided by conversion

process.Correct Answer True

Your Answer True


Correct Answer Output , Quality , Cost



Correct Answer Reducing process variability , Bringing target & average to fall at thesame point , Examine possibility of relaxing specification

Your Answer Reducing process variability , Bringing target & average to fall at thesame point , Use of less precision machine


Correct Answer Express value of each category as percentage of total of allcategories & calculate the degree of angle form by each category byequation degree = Value of groups/Total value * 360 , Draw thecircle & segment the circle into angles calculated in step one ,Colour different segments & enter the percentage of each categoryinto pie chart

Your Answer Express value of each category as percentage of total of allcategories & calculate the degree of angle form by each category byequation degree = Value of groups/Total value * 360 , Draw thecircle & segment the circle into angles calculated in step one ,Colour different segments & enter the percentage of each categoryinto pie chart


Correct Answer Everyone, clerk to officer does cleaning his area , No sweeper orcleaner employees , Every family does cleaning of pavement of theirresidence

Your Answer Everyone, clerk to officer does cleaning his area , No sweeper orcleaner employees , Every family does cleaning of pavement of theirresidence

Select The BlankQuestion Poka Yoke designed to help operators to know immediately

________ of the defeat called detection type Poka-Yoke.Correct Answer On occurrence


Select The BlankQuestion Flow chart helps to dissect a process for better understanding &

________ of process.Correct Answer Analysis



Correct Answer Employees of different department related to the problem


Select The Blank

Question Graphs convey a situation more ________ than summary of data orfigures.



Multiple Choice Single AnswerQuestion Number of Kaizen projects suggested and implemented is checking

point for :-Correct Answer Continual Improvement



Multiple Choice Multiple AnswerQuestion Quality maintenance & pillar focuses on following production

inputs :-Correct Answer Material , Men , Machine











Multiple Choice Single AnswerQuestion Identifying key preventive operational functions and comparing

these operational functions within the firm's own division &branches comes under :-

Correct Answer Internal benchmarking






there is positive relationship upto certain level & negativethereafter or negative relationship upto certain level & positivethereafter.





Correct Answer True

Your Answer True


Correct Answer Nature of compliant i.e. defective product , Delayed delivery ,Short/excess quantity

Your Answer Nature of compliant i.e. defective product , Delayed delivery ,Short/excess quantity

True/FalseQuestion In case of more than one quality characteristics, separate chart

is made for each quality characteristics.Correct Answer True

Your Answer True

True/FalseQuestion Safety, hygiene and environment control is one of the pillar of

TPM.Correct Answer True

Your Answer True




Match The Following

Question Correct Answer Your Answer

Reduce time of externalsetup







Reduce clamping &declamping time








Parato analysisunderlines & operates on













Correct Answer True

Your Answer True


value of 'y' somewhat decreases as the value of 'x' increases.Correct Answer Weak negative





Your Answer Cloud





Correct Answer Collect paired data (X,Y) from two variables who's relationship isto be studied , Find out max & min values for both X & Y andthese values to scale X & Y axis & plot the paired data ,Examine the shape of the cloud of points & discover type &strength of relationship

Your Answer Collect paired data (X,Y) from two variables who's relationship isto be studied , Find out max & min values for both X & Y andthese values to scale X & Y axis & plot the paired data ,Examine the shape of the cloud of points & discover type &strength of relationship




Select The BlankQuestion Each quality characteristic has permitted variation & is equal to

________.Correct Answer USL - LSL







Correct Answer True

Your Answer False

True/FalseQuestion Gap analysis for production & dispatches is discussed in

monthly meeting.Correct Answer False

Your Answer False




Select The BlankQuestion ________ is most difficult 'S' to implement & achieve.



True/FalseQuestion Presentation of graphs in pictorial form of data collection are for

easy understanding.Correct Answer True

Your Answer True

Select The Blank

Question Graphs convey a situation more ________ than summary ofdata or figures.








range , Scale selected should be right to avoid wrongconclusions , Data should be free from bias or undueimportance

Your Answer Data should be properly stratified & should be collected for fullrange , Scale selected should be right to avoid wrongconclusions , Data should be free from bias or undueimportance

True/FalseQuestion Globalization of trade and industrial operations have forced

Indian companies to become more & more competitive andcustomer driven.

Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion If 'Annual saving in procurement expenses is managing point',

then checking points will be :-Correct Answer Price revision , Credit period , Transport expenses





True/False

Question Flow chart is pictorial representation of the steps in productioncontrol.


Your Answer False







Select The BlankQuestion Identification of non-value added operations & their elimination

is the first step to eliminate muda of ________.Correct Answer Processing


Select The BlankQuestion A 'Radar chart' is used to portray ________ strength or

weakness of the activity.Correct Answer Relative






withdrawn is permitted.Correct Answer False

Your Answer False


Correct Answer Improved reliability mean time between failures , Improvedmaintainability mean time to repair , Improvement in breakdown

Your Answer Improved reliability mean time between failures , Improvedmaintainability mean time to repair

Multiple Choice Multiple AnswerQuestion Gap analysis & problem identification is done during converting

internal setups into external setups in the areas like :-Correct Answer Equipment , Method , Human









Correct Answer Reduction in customer quality complaints , Reduction ininspection time

Your Answer Reduction in customer quality complaints , Reduction ininspection time




financial ratios at the aggregate level.Correct Answer False

Your Answer False




Multiple Choice Single AnswerQuestion Participants of the groups for quality circles should be decided

by :-Correct Answer Employees coming together by their own enthusiasm























Select The BlankQuestion If some defective parts are discovered by the subsequent

process they should be returned to the ________ to preventreoccurrence.

Correct Answer Preceding process





Your Answer Efforts to avoid the problem permanently , Publication oradvertisement of your contribution , Attacking the real rootcauses & all possibilities




Parato analysis underlines& operates on










Correct Answer Brainstorming to enlist characteristics which require to beevaluated & draw the circle & divide it into 'slices' equal tonumber of characteristics , The first slice begins at 12 noon.Then draw vertical line & calibrate it equal to the number of


levels required , Draw concentric circles from each gradiationusing 'o' point as centre

Your Answer Brainstorming to enlist characteristics which require to beevaluated & draw the circle & divide it into 'slices' equal tonumber of characteristics , The first slice begins at 12 noon.Then draw vertical line & calibrate it equal to the number oflevels required , Draw concentric circles from each gradiationusing 'o' point as centre



Your Answer Monthly


Correct Answer True

Your Answer False






Your Answer Monitor progress of six sigma projects , Approve six sigmaprojects , Remove road block in the path of six sigmaimplementation

Multiple Choice Multiple AnswerQuestion To draw control charts, sample must be representative of

homogeneous segment of production for which :-Correct Answer The items of the sample should be from the same machine

setting , The items should be of the same batch , Items shouldbe made from the same raw material batch

Your Answer The items of the sample should be from the same machinesetting , The items should be of the same batch , Items shouldbe made from the same raw material batch



Question Failure mode and effect analysis (FMEA) establish





Your Answer Decide level of benchmarking , List down a few prospectivecandidates of partnership , Collect information of short listedpartners











wheel etc can be monitored through ________ type of controlchart.


Your Answer c-chart




Your Answer True




Multiple Choice Single AnswerQuestion Benchmarking helps to identify the gap between the current

performance of the organization and the :-Correct Answer Performance of the best organization




Your Answer True





called ________.Correct Answer c-chart

Your Answer c-chart

Select The BlankQuestion Procedure for implementation of TPM consists of ________

numbers of steps.Correct Answer 12

Your Answer 8










Correct Answer True

Your Answer True


desirable :-Correct Answer Standardize clamping bolts / screws , Cut off unnecessary

threads , Use quick clamping deviceYour Answer Standardize clamping bolts / screws , Cut off unnecessary

threads , Use quick clamping device





Correct Answer Worried about losing jobs , Afraid of being reprimanded if thereare mistakes , Scared of their bosses

Your Answer Worried about losing jobs , Afraid of being reprimanded if thereare mistakes , Scared of their bosses



Your Answer False




Your Answer Equipment analysis , Setup change analysis , Preparation items(storage place , method) analysis



Your Answer True









Your Answer False





Correct Answer True

Your Answer False

Multiple Choice Multiple AnswerQuestion An erratic patterns falling above & below the control limits

indicates :-


Correct Answer Defect in materials , Frequent adjustment of machines , Poorlytrained operators


True/FalseQuestion Sample size for the construction of p-chart are larger than X bar-

R chart.Correct Answer True

Your Answer True




Your Answer An idea of what is happening to the process , Whether theprocess is capable of meeting process or not i.e. around correctaverage & within specific limits , A bird's eye view of the variation







Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of the histogram gives :-Correct Answer It shows cause which affects the process , An idea of what is

happening to the process , Whether the process is capable of meeting process or not i.e.around correct average & within specific limits

Your Answer It shows cause which affects the process , An idea of what is happeningto the process , Whether the process is capable of meeting process or not i.e. aroundcorrect average & within specific limits , A bird's eye view of the variation

True/FalseQuestion In bar graph each bar is of same height.Correct Answer FalseYour Answer False


assignable cause.Correct Answer Separate outYour Answer Separate out

Multiple Choice Multiple AnswerQuestion Benefits of stratification are :-Correct Answer It helps to separate data into groups so that you can draw connect &

meaningful inference , It helps to diagnose & localize problem , It helps to identify theinfluencing factors

Your Answer It helps to separate data into groups so that you can draw connect &meaningful inference , It helps to diagnose & localize problem , It helps to identify theinfluencing factors , Finding out different reasons




Multiple Choice Single AnswerQuestion In cellular manufacturing system, the cells are designed so that the material

flow within the cell and between the cells are :-Correct Answer MinimizedYour Answer Minimized


manufacturing at parts is carried out at different locations.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Causes of Muda of transport are :-Correct Answer Faulty layout , Over productionYour Answer Faulty layout , Over production , Proper material handling equipment ,

Low rejection / rework

Multiple Choice Multiple AnswerQuestion Types of meetings held in DWM are :-Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCA

meetingYour Answer Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA

meeting

Multiple Choice Multiple AnswerQuestion Customers complaints may be segregated by :-Correct Answer Nature of compliant i.e. defective product , Delayed delivery ,

Short/excess quantityYour Answer Nature of compliant i.e. defective product , Delayed delivery ,

Short/excess quantity , Payment problem

Multiple Choice Multiple AnswerQuestion Cleaning your own area/equipments gives benefits of :-Correct Answer You know your self how to avoid dust , When you touch while

cleaning you may find a fault , Saving of further failure due to dust

Your Answer You know your self how to avoid dust , When you touch while cleaningyou may find a fault , Saving of further failure due to dust , Utilization of spare time

Multiple Choice Multiple AnswerQuestion Role of champions are :-Correct Answer Approve six sigma projects , Remove road block in the path of six

sigma implementation , Monitor progress of six sigma projectsYour Answer Approve six sigma projects , Remove road block in the path of six sigma

implementation , Monitor progress of six sigma projects , Deliver presentation to teamson six sigma projects

Select The BlankQuestion Benchmarking shows how an organization is ________ in comparison to its

competitors.Correct Answer PerformingYour Answer Performing





Multiple Choice Multiple AnswerQuestion Key principles of TQM :-Correct Answer Continuous improvement , People involvement , Cost of qualityYour Answer Continuous improvement , People involvement , Cost of quality ,

Competitor focus

Select The BlankQuestion A histogram is a graphical display of distribution of measurements & reveals

the amounts of ________ within the process.

Correct Answer VariationYour Answer Variation




Multiple Choice Single AnswerQuestion Setting & maintaining optimal process condition to get quality product is the

aim of :-Correct Answer Quality maintenanceYour Answer Quality maintenance




Customer satisfaction measurement Customer complaints per period Customercomplaints per period


Multiple Choice Single AnswerQuestion Recording of the entire setup operators focusing on hand, eye and body

movements of the person doing the setting is done through :-Correct Answer Video recordingYour Answer Video recording


In scatter diagram, the strength of relationship can be determined By "correlationcoefficient" By "correlation coefficient"

The scatter diagram provides the technique to establish The possible relationship betweena pair of variables The possible dependency between a pair of variables

The scatter diagram displays The pair of data as a cloud of points The possiblerelationship between a pair of variables





Multiple Choice Single AnswerQuestion Allowing worker's to stop machine / assembly line if they believe that

product quality is below standard' is an example of :-Correct Answer EmpowermentYour Answer Empowerment

Multiple Choice Single AnswerQuestion Kanban Signals are required when :-Correct Answer Set up time on the feeding operation is higher then the receiving

operation.Your Answer Set up time on the feeding operation is higher then the receiving

operation.



Question Quality problem solving tool is used to :-Correct Answer Improve qualityYour Answer Improve quality



Multiple Choice Multiple AnswerQuestion Flow chart is required :-Correct Answer When trying to improve the process , At the time of review of the

process , To understand steps in a process by pictorial presentationYour Answer When trying to improve the process , At the time of review of the

process , To understand steps in a process by pictorial presentation , For defects findingof the products





Select The BlankQuestion Inspection activity for semi finished & finished component should be

________ to reduce muda of transport .Correct Answer Decentralized

Your Answer Decentralized






Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of the histogram gives :-Correct Answer It shows cause which affects the process , An idea of what is

happening to the process , Whether the process is capable of meeting process or not i.e.around correct average & within specific limits

Your Answer It shows cause which affects the process , An idea of what is happeningto the process , Whether the process is capable of meeting process or not i.e. aroundcorrect average & within specific limits , A bird's eye view of the variation



assignable cause.Correct Answer Separate outYour Answer Separate out

Multiple Choice Multiple AnswerQuestion Benefits of stratification are :-Correct Answer It helps to separate data into groups so that you can draw connect &

meaningful inference , It helps to diagnose & localize problem , It helps to identify theinfluencing factors

Your Answer It helps to separate data into groups so that you can draw connect &meaningful inference , It helps to diagnose & localize problem , It helps to identify theinfluencing factors , Finding out different reasons




Multiple Choice Single AnswerQuestion In cellular manufacturing system, the cells are designed so that the material

flow within the cell and between the cells are :-Correct Answer MinimizedYour Answer Minimized


manufacturing at parts is carried out at different locations.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Causes of Muda of transport are :-Correct Answer Faulty layout , Over productionYour Answer Faulty layout , Over production , Proper material handling equipment ,

Low rejection / rework

Multiple Choice Multiple AnswerQuestion Types of meetings held in DWM are :-Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCA

meetingYour Answer Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA

meeting

Multiple Choice Multiple AnswerQuestion Customers complaints may be segregated by :-Correct Answer Nature of compliant i.e. defective product , Delayed delivery ,

Short/excess quantityYour Answer Nature of compliant i.e. defective product , Delayed delivery ,

Short/excess quantity , Payment problem

Multiple Choice Multiple AnswerQuestion Cleaning your own area/equipments gives benefits of :-Correct Answer You know your self how to avoid dust , When you touch while

cleaning you may find a fault , Saving of further failure due to dust

Your Answer You know your self how to avoid dust , When you touch while cleaningyou may find a fault , Saving of further failure due to dust , Utilization of spare time

Multiple Choice Multiple AnswerQuestion Role of champions are :-Correct Answer Approve six sigma projects , Remove road block in the path of six

sigma implementation , Monitor progress of six sigma projectsYour Answer Approve six sigma projects , Remove road block in the path of six sigma

implementation , Monitor progress of six sigma projects , Deliver presentation to teamson six sigma projects

Select The BlankQuestion Benchmarking shows how an organization is ________ in comparison to its

competitors.Correct Answer PerformingYour Answer Performing





Multiple Choice Multiple AnswerQuestion Key principles of TQM :-Correct Answer Continuous improvement , People involvement , Cost of qualityYour Answer Continuous improvement , People involvement , Cost of quality ,

Competitor focus

Select The BlankQuestion A histogram is a graphical display of distribution of measurements & reveals

the amounts of ________ within the process.

Correct Answer VariationYour Answer Variation




Multiple Choice Single AnswerQuestion Setting & maintaining optimal process condition to get quality product is the

aim of :-Correct Answer Quality maintenanceYour Answer Quality maintenance




Customer satisfaction measurement Customer complaints per period Customercomplaints per period


Multiple Choice Single AnswerQuestion Recording of the entire setup operators focusing on hand, eye and body

movements of the person doing the setting is done through :-Correct Answer Video recordingYour Answer Video recording


In scatter diagram, the strength of relationship can be determined By "correlationcoefficient" By "correlation coefficient"

The scatter diagram provides the technique to establish The possible relationship betweena pair of variables The possible dependency between a pair of variables

The scatter diagram displays The pair of data as a cloud of points The possiblerelationship between a pair of variables





Multiple Choice Single AnswerQuestion Allowing worker's to stop machine / assembly line if they believe that

product quality is below standard' is an example of :-Correct Answer EmpowermentYour Answer Empowerment

Multiple Choice Single AnswerQuestion Kanban Signals are required when :-Correct Answer Set up time on the feeding operation is higher then the receiving

operation.Your Answer Set up time on the feeding operation is higher then the receiving

operation.



Question Quality problem solving tool is used to :-Correct Answer Improve qualityYour Answer Improve quality



Multiple Choice Multiple AnswerQuestion Flow chart is required :-Correct Answer When trying to improve the process , At the time of review of the

process , To understand steps in a process by pictorial presentationYour Answer When trying to improve the process , At the time of review of the

process , To understand steps in a process by pictorial presentation , For defects findingof the products





Select The BlankQuestion Inspection activity for semi finished & finished component should be

________ to reduce muda of transport .Correct Answer Decentralized

Your Answer Decentralized



1. TPM 1. Waste elimination

2. JIT 2. Visual management

3. Kanban 3. Best way of doing job

4. Work standards 4. Reducing breakdown of machines

5. Pull system6. Statistical process control

1. Parato analysis underlines &operates on

1. Arranging data according to thedescending order of their frequency ofoccurrence

2. Parato analysis is technique ofidentifying vital causes by

2. Philosophy of 20% of the activity causes80% of the effect

3. Parato diagram is a Bar graphwith height or value drawn by


4. Parato diagram alwaysindicates


5. Arranging data in descending order

6. Philosophy of "vital few:trivial many"


a)

b)

c)

d)

Unity

Zero

Infinity

Six

U shape arrangement of layout provides the operator degree of mobility.

48. Quality problems may be segregated by & regrouped by :-

a)

b)

c)

Machines

Workers

Materials

d)Suggestion



Correct Answer Scared of their bosses , Worried about losing jobs , Afraid ofbeing reprimanded if there are mistakes

Your Answer Scared of their bosses , Worried about losing jobs , Afraid ofbeing reprimanded if there are mistakes








SMED Setup time reduction Setup time reduction

5 'S Cleanliness Total productivemaintenance

Muda elimination Waste elimination Waste elimination

Poka-Yoke Error proofing Error proofing

Multiple Choice Single AnswerQuestion Allowing worker's to stop machine / assembly line if they believe

that product quality is below standard' is an example of :-Correct Answer Empowerment




Your Answer Workmen

Select The BlankQuestion Ratio of ________ to the number of pieces inspected is called

fraction defectives.Correct Answer Number of item rejected






customers who gives business includes :-Correct Answer Present & past customers





Multiple Choice Multiple AnswerQuestion Steps to six sigma process consists of :-

Correct Answer Identify the work you do , Identify your customers , Map theprocess

Your Answer Identify the work you do , Identify your customers , Map theprocess




Your Answer Cloud



Your Answer True




Multiple Choice Single AnswerQuestion TQM is a way to improve quality of product and service :-







In scatter diagram, thestrength of relationshipcan be determined


The scatter diagramprovides the technique toestablish

The possible relationshipbetween a pair ofvariables

The possible relationshipbetween a pair of variables

The scatter diagramdisplays

The pair of data as acloud of points

The pair of data as a cloudof points

The scatter is also knownas




Your Answer True




Multiple Choice Single AnswerQuestion Pareto diagram always indicate magnitude of :-





Your Answer False






Correct Answer True

Your Answer True

Multiple Choice Single AnswerQuestion Abnormal variations can occur if :-





Your Answer Prevention type Poka-Yoke , Detection type Poka-Yoke ,Standards type Poka-Yoke



Your Answer True

Select The BlankQuestion Kaizen is an excellent method to involve ________ to unearth &

eliminate hidden waste.Correct Answer Employees


Multiple Choice Multiple AnswerQuestion To reduce Muda of transport, techniques used are :-




Correct Answer 2

Your Answer 2




True/False

Question Processing cost of a product is mainly decided by conversionprocess.

Correct Answer True

Your Answer True

Select The BlankQuestion Production in last shift & production plan for next shift is

discussed during ________.Correct Answer Shift beginning & shift end/change meeting


Multiple Choice Multiple AnswerQuestion Material Supply on DSL basis helps :-

Correct Answer To eliminate handling , To reduce transporting , To reduceinspection

Your Answer To eliminate handling , To reduce transporting , To reduceinspection


Correct Answer True

Your Answer True

True/FalseQuestion Most of the external setups are treated as internal setup.

Correct Answer True

Your Answer False



Your Answer Reduce work in process , Better average daily production ,Increase capacity




True/FalseQuestion Low level of delegation is an example of muda in office.

Correct Answer True

Your Answer False







Your Answer Data should be properly stratified & should be collected for fullrange , Scale selected should be right to avoid wrongconclusions , Data should be free from bias or undue importance


kobetsu-kaizen is continuously improve utilization of :-Correct Answer Worker, equipment & material



standardization.Correct Answer False

Your Answer False



Your Answer 8 to 10






Your Answer Process

Multiple Choice Single AnswerQuestion Gap in performance = Ideal situation minus :-



Select The BlankQuestion Seminar talks and video show are organized to introduce TPM

concept to ________Correct Answer General employees


TechniquesForOperationsEfficiency_8LIST OF ATTEMPTED QUESTIONS AND ANSWERS

Select The BlankQuestion Seiketsu is to ensure that ________ of first three 'S' i.e. Seiri,

Seiton & Seiso.Correct Answer ImplementationYour Answer Implementation

True/FalseQuestion Benefits of DWN is faster response to customer needs.Correct Answer TrueYour Answer True

Multiple Choice Single AnswerQuestion Recording of the entire setup operators focusing on hand, eye and

body movements of the person doing the setting is done through :-Correct Answer Video recordingYour Answer Video recording

Multiple Choice Multiple AnswerQuestion During SMED implementation, primary study consists of :-Correct Answer Equipment analysis , Setup change analysis , Preparation

items (storage place , method) analysisYour Answer Equipment analysis , Setup change analysis , Preparation

items (storage place , method) analysis

Select The BlankQuestion Ideally the histogram will have a symmetrical ( i.e. also called as

bell) shape tapering away on both sides from ________ value.Correct Answer AverageYour Answer Average


Multiple Choice Multiple AnswerQuestion Role of champions are :-Correct Answer Approve six sigma projects , Remove road block in the path

of six sigma implementation , Monitor progress of six sigma projectsYour Answer Approve six sigma projects , Remove road block in the path of

Page 1

TechniquesForOperationsEfficiency_8six sigma implementation , Monitor progress of six sigma projects

Multiple Choice Multiple AnswerQuestion For 'Control on PPM and rework level;, checking points' will be :-Correct Answer PPM level , Initiate corrective actions on rejection/rework ,

Initiate preventive action on rejection / reworkYour Answer PPM level , Initiate corrective actions on rejection/rework ,

Initiate preventive action on rejection / rework

Multiple Choice Single AnswerQuestion POP is :-Correct Answer Process Oriented ManagementYour Answer Process Oriented Management

True/FalseQuestion TQM improves the quality by improving processes.Correct Answer TrueYour Answer True

True/FalseQuestion Review is important step in problem solving.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion After finding out the solution & working on it, the equally

important job is :-Correct Answer Prepare for the presentation of your work , Explain the

progress by presentation to steering committee , Convince committee forfinancial help for running the projectYour Answer Prepare for the presentation of your work , Explain the

progress by presentation to steering committee , Convince committee forfinancial help for running the project


In scatter diagram, the strength of relationship can be determined By"correlation coefficient" By "correlation coefficient"

The scatter diagram provides the technique to establish The possiblerelationship between a pair of variables The possible relationship between a

Page 2

TechniquesForOperationsEfficiency_8pair of variables

The scatter diagram displays The pair of data as a cloud of points The pair ofdata as a cloud of points



withdrawn is permitted.Correct Answer FalseYour Answer False

Select The BlankQuestion ________ is the root cause of the problems.Correct Answer VariationYour Answer Variation

Multiple Choice Single AnswerQuestion While assessing the current status during problem solving Go to

Gamba and look at gembustu is :-Correct Answer EssentialYour Answer Essential depends upon situation

Multiple Choice Multiple AnswerQuestion In absence of P-kanban the workman may :-Correct Answer Carry out machine clean up , Work on improvement

project. , Receive trainingYour Answer Carry out machine clean up , Work on improvement project.

Multiple Choice Single AnswerQuestion The concept of quality circle was mooted by :-Correct Answer Prof. KaoishikawaYour Answer Prof. Kaoishikawa

Select The BlankQuestion ________ helps to generate creative ideas .Correct Answer BrainstormingYour Answer Brainstorming

Multiple Choice Single AnswerPage 3

TechniquesForOperationsEfficiency_8Question For small batch quality production, number of setups :-Correct Answer IncreasesYour Answer Increases

True/FalseQuestion Process capability refers to ability of the process to meet the

design specification for a product or a service.Correct Answer TrueYour Answer True

True/FalseQuestion Kaizen looks at process as a part of quality & quantity as a part of

processCorrect Answer FalseYour Answer True

Select The BlankQuestion ________ participants in monthly meeting(MRM)Correct Answer GM, operation heads, corporate functional headsYour Answer Department heads & supervisors

Multiple Choice Multiple AnswerQuestion Examples of Muda of defects are :-Correct Answer Customer complaints , Poor material yield , Rejection and

reworkYour Answer Customer complaints , Poor material yield , Rejection and

rework

Multiple Choice Single AnswerQuestion Vilfredo Pareto had discovered a universal law as :-Correct Answer "around 20% of the activity causes 80% of the effect"Your Answer "around 20% of the activity causes 80% of the effect"

Multiple Choice Multiple AnswerQuestion Benefits from the standardized containers areCorrect Answer Minimization of transit damages , Ease in verification of

quantity of parts , Automatic signal to supplier to replenish stockYour Answer Minimization of transit damages , Ease in verification of

quantity of parts , Automatic signal to supplier to replenish stock

True/FalseQuestion TQM organizations also harness the goodwill and interest of the

Page 4

TechniquesForOperationsEfficiency_8family members of the employees.Correct Answer TrueYour Answer True

Select The BlankQuestion Technique involved in listing of setup task, establishing

technological relationship between tasks, drawing arrow diagram is called as________.Correct Answer Network diagramYour Answer Flow chart

Multiple Choice Multiple AnswerQuestion Kanban System may be :-Correct Answer Single card kanban system , Double card kanban systemYour Answer Single card kanban system , Double card kanban system

Multiple Choice Single AnswerQuestion Bulk production, to reduce setup time is an example of :-Correct Answer Over productionYour Answer Machine utilization

Multiple Choice Single AnswerQuestion SWOT analysis is an important step in :-Correct Answer Deciding what to benchmarkYour Answer Deciding what to benchmark

Multiple Choice Multiple AnswerQuestion Remedial actions for error of misunderstanding is :-Correct Answer Training , Checking in advance , Standardizing work

proceduresYour Answer Training , Checking in advance , Standardizing work

procedures

Select The BlankQuestion ________ is a must in meeting of quality circles.Correct Answer BrainstormingYour Answer Brainstorming

Multiple Choice Single AnswerQuestion The Steering committee as apex body should be :-Correct Answer Only one for all the groups in organizationYour Answer Only one for all the groups in organization

Page 5

TechniquesForOperationsEfficiency_8

Multiple Choice Single AnswerQuestion Muda of transport can be eliminated significantly by :-Correct Answer Self inspection by suppliers & operatorsYour Answer Self inspection by suppliers & operators

Select The BlankQuestion A histogram is a graphical display of distribution of

measurements & reveals the amounts of ________ within the process.Correct Answer VariationYour Answer Variation

Multiple Choice Single AnswerQuestion Statistical process control is application of statistical technique to

control :-Correct Answer ProcessYour Answer Process

Multiple Choice Single AnswerQuestion In India quality circle was first launched by :-Correct Answer Hyderabad unit of BHELYour Answer Hyderabad unit of BHEL

True/FalseQuestion A control chart is a chart with UCL & LCL placed at 6 Sigma

distance on either side of the process average.Correct Answer FalseYour Answer False

True/FalseQuestion Control limits of control charts should be revised from time to time

as additional data is accumulated.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Examples of Muda of motion are :-Correct Answer Lifting objects , Walking to reach object , Searching for

objectYour Answer Lifting objects , Walking to reach object , Searching for object

True/FalsePage 6

TechniquesForOperationsEfficiency_8Question Kanban signals are required when assembly work, subassembly

work and manufacturing at parts is carried out at different locations.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Six sigma organization consists of :-Correct Answer Champions , Black Belts , Green BeltsYour Answer Champions , Black Belts , Green Belts


LCLnp n p - 3 ( sq.root( n p( 1- p ))) n p - 3 ( sq.root( n p( 1- p )))

UCLp p + 3 ( sq.root( p ( 1 - p ) / n )) p + 3 ( sq.root( p ( 1 - p ) / n ))

LCLp p - 3 ( sq.root( p ( 1- p ) / n)) p - 3 ( sq.root( p ( 1- p ) / n))

UCLnp n p + 3 ( sq.root( n p ( 1- p ))) n p + 3 ( sq.root( n p ( 1- p )))

Multiple Choice Multiple AnswerQuestion Product benchmarking requires, comparison of product :-Correct Answer Performance , Features , CostYour Answer Performance , Features , Cost


Select The BlankQuestion Poka Yoke is ________.Correct Answer Simple techniqueYour Answer Simple technique



Page 7

TechniquesForOperationsEfficiency_8Correct Answer To all places including homesYour Answer To all places including homes

Multiple Choice Single AnswerQuestion Empowerment means making best use of the firm's most valuable

resource, namely:-Correct Answer HumanYour Answer Human


wheel etc can be monitored through ________ type of control chart.Correct Answer c-chartYour Answer c-chart

Multiple Choice Single AnswerQuestion TQM is a way to improve quality of product and service :-Correct Answer ContinuouslyYour Answer Continuously

Multiple Choice Multiple AnswerQuestion Best practices for standardization in implementing Seiketsu are :-Correct Answer Create as many visual control systems as possible , Use

colour code system for easy control , Fix one colour (e.g. Red) for dangerzones/out of controlsYour Answer Create as many visual control systems as possible , Use colour

code system for easy control , Display warning notices

True/FalseQuestion JIT is not possible for each and every item held as inventoryCorrect Answer TrueYour Answer False

True/FalseQuestion Customer wise outstanding is discussed in daily work

management meeting by operations head.Correct Answer FalseYour Answer False

Select The BlankQuestion Poka-Yoke devices under category 'locating pins' to eliminate

cause of ________Page 8

TechniquesForOperationsEfficiency_8Correct Answer Incorrect positioningYour Answer Incorrect positioning

Multiple Choice Single AnswerQuestion Customer's return is an indicators of the MUDA of :-Correct Answer DefectYour Answer Defect


Evolve standard operating procedure & implement. Seiketsu Seiketsu

Hidden faults come out while implementing. Cleaning yourself yourequipments Seiso

Fix the place of items, tools as per frequency of use Seiri Seiton

Responsibility same from top to bottom Seiso shitsuke

Multiple Choice Single AnswerQuestion Accountability means :-Correct Answer Responsibility of Business ResultsYour Answer Responsibility Execution or Action



financial ratios at the aggregate level.Correct Answer FalseYour Answer False

Multiple Choice Single AnswerQuestion Competitive benchmarking is usually conducted :-Correct Answer Through third party researchYour Answer Through third party research

Page 9

TechniquesForOperationsEfficiency_8Multiple Choice Single AnswerQuestion Small groups forming a circle should consist of :-Correct Answer Employees of different department related to the problemYour Answer Employees of different department related to the problem

True/FalseQuestion In cellular manufacturing system cell may consist of a single

machine or more than one machine arranged in line.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Histograms are useful to :-Correct Answer Measure the current pattern & extent of variation , Assess

current conformance to specification & scope of improvement , Determinewhether or not the process is in the state of controlYour Answer Measure the current pattern & extent of variation , Assess

current conformance to specification & scope of improvement , Determinewhether or not the process is in the state of control


addressed by office TPM.Correct Answer TrueYour Answer True


called ________.Correct Answer c-chartYour Answer c-chart

True/FalseQuestion Fishbone analysis is used both in analysis & planning.Correct Answer TrueYour Answer True

Select The BlankQuestion Inspection activity for semi finished & finished component should

be ________ to reduce muda of transport .Correct Answer DecentralizedYour Answer Decentralized

Page 10


Multiple Choice Multiple AnswerQuestion Scatter diagram is used :-Correct Answer To discover relationship between two associated sets of

data , To display the relationship between two variables , To confirmanticipated relationship between two variables / associated sets of dataYour Answer To discover relationship between two associated sets of data ,

To display the relationship between two variables , To confirm anticipatedrelationship between two variables / associated sets of data

Select The BlankQuestion U shape arrangement of layout provides the operator ________

degree of mobility.Correct Answer 360Your Answer 360

True/FalseQuestion Chance causes can not be identified.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion During the steps of Deming cycle of PDCA what is important?Correct Answer Plan unitedly for the target within reach , Make plan active

by "doing it" i.e. everyone working , After some time check the results forsuccessYour Answer Plan unitedly for the target within reach , Make plan active by

"doing it" i.e. everyone working , After some time check the results for success

Multiple Choice Multiple AnswerQuestion Benefits of Quality maintenance are :-Correct Answer Reduction in customer quality complaints , Reduction in

inspection timeYour Answer Reduction in customer quality complaints , Reduction in

inspection time

Multiple Choice Multiple AnswerQuestion Causes of Muda of transport are :-Correct Answer Faulty layout , Over productionYour Answer Faulty layout , Over production

Page 11

TechniquesForOperationsEfficiency_8Multiple Choice Multiple AnswerQuestion Types of Poka-Yoke are :-Correct Answer Prevention type Poka-Yoke , Detection type Poka-YokeYour Answer Prevention type Poka-Yoke , Detection type Poka-Yoke ,

Standards type Poka-Yoke

Multiple Choice Single AnswerQuestion Pie chart is also called as :-Correct Answer Angular diagramYour Answer Angular diagram

Multiple Choice Multiple AnswerQuestion The aim of education & training under TPM is :-Correct Answer To develop abilities to respond quickly to abnormalities , To

develop abilities to discover analyze malfunctionYour Answer To develop abilities to respond quickly to abnormalities , To

develop abilities to discover analyze malfunction , To have multiskilledemployees in all departments

Multiple Choice Multiple AnswerQuestion Material Supply on DSL basis helps :-Correct Answer To eliminate handling , To reduce transporting , To reduce

inspectionYour Answer To eliminate handling , To reduce transporting , To reduce

inspection

Select The BlankQuestion Poka Yoke designed to help operators to know immediately

________ of the defeat called detection type Poka-Yoke.Correct Answer On occurrenceYour Answer On occurrence

Multiple Choice Multiple AnswerQuestion Typical examples of process benchmark are :-Correct Answer Procurement procedures , Budgeting , RecruitmentYour Answer Procurement procedures , Budgeting , Recruitment

Multiple Choice Single AnswerQuestion The area enclosed under normal distribution curve between mean

+2standard deviation is :-Correct Answer 0.9545Your Answer 1

Page 12



manufacturing areas like procurement, QA, HRD etc.Correct Answer TrueYour Answer True


4 th level in six sigma organization Green Belts Green Belts

1 st level in six sigma organization Champions Champions

2 nd level in six sigma organization Master Black Belts Master Black Belts

3 rd level in six sigma organization Black Belts Black Belts

Select The BlankQuestion ________ PDCA cycle is the systematic approach towards

meeting the target.Correct Answer KaoishikawaYour Answer Deming

Select The BlankQuestion ________is serve as a stepping stone to TQMCorrect Answer ISO-9000 quality standardYour Answer TPM

Select The BlankQuestion Histogram is a diagrammatic presentation of the ________

distribution of characteristics such as strength, diameter, etc.Correct Answer FrequencyYour Answer Frequency


kobetsu-kaizen is continuously improve utilization of :-Correct Answer Worker, equipment & materialYour Answer Worker, equipment & material

Page 13

TechniquesForOperationsEfficiency_8Multiple Choice Single AnswerQuestion Frequencies, values, tabulated in the frequency table, can be

represented pictorially in the form of bar graph & this graph of frequency iscalled as :-Correct Answer HistogramYour Answer Histogram

Multiple Choice Multiple AnswerQuestion Muda of waiting is due to :-Correct Answer Interrupted flow of work , Delay in movement of raw

material from storesYour Answer Interrupted flow of work , Delay in movement of raw

material from stores

Select The BlankQuestion CFT ( cross functional team ) consisting of ________Correct Answer Operators, supervisors from different departmentsYour Answer Operators, supervisors from different departments

Select The BlankQuestion In PDCA cycle for benchmarking 'Identification of performance

gap' is done in ________.Correct Answer CheckingYour Answer Checking

Multiple Choice Multiple AnswerQuestion Management skill includes :-Correct Answer Leadership , Motivation , Performance appraisalsYour Answer Leadership , Motivation

Multiple Choice Single AnswerQuestion Zero loss concept means :-Correct Answer Zero accident, zero defect, zero breakdownYour Answer Zero accident, zero defect, zero breakdown

True/FalseQuestion Flow charts are drawn to identify deviations by observing actual

& comparing with running process.Correct Answer FalseYour Answer False

LIST OF ATTEMPTED QUESTIONS AND ANSWERSPage 14


Multiple Choice Multiple AnswerQuestion TQM can never flourish if the staff are:-Correct Answer Worried about losing jobs , Afraid of being reprimanded if

there are mistakes , Scared of their bossesYour Answer Worried about losing jobs , Afraid of being reprimanded if

there are mistakes , Scared of their bosses

Multiple Choice Single AnswerQuestion Toyota, Honda & Nissan are world class benchmarking

candidates in :-Correct Answer Employee selectionYour Answer Employee selection

Multiple Choice Single AnswerQuestion The leader of the circle should be selected by :-Correct Answer Circle membersYour Answer Steering committee

Multiple Choice Multiple AnswerQuestion Missing parts is due to :-Correct Answer Willful errors , Inadvertent error , Judgment errorYour Answer Willful errors , Inadvertent error

Multiple Choice Single AnswerQuestion Rushing to complete a job is considered symptom of :-Correct Answer Poor planningYour Answer Poor planning

Multiple Choice Multiple AnswerQuestion The purpose of Shitsuke is especially for :-Correct Answer Maintaining the 4-S consistently , Develop discipline

attitude in everyone , Any day throughout the year sustain the disciplineYour Answer Maintaining the 4-S consistently , Develop discipline attitude

in everyone , Any day throughout the year sustain the discipline

Multiple Choice Multiple AnswerQuestion Few typical shapes of histograms are :-Correct Answer Symmetrical (or bell shaped) , Asymmetrical skewed

positive , Double peakedYour Answer Symmetrical (or bell shaped) , Asymmetrical skewed positive ,

Double peakedPage 15


Multiple Choice Single AnswerQuestion In autonomus modules or cells, rate of production increases :-Correct Answer Number of operators increasesYour Answer Number of operators increases

True/FalseQuestion Inspection is poor method of assuring 100% quality.Correct Answer TrueYour Answer True

Select The BlankQuestion ________ used to detect drop in air pressure.Correct Answer Buzzers / alarmsYour Answer Buzzers / alarms

Multiple Choice Multiple AnswerQuestion Breakdown problem may be stratified by :-Correct Answer Sections , Machines , Type of breakdown (e.g mech. Or

electrical)Your Answer Sections , Machines , Type of breakdown (e.g mech. Or

electrical)

Multiple Choice Multiple AnswerQuestion Advantages of JIT :-Correct Answer Reduce inventory , Lower per unit cost , Reduce incoming

inspectionYour Answer Reduce inventory , Lower per unit cost , Reduce incoming

inspection

Multiple Choice Single AnswerQuestion Assignable causes :-Correct Answer Can be eliminatedYour Answer Can be eliminated

Multiple Choice Multiple AnswerQuestion If 'Inventory investment' is managing point, then checking point

will be :-Correct Answer Stores inventory , Vendor stock , WIPYour Answer WIP , Stores inventory , Vendor stock

True/FalsePage 16

TechniquesForOperationsEfficiency_8Question Globalization of trade and industrial operations have forced

Indian companies to become more & more competitive and customer driven.Correct Answer TrueYour Answer True

Multiple Choice Single AnswerQuestion Flow charts are used to train new employees by :-Correct Answer Providing a documented description of the tasks involvedYour Answer Providing a documented description of the tasks involved



Review your efforts & success achieved Check Check

Act about the causes found out Do Act

Collect the initial data for the problem Plan Plan

Actions further after reviewing the progress Act Repeat

Select The BlankQuestion Create as many ________ system as possible for better Seiketsu.Correct Answer Visual controlYour Answer Visual control

Multiple Choice Single AnswerQuestion A flow chart is a pictorial representation of the steps in a :-Correct Answer ProcessYour Answer Process

Multiple Choice Multiple AnswerQuestion Few steps in construction of Pie chart are :-Correct Answer Express value of each category as percentage of total of all

categories & calculate the degree of angle form by each category by equationdegree = Value of groups/Total value * 360 , Draw the circle & segment the

Page 17

TechniquesForOperationsEfficiency_8circle into angles calculated in step one , Colour different segments & enter thepercentage of each category into pie chartYour Answer Express value of each category as percentage of total of all

categories & calculate the degree of angle form by each category by equationdegree = Value of groups/Total value * 360 , Draw the circle & segment thecircle into angles calculated in step one , Colour different segments & enter thepercentage of each category into pie chart


customers who gives business includes :-Correct Answer Present & past customersYour Answer Present & past customers

Multiple Choice Single AnswerQuestion Benefits of Seiton meansCorrect Answer Easy irretrievability of materialYour Answer Cost saving in unwanted items

Multiple Choice Multiple AnswerQuestion As benchmark in Japan seiso activities means :-Correct Answer Everyone, clerk to officer does cleaning his area , No

sweeper or cleaner employees , Every family does cleaning of pavement oftheir residenceYour Answer Everyone, clerk to officer does cleaning his area , Every

family does cleaning of pavement of their residence , Separate department forcleaning supervision

True/FalseQuestion Six sigma process requires 100 % inspectionCorrect Answer FalseYour Answer False

True/FalseQuestion Graph is a tabulated representation of the data which is easily

understandable at a glance.Correct Answer FalseYour Answer True

Multiple Choice Multiple AnswerQuestion What are the steps in deciding the benchmarking partner?Correct Answer Decide level of benchmarking , List down a few prospective

Page 18

TechniquesForOperationsEfficiency_8candidates of partnership , Collect information of short listed partnersYour Answer Decide level of benchmarking , List down a few prospective

candidates of partnership , Collect information of short listed partners

Select The BlankQuestion ________feel that quality circle cause erosion of their control

over workmen.Correct Answer SupervisorsYour Answer Supervisors

True/FalseQuestion Errors are inevitable but can be eliminated.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion According to Seiketsu Standardization means :-Correct Answer To develop easy to follow standards , Evolve standard

operating procedure , Better visual managementYour Answer To develop easy to follow standards , Evolve standard

operating procedure , Better visual management

Select The BlankQuestion Ford, general electric & Motorola are word class benchmarking

for ________Correct Answer TrainingYour Answer Training

Select The BlankQuestion Cpk for six sigma process is ________Correct Answer 1.5Your Answer 1.5

Multiple Choice Single AnswerQuestion 5 'S rating after audit is check point for :-Correct Answer Work place improvementYour Answer Work place improvement

True/FalseQuestion Process capability index Cp is a measure of capability of the

process to meet the specification limits.Correct Answer True

Page 19

TechniquesForOperationsEfficiency_8Your Answer True

Select The BlankQuestion ________ should be used to exercise control on the process.Correct Answer Control chartYour Answer Control chart

Select The BlankQuestion Flow chart helps to dissect a process for better understanding &

________ of process.Correct Answer AnalysisYour Answer Analysis

Select The BlankQuestion ________ is benefit of TPM.Correct Answer Low production costYour Answer Low production cost

Multiple Choice Multiple AnswerQuestion Example of mechanizations are :-Correct Answer Use of fork-lifts / cranes for die - movements , Using

moving bolster , Using roller die cartsYour Answer Use of fork-lifts / cranes for die - movements , Using moving

bolster , Using roller die carts

Multiple Choice Single AnswerQuestion To maintain smoothness in production :-Correct Answer Elimination of buffer stock is recommendedYour Answer Maintenance of buffer stock is recommended.


Monthly meeting Discussion for capital expenditure & customer outstanding.Discussion for capital expenditure & customer outstanding.

Shift begining & shift end / change meeting Discussion on production in lastshift & plan for next shift Discussion on production in last shift & plan for nextshift

Daily work management meeting Discussion on gap analysis for productionmaintenance, dispatch Discussion on gap analysis for production

Page 20

TechniquesForOperationsEfficiency_8maintenance, dispatch

Weekly meeting Discussion for customer complaints Discussion for customercomplaints

True/FalseQuestion TQM improves manufacturing as well as clerical activities.Correct Answer TrueYour Answer True

Select The BlankQuestion To find out root cause ________usedCorrect Answer Why-why TechniqueYour Answer Why-why Technique

Multiple Choice Single AnswerQuestion Percentage of gross revenues spent on correcting mistakes,

checking & rechecking and things which do not add values, by manufacturingcompany is:-Correct Answer 20-30%Your Answer 0.6

True/FalseQuestion U-Line layout is better than straight lime layout.Correct Answer TrueYour Answer True

Select The BlankQuestion In traditional purchasing ________ inventory is required.Correct Answer Plenty ofYour Answer Plenty of

Select The BlankQuestion The process capability of the process =________(where sigma is

the standard deviation of the population / lot.Correct Answer 6 sigmaYour Answer 2 sigma

True/FalseQuestion A radar chart is combination of a circle & line graphCorrect Answer True

Page 21


Page 22


Select The BlankQuestion Inspection activity for semi finished & finished component

should be ________ to reduce muda of transport .Correct Answer Decentralized

Your Answer Carry out in QA department

True/FalseQuestion Concept of six sigma is not applicable for non

manufacturing sectors.Correct Answer False

Your Answer False

Multiple Choice Multiple AnswerQuestion Few main steps to construct a Histogram after deciding

classes, class width & class boundaries are :-Correct Answer Compute mid-point of the class (cell) & fill up the tally

sheet determining the cell or class into which each valuefalls , Count the tally marks i.e. frequency in each class &construct a histogram by plotting a bar graph for eachclass , Analyze & conclude whether process is is meetingthe requirement or not & take connective actions ifneeded.

Your Answer Compute mid-point of the class (cell) & fill up the tallysheet determining the cell or class into which each valuefalls , Count the tally marks i.e. frequency in each class &construct a histogram by plotting a bar graph for eachclass , Analyze & conclude whether process is is meetingthe requirement or not & take connective actions ifneeded.

Multiple Choice Single AnswerQuestion A drive for people involved should start with the :-

Correct Answer Study of staff attitudes

Your Answer Staff empowerment

Multiple Choice Single AnswerQuestion Poka-yoke for employee not performing work as per

established method is :-



Multiple Choice Multiple AnswerQuestion Implementation of TPM in Indian industries is difficult due

to :-Correct Answer Lack of knowledge of the TPM , Resistance to change ,

Fear to loss of jobYour Answer Lack of knowledge of the TPM , Resistance to change ,

Fear to loss of job

Multiple Choice Single AnswerQuestion Identifying key preventive operational functions and

comparing these operational functions within the firm'sown division & branches comes under :-


Your Answer Functional benchmarking

True/FalseQuestion "Display of safety posture & slogans" is an essential step

of TPM.Correct Answer False

Your Answer True




Multiple Choice Multiple AnswerQuestion The purpose of Shitsuke is especially for :-

Correct Answer Maintaining the 4-S consistently , Develop disciplineattitude in everyone , Any day throughout the yearsustain the discipline

Your Answer Maintaining the 4-S consistently , Develop disciplineattitude in everyone , Any day throughout the yearsustain the discipline

True/FalseQuestion Change of job titles can help to raise employee's morale.

Correct Answer True

Your Answer True


Correct Answer Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes asper review & name it & put the data & use it as 'Record' ,Decide on the objective of flowchart & define boundariesof the process

Your Answer Decide on the objective of flowchart & define boundariesof the process , Identify steps in the process & constructa draft of the flowchart , Review the draft & connect thechanges as per review & name it & put the data & use itas 'Record'

Select The BlankQuestion In scatter diagram "________" relationship is said to exist

when value of 'y' decreases as the value of 'x' increases.Correct Answer Strong negative


Multiple Choice Single AnswerQuestion Whatever you are doing you can do better by :-

Correct Answer Kaizen

Your Answer Kaizen

Multiple Choice Single AnswerQuestion Frequencies, values, tabulated in the frequency table,

can be represented pictorially in the form of bar graph &this graph of frequency is called as :-

Correct Answer Histogram

Your Answer Histogram

True/FalseQuestion Exercise to identify MURA, MUDA & MURI is not helpful

to identify problems.Correct Answer False

Your Answer False




Multiple Choice Single AnswerQuestion Number of Kaizen projects suggested and implemented

is checking point for :-Correct Answer Continual Improvement



Flow chart are drawn toeffect improvement inthe process by

Identifying non-valueadded activities

Providing a documenteddescription of the tasksinvolved

Flow chart are drawn todocument a process by

charting the tasksperformed & thesequence in whichtasks are performed

Steps in a process bypictorial representation

Flow chart are preparedto enhance theemployeesunderstanding of theprocess by

Indicatinginterrelationship withinprocess

charting the tasksperformed & thesequence in which tasksare performed

Flow charts are drawnto identify deviations by

Observing actual &comparing withdocumented process

Indicatinginterrelationship withinprocess

Multiple Choice Single AnswerQuestion Quality is the responsibility of :-

Correct Answer Everyone in the organization

Your Answer Everyone in the organization

Select The BlankQuestion ________is serve as a stepping stone to TQM

Correct Answer ISO-9000 quality standard

Your Answer ISO-9000 quality standard

True/FalseQuestion Generally time interval should be proportional to the

average frequency of out of control conditions.Correct Answer True

Your Answer True


Correct Answer Reduce inventory , Lower per unit cost , Reduceincoming inspection

Your Answer Reduce inventory , Lower per unit cost

Multiple Choice Multiple AnswerQuestion Flow chart is prepared when :-

Correct Answer Defining the problem , Trying to know the activitiesinvolved in the process , Identifying the root causes

Your Answer Defining the problem , Trying to know the activitiesinvolved in the process , Identifying the root causes

Multiple Choice Single AnswerQuestion Difference between the specification limits is called as :-

Correct Answer Design tolerance

Your Answer Design tolerance


Productivityperformancemeasurement

Turnover employee Turnover employee




Customer complaintsper period

Customer complaintsper period




True/False

Question Shitsuke is most difficult out of all 5-S because it meansto sustain all the first 4-S throughout the year.

Correct Answer True

Your Answer True

Select The BlankQuestion Graphs convey a situation more ________ than summary

of data or figures.Correct Answer Effectively & clearly


True/FalseQuestion Key element of JIT is continuous improvement.

Correct Answer True

Your Answer False

Select The BlankQuestion Histogram is a diagrammatic presentation of the

________ distribution of characteristics such as strength,diameter, etc.

Correct Answer Frequency

Your Answer Frequency

Multiple Choice Single AnswerQuestion Control chart indicates :-

Correct Answer Trend of process

Your Answer Control on process

Select The BlankQuestion Shitsuke means ________ all the previous 4-S

throughout the month/year.Correct Answer Sustaining

Your Answer Sustaining

Multiple Choice Single AnswerQuestion Competitive benchmarking is usually conducted :-

Correct Answer Through third party research

Your Answer Through third party research

Multiple Choice Single AnswerQuestion Ishikawa diagram is also known as :-

Correct Answer Cause & effect diagram

Your Answer Cause & effect diagram

Select The BlankQuestion JIT helps to ________ the waste in the purchasing

process.Correct Answer Eliminates

Your Answer Eliminates

Select The BlankQuestion To assess effectiveness of training ________ is

essential.Correct Answer Evaluation

Your Answer Evaluation


Correct Answer Daily PDCA meeting , Weekly PDCA meeting , MonthlyPDCA meeting

Your Answer Daily PDCA meeting , Weekly PDCA meeting , MonthlyPDCA meeting

Select The BlankQuestion A 'Radar chart' is a combination of circle & ________

Graph.Correct Answer Line

Your Answer Line

True/FalseQuestion Kaizen looks at process as a part of quality & quantity as

a part of processCorrect Answer False

Your Answer True

True/FalseQuestion TQM improves manufacturing as well as clerical

activities.Correct Answer True

Your Answer True




Multiple Choice Single AnswerQuestion Japanese concept of good house keeping is for:

Correct Answer Good environment for quality products

Your Answer To reduce waste

Select The BlankQuestion The process capability of the process =________(where

sigma is the standard deviation of the population / lot.Correct Answer 6 sigma

Your Answer 6 sigma

Multiple Choice Multiple AnswerQuestion 3M' is world class benchmarking ' candidates in the field

of :-Correct Answer Product development , Technology transfer ,

Environmental ManagementYour Answer Product development , Environmental Management ,

Billing & collection

Multiple Choice Multiple AnswerQuestion Poka-Yoke devices which can help to avoid the defects

are :-Correct Answer Guide pins , Limit switches , Checklist

Your Answer Guide pins , Limit switches , Checklist

True/False

Question Gap analysis for production & dispatches is discussed inmonthly meeting.


Your Answer False

Multiple Choice Multiple AnswerQuestion Actions to be taken to help staff to develop their careers

are :-Correct Answer Job rotation exercise , Preference to be given to

employees during job vacancies , Encourage employeesto improve their qualification

Your Answer Job rotation exercise , Preference to be given toemployees during job vacancies , Encourage employeesto improve their qualification

1. SMED 1. To eliminate MUDA oftransport

2. VMI ( Vendor ManagementInventory) system

2. To eliminate MUDA ofprocessing

3. Flow / string diagram 3. To eliminate MUDA ofdefect

4. Value analysis / valueengineering

4. To eliminate MUDA of stock

5. To eliminate MUDA of overproduction6. To eliminate MUDA of office

1. Control chart is agraphical method ofchecking

1. How much variability in the process is dueto random causes & how much is due toassignable causes

2. Control chart can beused to determine

2. As process monitoring tool

3. Control chart is a chartwith UCL & LCL placed

3. For quality monitoring

4. Control chart can beused

4. At 6 Sigma distance on either side of theprocess average

5. At 3 Sigma distance on either side of theprocess average

6. Stability of the process

1. UCLp 1. n p + 3 ( sq.root( n p ( 1- p )))

2. LCLp 2. p + 3 ( sq.root( n p ( 1- p )))

3. UCLnp 3. p - 3 ( sq.root( n p( 1- p )))

4. LCLnp 4. p + 3 ( sq.root( p ( 1 - p ) / n ))

5. p - 3 ( sq.root( p ( 1- p ) / n))6. n p - 3 ( sq.root( n p( 1- p )))

1. Histogram is a graphical display ofdistribution of measurements and

1. Tapering away on the bothsides from average value

2. Histogram is a diagrammaticpresentation of

2. The frequency distribution ofdefects in the process

3. The shape of histogram can 3. The frequency distribution ofa characteristics

4. Ideally the histogram will have a bellshape

4. Provide a clue about thequality of the lot5. Reveals the amount ofvariation within the process

6. Provides the clue about theprocess information

1. Shift begining & shift end /change meeting

1. Discussion for customer complaints

2. Daily work managementmeeting

2. Discussion on performance of sistercompany.

3. Weekly meeting 3. Discussion for capital expenditure &customer outstanding.

4. Monthly meeting 4. Discussion on production in last shift &plan for next shift5. Discussion on Competitors progress6. Discussion on gap analysis forproduction maintenance, dispatch

1. World class benchmarking company inmarketing

1. Ford

2. World class benchmarking company in quality 2. Motorola

3. World class benchmarking company in training 3. General Electric

4. World class benchmarking company in assemblyautomation

4. British airways

5. Microsoft

6. AmericanExpress

1. Early management 1. To achieve zero defect by ensuringdefect free equipment

2. Quality management 2. To achieve zero breakdown.

3. Safety, hygiene andenvironment

3. To improve product features

4. Planned maintenance 4. To achieve zero accident &zerocontamination5. To ensure easy to manufacture productdevelopment6. To manage breakdown

15. The area enclosed under normal distribution curve between mean +3standarddeviation is :-

a)

b)

c)

d)

0.9973

0.9545

0.6826

1

37. If 'Annual saving in procurement expenses is managing point', then checkingpoints will be :-

a)

b)

c)

Price revision

Credit period

Transport expenses

d)Productivity improvement

After finding out the solution & working on it, theequally important job is:-Prepare for the presentation of your workExplain the progress by presentation to steeringcommitteeConvince committee for your next projectConvince committee for financial help for runningthe project



Multiple Choice Multiple AnswerQuestion Advantages of JIT :-Correct Answer Reduce incoming inspection , Reduce inventory , Lower

per unit costYour Answer Reduce incoming inspection , Reduce inventory , Lower

per unit cost




Multiple Choice Multiple AnswerQuestion Benefits from SMED are :-Correct Answer Reduce work in process , Better average daily

production , Increase capacityYour Answer Reduce work in process , Increase capacity

Multiple Choice Single AnswerQuestion Competitive benchmarking involves identifying key

competitive product, services or processes & comparing with those of :-Correct Answer Main competitorYour Answer Main competitor

Multiple Choice Multiple AnswerQuestion Benefits of stratification are :-Correct Answer It helps to separate data into groups so that you can

draw connect & meaningful inference , It helps to diagnose & localize problem, It helps to identify the influencing factorsYour Answer It helps to separate data into groups so that you can

draw connect & meaningful inference , It helps to diagnose & localize problem, Finding out different reasons

Multiple Choice Multiple AnswerQuestion Quality maintenance & pillar focuses on following

production inputs :-Correct Answer Men , Machine , Material

Page 1

TechniquesForOperationsEfficiency_9Your Answer Men , Machine , Management

Multiple Choice Single AnswerQuestion The success indicators in quality, cost, delivery &

product development are :-Correct Answer Managing pointsYour Answer Accountability

Multiple Choice Multiple AnswerQuestion Steps in setup time reduction are :-Correct Answer Team formation , Training , Recoding of activities on

multiple activity chartsYour Answer Team formation , Recoding of activities on multiple

activity charts , Convert external setups in to internal setups

Multiple Choice Multiple AnswerQuestion POM essentially consists of :-Correct Answer Time management , Team participation and

performance , Moral boostingYour Answer Time management , Team participation and

performance , Cost Management

Multiple Choice Single AnswerQuestion Activity under quality management is :-Correct Answer Use team approach to track down root causes of the

problemYour Answer Maintenance of equipment condition by eliminating

lubricant leakage.


standardization.Correct Answer FalseYour Answer True

Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of

the histogram gives :-Correct Answer It shows cause which affects the process , An idea of

what is happening to the process , Whether the process is capable of meetingprocess or not i.e. around correct average & within specific limitsYour Answer It shows cause which affects the process , An idea of

Page 2

TechniquesForOperationsEfficiency_9what is happening to the process , Whether the process is capable of meetingprocess or not i.e. around correct average & within specific limits


Productivity performance measurement Turnover employee Sales of themonths

Financial performance measurement Sales of the months Cash savingper department

Customer satisfaction measurement Customer complaints per periodCustomer complaints per period

Staff attitude measurement Employee satisfaction index Employeesatisfaction index

Multiple Choice Single AnswerQuestion TPM helps to reduce down time due to:-Correct Answer Breakdown of machineYour Answer Breakdown of machine

Multiple Choice Single AnswerQuestion Kaizen emphasizes :-Correct Answer Implementation of ideasYour Answer Collection of ideas

Select The BlankQuestion Create as many ________ system as possible for better

Seiketsu.Correct Answer Visual controlYour Answer Visual control

True/FalseQuestion Inadequate maintenance of machine leads to muda of

defectsCorrect Answer TrueYour Answer False

Select The BlankPage 3

TechniquesForOperationsEfficiency_9Question The shape of histogram can provide a clue about the

________ of the lot.Correct Answer QualityYour Answer Distribution


Multiple Choice Single AnswerQuestion In bar graph the interval (gap) between the bars is :-Correct Answer EqualYour Answer Symmetrical


True/FalseQuestion A radar chart is combination of a circle & line graphCorrect Answer TrueYour Answer True

Multiple Choice Single AnswerQuestion A workshop is to be treated as :-Correct Answer Place where one's creativity can be appliedYour Answer Place where one's creativity can be applied


management meeting by operations head.Correct Answer FalseYour Answer True

True/FalseQuestion Number of operation can change according to

production requirement in U-Line arrangement.Correct Answer FalseYour Answer True

Page 4

TechniquesForOperationsEfficiency_9True/FalseQuestion Automation can correct the basic faults of a improper

setup process.Correct Answer FalseYour Answer True

Select The BlankQuestion Cp for six sigma process is ________Correct Answer 2Your Answer 1.66

Select The BlankQuestion Range ( R ) is obtained as the difference between the

highest and ________ measurement of a sample.Correct Answer LowestYour Answer Second highest

Select The BlankQuestion ________is an important step toward successful JIT

purchasing.Correct Answer JIT ContractYour Answer JIT Contract


Multiple Choice Single AnswerQuestion TQM applicable to :-Correct Answer Marketing, design & manufacturingYour Answer Quality Control department

Select The BlankQuestion Bar graph is display of data that facilitates ________

of quality.Correct Answer ComparisonYour Answer Performance

Multiple Choice Single AnswerQuestion Production kanban is presented by :-Correct Answer P-kanban

Page 5

TechniquesForOperationsEfficiency_9Your Answer R-kanban

Multiple Choice Single AnswerQuestion Check sheet are also used as :-Correct Answer Data gathering & interpretation toolYour Answer Cause finding & effect finding tool

Select The BlankQuestion Japanese believe that when they are ________ they

are cleaning there minds too.Correct Answer CleaningYour Answer Repairing machines

Select The BlankQuestion Poka-Yoke devices under category use ________ to

distinguish between similar parts which may be assembled in wrong position.Correct Answer Color codingYour Answer Counting device


throughout the month/year.Correct Answer SustainingYour Answer Implementing

Multiple Choice Multiple AnswerQuestion Types of meetings held in DWM are :-Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly

PDCA meetingYour Answer Weekly PDCA meeting , Monthly PDCA meeting , Yearly

PDCA meeting

True/FalseQuestion By TPM, consumption of electrical energy can be

reduced.Correct Answer TrueYour Answer True


operating procedure , Better visual managementPage 6

TechniquesForOperationsEfficiency_9Your Answer To develop easy to follow standards , Evolve standard

operating procedure , Reduction of wastage

True/FalseQuestion Flow chart helps to stop an old process.Correct Answer FalseYour Answer True

Multiple Choice Multiple AnswerQuestion Training related to Quality includes:-Correct Answer Quality measures , Quality failureYour Answer Quality measures , Quality failure , Goal of business

Multiple Choice Single AnswerQuestion Total area under the normal curve isCorrect Answer UnityYour Answer Six

Multiple Choice Multiple AnswerQuestion Cpk =Correct Answer (x - USL)/3 sigma , (x - LSL)/3 sigmaYour Answer (x - USL)/6 sigma


measurements & reveals the amounts of ________ within the process.Correct Answer VariationYour Answer Percentage defects


Value analysis / value engineering To eliminate MUDA of processingTo eliminate MUDA of over production

SMED To eliminate MUDA of over production To eliminate MUDA ofdefect

VMI ( Vendor Management Inventory) system To eliminate MUDA ofstock To eliminate MUDA of stock

Flow / string diagram To eliminate MUDA of transport ToPage 7

TechniquesForOperationsEfficiency_9eliminate MUDA of processing

Select The BlankQuestion A 'Radar chart' is used to portray ________ strength

or weakness of the activity.Correct Answer RelativeYour Answer Comparative

------------------------------------------------------------


True/FalseQuestion Performance benchmarking does not involves

comparison of financial ratios at the aggregate level.Correct Answer FalseYour Answer False

Multiple Choice Multiple AnswerQuestion Few steps to construct a flow chart are :-Correct Answer Decide on the objective of flowchart & define boundaries

of the process , Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes as per review & name it &put the data & use it as 'Record'Your Answer Decide on the objective of flowchart & define boundaries

of the process , Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes as per review & name it &put the data & use it as 'Record'

Select The BlankQuestion In PDCA cycle for benchmarking 'Identification of

performance gap' is done in ________.Correct Answer CheckingYour Answer Checking

Select The BlankQuestion 5 S audit result is discussed in ________ meeting.Correct Answer MonthlyYour Answer Shift beginning

Page 8


Select The BlankQuestion In scatter diagram "________" relationship is said to

exist when value of 'y' decreases as the value of 'x' increases.Correct Answer Strong negativeYour Answer Strong negative

Select The BlankQuestion Kaizen projects are managed by ________Correct Answer Cross functional teamYour Answer Management


established method is :-Correct Answer Implement work standardYour Answer Implement work standard


Multiple Choice Multiple AnswerQuestion What are the steps in deciding the benchmarking

partner?Correct Answer Decide level of benchmarking , List down a few

prospective candidates of partnership , Collect information of short listedpartnersYour Answer Decide level of benchmarking , Collect information of

short listed partners

Multiple Choice Single AnswerQuestion Errors by armatures is :-Correct Answer Lack of experienceYour Answer Absent mindedness

True/FalseQuestion Control chart is also called as run-chart.Correct Answer TrueYour Answer True

Page 9

TechniquesForOperationsEfficiency_9Match The FollowingQuestion Correct Answer Your Answer

Reduce clamping & declamping time Use U-shaped washer UseU-shaped washer

Reduce time of external setup Improve work aids positioning methodImprove work aids positioning method

Convert internal setup into external setup Preparation of tools / dies as offline activity Preparation of tools / dies as off line activity


Multiple Choice Single AnswerQuestion Muda of defect is very serious in case of:-Correct Answer High speed automatic machinesYour Answer High speed automatic machines

Multiple Choice Multiple AnswerQuestion To reduce clamping & declamping time, following

actions are desirable :-Correct Answer Standardize clamping bolts / screws , Cut off

unnecessary threads , Use quick clamping deviceYour Answer Standardize clamping bolts / screws , Cut off

unnecessary threads , Use quick clamping device

Multiple Choice Single AnswerQuestion Requirement of more machines, is an example of :-Correct Answer Muda of overproductionYour Answer Muda of waiting




Page 10

TechniquesForOperationsEfficiency_9Environmental ManagementYour Answer Product development , Technology transfer ,


Multiple Choice Single AnswerQuestion Responsibility for Quality should rest on:-Correct Answer Who produce the productYour Answer Quality control department

True/FalseQuestion Increase in defect rate is an example of 'Deviation from

an established norms'Correct Answer TrueYour Answer True

Select The BlankQuestion ________ are implemented for defect detection &

prevention.Correct Answer Poka-YokesYour Answer Poka-Yokes


Multiple Choice Single AnswerQuestion Implication of Quality problem is:-Correct Answer Gap in performanceYour Answer Lower efficiency

True/FalseQuestion Presentation of graphs in pictorial form of data

collection are for easy understanding.Correct Answer TrueYour Answer True

Select The BlankQuestion ________ waste is probably the biggest waste in most

of the organizations.Correct Answer TimeYour Answer Labor

Page 11


True/FalseQuestion Globalization of trade and industrial operations have

forced Indian companies to become more & more competitive and customerdriven.Correct Answer TrueYour Answer True


Multiple Choice Multiple AnswerQuestion An erratic patterns falling above & below the control

limits indicates :-Correct Answer Poorly trained operators , Defect in materials , Frequent

adjustment of machinesYour Answer Defect in materials , Frequent adjustment of machines ,

Poorly trained operators

Multiple Choice Single AnswerQuestion Defects per million for the process at six sigma level are

:-Correct Answer 3.4Your Answer 6210

Multiple Choice Single AnswerQuestion To provide flexibility to supervisors in allocation of task,

JIT emphasizes :-Correct Answer Multiskilled operatorsYour Answer Multiskilled operators


Select The BlankQuestion ________ should be used to exercise control on the

process.Correct Answer Control chart

Page 12

TechniquesForOperationsEfficiency_9Your Answer Latest checking instruments


Ideally the histogram will have a bell shape Tapering away on theboth sides from average value Tapering away on the both sides fromaverage value

Histogram is a graphical display of distribution of measurements andReveals the amount of variation within the process Reveals the amount ofvariation within the process

Histogram is a diagrammatic presentation of The frequencydistribution of a characteristics The frequency distribution of a characteristics

The shape of histogram can Provide a clue about the quality of the lotProvide a clue about the quality of the lot

True/FalseQuestion In single card kanban system production greater than

quantity withdrawn is permitted.Correct Answer FalseYour Answer False

True/FalseQuestion Flow chart are drawn to document a process charting

the tasks performed & the sequence in which tasks are performed.Correct Answer TrueYour Answer True



abnormalities while cleaning your own area.Correct Answer TrueYour Answer True

Page 13


Multiple Choice Multiple AnswerQuestion Some steps for stratification are :-Correct Answer Define the problem & identify the stratification variables

, Sort out data into categories & summarise information in each category ,Present the information in graphical form & study, decide if furtherstratification is required?Your Answer Define the problem & identify the stratification variables

, Sort out data into categories & summarise information in each category ,Present the information in graphical form & study, decide if furtherstratification is required?

True/FalseQuestion Processing cost of a product is mainly decided by

conversion process.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Work standards enable management to minimize

variation in :-Correct Answer Output , Quality , CostYour Answer Output , Quality , Cost

Multiple Choice Multiple AnswerQuestion Process can be made capable by :-Correct Answer Reducing process variability , Bringing target & average

to fall at the same point , Examine possibility of relaxing specificationYour Answer Reducing process variability , Bringing target & average

to fall at the same point , Use of less precision machine

Multiple Choice Multiple AnswerQuestion Few steps in construction of Pie chart are :-Correct Answer Express value of each category as percentage of total of

all categories & calculate the degree of angle form by each category byequation degree = Value of groups/Total value * 360 , Draw the circle &segment the circle into angles calculated in step one , Colour differentsegments & enter the percentage of each category into pie chartYour Answer Express value of each category as percentage of total of

all categories & calculate the degree of angle form by each category byequation degree = Value of groups/Total value * 360 , Draw the circle &segment the circle into angles calculated in step one , Colour different

Page 14

TechniquesForOperationsEfficiency_9segments & enter the percentage of each category into pie chart


sweeper or cleaner employees , Every family does cleaning of pavement oftheir residenceYour Answer Everyone, clerk to officer does cleaning his area , No

sweeper or cleaner employees , Every family does cleaning of pavement oftheir residence

Select The BlankQuestion Poka Yoke designed to help operators to know

immediately ________ of the defeat called detection type Poka-Yoke.Correct Answer On occurrenceYour Answer Before Occurrence

Select The BlankQuestion Flow chart helps to dissect a process for better

understanding & ________ of process.Correct Answer AnalysisYour Answer Analysis

Multiple Choice Single AnswerQuestion Small groups forming a circle should consist of :-Correct Answer Employees of different department related to the

problemYour Answer Employees of same department

Select The BlankQuestion Graphs convey a situation more ________ than

summary of data or figures.Correct Answer Effectively & clearlyYour Answer Effectively & clearly


is checking point for :-Correct Answer Continual ImprovementYour Answer Continual Improvement

Page 15

TechniquesForOperationsEfficiency_9--------------------------------------------------------------------



production inputs :-Correct Answer Material , Men , MachineYour Answer Material , Men , Machine

Multiple Choice Multiple AnswerQuestion Histograms are useful to :-Correct Answer Measure the current pattern & extent of variation ,

Assess current conformance to specification & scope of improvement ,Determine whether or not the process is in the state of controlYour Answer Measure the current pattern & extent of variation ,

Assess current conformance to specification & scope of improvement ,Determine whether or not the process is in the state of control

Multiple Choice Single AnswerQuestion In problem solving the best alternative is that :-Correct Answer Which best meets the criteriaYour Answer Which best meets the criteria

Multiple Choice Single AnswerQuestion "Cause & effect" diagram was developed by :-Correct Answer DR.Kaoru IshikawaYour Answer DR.Kaoru Ishikawa


comparing these operational functions within the firm's own division &branches comes under :-Correct Answer Internal benchmarkingYour Answer Internal benchmarking

Select The BlankQuestion JIT advocates the philosophy at elimination of waste

from system which occurs due to ________.Correct Answer Over ProductionYour Answer Over Production

Page 16

TechniquesForOperationsEfficiency_9Select The BlankQuestion In scatter diagram "________" relationship is said to

exist when there is positive relationship upto certain level & negativethereafter or negative relationship upto certain level & positive thereafter.Correct Answer CurvilinearYour Answer Curvilinear

True/FalseQuestion Kanban signals are required when assembly work,

subassembly work and manufacturing at parts is carried out at differentlocations.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Customers complaints may be segregated by :-Correct Answer Nature of compliant i.e. defective product , Delayed

delivery , Short/excess quantityYour Answer Nature of compliant i.e. defective product , Delayed

delivery , Short/excess quantity

True/FalseQuestion In case of more than one quality characteristics,

separate chart is made for each quality characteristics.Correct Answer TrueYour Answer True

True/FalseQuestion Safety, hygiene and environment control is one of the

pillar of TPM.Correct Answer TrueYour Answer True



Reduce time of external setup Improve work aids positioning methodPage 17

TechniquesForOperationsEfficiency_9Improve work aids positioning method




Multiple Choice Single AnswerQuestion The facilitator should be normally :-Correct Answer Senior officer /Shop inchargeYour Answer Senior officer /Shop incharge


Parato diagram always indicates Magnitude of defects Philosophy of20% of the activity causes 80% of the effect

Parato analysis underlines & operates on Philosophy of "vital few:trivialmany" Philosophy of "vital few:trivial many"

Parato analysis is technique of identifying vital causes by Arrangingdata according to the descending order of their frequency of occurrenceArranging data according to the descending order of their frequency ofoccurrence

Parato diagram is a Bar graph with height or value drawn by Arrangingdata in descending order Magnitude of defects

Multiple Choice Single AnswerQuestion Quality problem solving tool is used to :-Correct Answer Improve qualityYour Answer Make work easy

True/FalseQuestion Pie chart is also called as angular diagram.Correct Answer True

Page 18



exist when value of 'y' somewhat decreases as the value of 'x' increases.Correct Answer Weak negativeYour Answer Weak negative

Multiple Choice Single AnswerQuestion From scatter diagram the strength of relationship

between two variables or associated set of data can be inferred from theexamination of the shape of :-Correct Answer CloudYour Answer Cloud

Multiple Choice Multiple AnswerQuestion Product benchmarking requires, comparison of product

:-Correct Answer Performance , Features , CostYour Answer Performance , Features , Cost

Multiple Choice Multiple AnswerQuestion Steps in construction of scatter diagram :-Correct Answer Collect paired data (X,Y) from two variables who's

relationship is to be studied , Find out max & min values for both X & Y andthese values to scale X & Y axis & plot the paired data , Examine the shape ofthe cloud of points & discover type & strength of relationshipYour Answer Collect paired data (X,Y) from two variables who's

relationship is to be studied , Find out max & min values for both X & Y andthese values to scale X & Y axis & plot the paired data , Examine the shape ofthe cloud of points & discover type & strength of relationship

Multiple Choice Single AnswerQuestion Implication of Quality problem is:-Correct Answer Gap in performanceYour Answer Gap in performance

Select The BlankQuestion Each quality characteristic has permitted variation & is

equal to ________.Correct Answer USL - LSLYour Answer USL - LSL

Page 19


Select The BlankQuestion Kaizen is ________ supported process.Correct Answer ManagementYour Answer Management


understanding of the process by indicating interrelationship within theprocess.Correct Answer TrueYour Answer False


monthly meeting.Correct Answer FalseYour Answer False



Select The BlankQuestion ________ is most difficult 'S' to implement & achieve.Correct Answer ShitsukeYour Answer Shitsuke





Page 20

TechniquesForOperationsEfficiency_9Multiple Choice Single AnswerQuestion Errors by armatures is :-Correct Answer Lack of experienceYour Answer Lack of experience

Multiple Choice Multiple AnswerQuestion While preparing scatter diagram following precautions

are to be taken :-Correct Answer Data should be properly stratified & should be collected

for full range , Scale selected should be right to avoid wrong conclusions ,Data should be free from bias or undue importanceYour Answer Data should be properly stratified & should be collected

for full range , Scale selected should be right to avoid wrong conclusions ,Data should be free from bias or undue importance



Multiple Choice Multiple AnswerQuestion If 'Annual saving in procurement expenses is managing

point', then checking points will be :-Correct Answer Price revision , Credit period , Transport expensesYour Answer Price revision , Credit period , Transport expenses

Multiple Choice Single AnswerQuestion Number of kaizen in Group kaizen categories are :-Correct Answer Two to three per yearYour Answer Two to three per year

True/FalseQuestion Flow chart is pictorial representation of the steps in

production control.Correct Answer FalseYour Answer False

Multiple Choice Single AnswerQuestion It is essential to convey customer's expectations to :-Correct Answer Top Management

Page 21

TechniquesForOperationsEfficiency_9Your Answer Supervisors & workmen

Multiple Choice Single AnswerQuestion Check sheet is easy to use because it is :-Correct Answer Simplest toolYour Answer Simplest tool

Select The BlankQuestion Identification of non-value added operations & their

elimination is the first step to eliminate muda of ________.Correct Answer ProcessingYour Answer Processing


or weakness of the activity.Correct Answer RelativeYour Answer Relative

Multiple Choice Single AnswerQuestion Pareto's analysis underlines & operates philosophy of :-Correct Answer Vital few = trivial manyYour Answer Vital few = trivial many



Multiple Choice Multiple AnswerQuestion Benefits of planned maintenance are :-Correct Answer Improved reliability mean time between failures ,

Improved maintainability mean time to repair , Improvement in breakdownYour Answer Improved reliability mean time between failures ,

Improved maintainability mean time to repair

Multiple Choice Multiple AnswerQuestion Gap analysis & problem identification is done during

converting internal setups into external setups in the areas like :-Correct Answer Equipment , Method , HumanYour Answer Equipment , Method , Human

Page 22


Multiple Choice Single AnswerQuestion Some quantity in stock of item, is desirable if :-Correct Answer Manufacturing lead time is moreYour Answer Manufacturing lead time is more

Multiple Choice Single AnswerQuestion Sorting of usable items should beCorrect Answer Planned storage based on frequency of useYour Answer Within visual reach method



inspection time

Page 23

TechniquesForOperationsEfficiency_10LIST OF ATTEMPTED QUESTIONS AND ANSWERS

Multiple Choice Multiple AnswerQuestion Advantages of JIT :-Correct Answer Reduce incoming inspection , Reduce inventory , Lower

per unit costYour Answer Reduce incoming inspection , Reduce inventory , Lower

per unit cost




Multiple Choice Multiple AnswerQuestion Benefits from SMED are :-Correct Answer Reduce work in process , Better average daily

production , Increase capacityYour Answer Reduce work in process , Increase capacity

Multiple Choice Single AnswerQuestion Competitive benchmarking involves identifying key

competitive product, services or processes & comparing with those of :-Correct Answer Main competitorYour Answer Main competitor

Multiple Choice Multiple AnswerQuestion Benefits of stratification are :-Correct Answer It helps to separate data into groups so that you can

draw connect & meaningful inference , It helps to diagnose & localize problem, It helps to identify the influencing factorsYour Answer It helps to separate data into groups so that you can

draw connect & meaningful inference , It helps to diagnose & localize problem, Finding out different reasons


production inputs :-Correct Answer Men , Machine , MaterialYour Answer Men , Machine , Management

Page 1


Multiple Choice Single AnswerQuestion The success indicators in quality, cost, delivery &

product development are :-Correct Answer Managing pointsYour Answer Accountability

Multiple Choice Multiple AnswerQuestion Steps in setup time reduction are :-Correct Answer Team formation , Training , Recoding of activities on

multiple activity chartsYour Answer Team formation , Recoding of activities on multiple

activity charts , Convert external setups in to internal setups

Multiple Choice Multiple AnswerQuestion POM essentially consists of :-Correct Answer Time management , Team participation and

performance , Moral boostingYour Answer Time management , Team participation and

performance , Cost Management

Multiple Choice Single AnswerQuestion Activity under quality management is :-Correct Answer Use team approach to track down root causes of the

problemYour Answer Maintenance of equipment condition by eliminating

lubricant leakage.


standardization.Correct Answer FalseYour Answer True

Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of

the histogram gives :-Correct Answer It shows cause which affects the process , An idea of

what is happening to the process , Whether the process is capable of meetingprocess or not i.e. around correct average & within specific limitsYour Answer It shows cause which affects the process , An idea of

what is happening to the process , Whether the process is capable of meetingPage 2

TechniquesForOperationsEfficiency_10process or not i.e. around correct average & within specific limits


Productivity performance measurement Turnover employee Sales of themonths

Financial performance measurement Sales of the months Cash savingper department

Customer satisfaction measurement Customer complaints per periodCustomer complaints per period

Staff attitude measurement Employee satisfaction index Employeesatisfaction index



Select The BlankQuestion Create as many ________ system as possible for better

Seiketsu.Correct Answer Visual controlYour Answer Visual control

True/FalseQuestion Inadequate maintenance of machine leads to muda of

defectsCorrect Answer TrueYour Answer False

Select The BlankQuestion The shape of histogram can provide a clue about the

Page 3

TechniquesForOperationsEfficiency_10________ of the lot.Correct Answer QualityYour Answer Distribution







management meeting by operations head.Correct Answer FalseYour Answer True

True/FalseQuestion Number of operation can change according to

production requirement in U-Line arrangement.Correct Answer FalseYour Answer True

True/FalsePage 4

TechniquesForOperationsEfficiency_10Question Automation can correct the basic faults of a improper

setup process.Correct Answer FalseYour Answer True


Select The BlankQuestion Range ( R ) is obtained as the difference between the

highest and ________ measurement of a sample.Correct Answer LowestYour Answer Second highest

Select The BlankQuestion ________is an important step toward successful JIT

purchasing.Correct Answer JIT ContractYour Answer JIT Contract



Select The BlankQuestion Bar graph is display of data that facilitates ________

of quality.Correct Answer ComparisonYour Answer Performance

Multiple Choice Single AnswerQuestion Production kanban is presented by :-Correct Answer P-kanbanYour Answer R-kanban

Page 5



Select The BlankQuestion Japanese believe that when they are ________ they

are cleaning there minds too.Correct Answer CleaningYour Answer Repairing machines

Select The BlankQuestion Poka-Yoke devices under category use ________ to

distinguish between similar parts which may be assembled in wrong position.Correct Answer Color codingYour Answer Counting device


throughout the month/year.Correct Answer SustainingYour Answer Implementing

Multiple Choice Multiple AnswerQuestion Types of meetings held in DWM are :-Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly

PDCA meetingYour Answer Weekly PDCA meeting , Monthly PDCA meeting , Yearly

PDCA meeting

True/FalseQuestion By TPM, consumption of electrical energy can be

reduced.Correct Answer TrueYour Answer True


operating procedure , Better visual managementYour Answer To develop easy to follow standards , Evolve standard

Page 6

TechniquesForOperationsEfficiency_10operating procedure , Reduction of wastage



Multiple Choice Single AnswerQuestion Total area under the normal curve isCorrect Answer UnityYour Answer Six



measurements & reveals the amounts of ________ within the process.Correct Answer VariationYour Answer Percentage defects


Value analysis / value engineering To eliminate MUDA of processingTo eliminate MUDA of over production

SMED To eliminate MUDA of over production To eliminate MUDA ofdefect

VMI ( Vendor Management Inventory) system To eliminate MUDA ofstock To eliminate MUDA of stock

Flow / string diagram To eliminate MUDA of transport Toeliminate MUDA of processing

Page 7



or weakness of the activity.Correct Answer RelativeYour Answer Comparative

------------------------------------------------------------


True/FalseQuestion Performance benchmarking does not involves

comparison of financial ratios at the aggregate level.Correct Answer FalseYour Answer False

Multiple Choice Multiple AnswerQuestion Few steps to construct a flow chart are :-Correct Answer Decide on the objective of flowchart & define boundaries

of the process , Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes as per review & name it &put the data & use it as 'Record'Your Answer Decide on the objective of flowchart & define boundaries

of the process , Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes as per review & name it &put the data & use it as 'Record'

Select The BlankQuestion In PDCA cycle for benchmarking 'Identification of

performance gap' is done in ________.Correct Answer CheckingYour Answer Checking

Select The BlankQuestion 5 S audit result is discussed in ________ meeting.Correct Answer MonthlyYour Answer Shift beginning

Page 8

TechniquesForOperationsEfficiency_10Select The BlankQuestion In scatter diagram "________" relationship is said to




established method is :-Correct Answer Implement work standardYour Answer Implement work standard


Multiple Choice Multiple AnswerQuestion What are the steps in deciding the benchmarking

partner?Correct Answer Decide level of benchmarking , List down a few

prospective candidates of partnership , Collect information of short listedpartnersYour Answer Decide level of benchmarking , Collect information of

short listed partners



Match The FollowingPage 9

TechniquesForOperationsEfficiency_10Question Correct Answer Your Answer





Multiple Choice Single AnswerQuestion Muda of defect is very serious in case of:-Correct Answer High speed automatic machinesYour Answer High speed automatic machines

Multiple Choice Multiple AnswerQuestion To reduce clamping & declamping time, following

actions are desirable :-Correct Answer Standardize clamping bolts / screws , Cut off

unnecessary threads , Use quick clamping deviceYour Answer Standardize clamping bolts / screws , Cut off

unnecessary threads , Use quick clamping device





Environmental ManagementPage 10

TechniquesForOperationsEfficiency_10Your Answer Product development , Technology transfer ,



True/FalseQuestion Increase in defect rate is an example of 'Deviation from

an established norms'Correct Answer TrueYour Answer True

Select The BlankQuestion ________ are implemented for defect detection &

prevention.Correct Answer Poka-YokesYour Answer Poka-Yokes





Select The BlankQuestion ________ waste is probably the biggest waste in most

of the organizations.Correct Answer TimeYour Answer Labor

Page 11

TechniquesForOperationsEfficiency_10True/FalseQuestion Globalization of trade and industrial operations have



Multiple Choice Multiple AnswerQuestion An erratic patterns falling above & below the control

limits indicates :-Correct Answer Poorly trained operators , Defect in materials , Frequent

adjustment of machinesYour Answer Defect in materials , Frequent adjustment of machines ,

Poorly trained operators

Multiple Choice Single AnswerQuestion Defects per million for the process at six sigma level are

:-Correct Answer 3.4Your Answer 6210

Multiple Choice Single AnswerQuestion To provide flexibility to supervisors in allocation of task,

JIT emphasizes :-Correct Answer Multiskilled operatorsYour Answer Multiskilled operators


Select The BlankQuestion ________ should be used to exercise control on the

process.Correct Answer Control chartYour Answer Latest checking instruments

Page 12



Ideally the histogram will have a bell shape Tapering away on theboth sides from average value Tapering away on the both sides fromaverage value

Histogram is a graphical display of distribution of measurements andReveals the amount of variation within the process Reveals the amount ofvariation within the process

Histogram is a diagrammatic presentation of The frequencydistribution of a characteristics The frequency distribution of a characteristics

The shape of histogram can Provide a clue about the quality of the lotProvide a clue about the quality of the lot



True/FalseQuestion Flow chart are drawn to document a process charting

the tasks performed & the sequence in which tasks are performed.Correct Answer TrueYour Answer True



abnormalities while cleaning your own area.Correct Answer TrueYour Answer True

Page 13

TechniquesForOperationsEfficiency_10Multiple Choice Multiple AnswerQuestion Some steps for stratification are :-Correct Answer Define the problem & identify the stratification variables

, Sort out data into categories & summarise information in each category ,Present the information in graphical form & study, decide if furtherstratification is required?Your Answer Define the problem & identify the stratification variables

, Sort out data into categories & summarise information in each category ,Present the information in graphical form & study, decide if furtherstratification is required?

True/FalseQuestion Processing cost of a product is mainly decided by

conversion process.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Work standards enable management to minimize

variation in :-Correct Answer Output , Quality , CostYour Answer Output , Quality , Cost

Multiple Choice Multiple AnswerQuestion Process can be made capable by :-Correct Answer Reducing process variability , Bringing target & average

to fall at the same point , Examine possibility of relaxing specificationYour Answer Reducing process variability , Bringing target & average

to fall at the same point , Use of less precision machine

Multiple Choice Multiple AnswerQuestion Few steps in construction of Pie chart are :-Correct Answer Express value of each category as percentage of total of

all categories & calculate the degree of angle form by each category byequation degree = Value of groups/Total value * 360 , Draw the circle &segment the circle into angles calculated in step one , Colour differentsegments & enter the percentage of each category into pie chartYour Answer Express value of each category as percentage of total of

all categories & calculate the degree of angle form by each category byequation degree = Value of groups/Total value * 360 , Draw the circle &segment the circle into angles calculated in step one , Colour differentsegments & enter the percentage of each category into pie chart

Page 14



sweeper or cleaner employees , Every family does cleaning of pavement oftheir residenceYour Answer Everyone, clerk to officer does cleaning his area , No

sweeper or cleaner employees , Every family does cleaning of pavement oftheir residence

Select The BlankQuestion Poka Yoke designed to help operators to know

immediately ________ of the defeat called detection type Poka-Yoke.Correct Answer On occurrenceYour Answer Before Occurrence

Select The BlankQuestion Flow chart helps to dissect a process for better

understanding & ________ of process.Correct Answer AnalysisYour Answer Analysis

Multiple Choice Single AnswerQuestion Small groups forming a circle should consist of :-Correct Answer Employees of different department related to the

problemYour Answer Employees of same department




is checking point for :-Correct Answer Continual ImprovementYour Answer Continual Improvement

--------------------------------------------------------------------Page 15




production inputs :-Correct Answer Material , Men , MachineYour Answer Material , Men , Machine

Multiple Choice Multiple AnswerQuestion Histograms are useful to :-Correct Answer Measure the current pattern & extent of variation ,

Assess current conformance to specification & scope of improvement ,Determine whether or not the process is in the state of controlYour Answer Measure the current pattern & extent of variation ,

Assess current conformance to specification & scope of improvement ,Determine whether or not the process is in the state of control




comparing these operational functions within the firm's own division &branches comes under :-Correct Answer Internal benchmarkingYour Answer Internal benchmarking

Select The BlankQuestion JIT advocates the philosophy at elimination of waste

from system which occurs due to ________.Correct Answer Over ProductionYour Answer Over Production

Select The BlankPage 16

TechniquesForOperationsEfficiency_10Question In scatter diagram "________" relationship is said to

exist when there is positive relationship upto certain level & negativethereafter or negative relationship upto certain level & positive thereafter.Correct Answer CurvilinearYour Answer Curvilinear

True/FalseQuestion Kanban signals are required when assembly work,

subassembly work and manufacturing at parts is carried out at differentlocations.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Customers complaints may be segregated by :-Correct Answer Nature of compliant i.e. defective product , Delayed

delivery , Short/excess quantityYour Answer Nature of compliant i.e. defective product , Delayed

delivery , Short/excess quantity

True/FalseQuestion In case of more than one quality characteristics,

separate chart is made for each quality characteristics.Correct Answer TrueYour Answer True

True/FalseQuestion Safety, hygiene and environment control is one of the

pillar of TPM.Correct Answer TrueYour Answer True




Page 17







Parato diagram always indicates Magnitude of defects Philosophy of20% of the activity causes 80% of the effect

Parato analysis underlines & operates on Philosophy of "vital few:trivialmany" Philosophy of "vital few:trivial many"

Parato analysis is technique of identifying vital causes by Arrangingdata according to the descending order of their frequency of occurrenceArranging data according to the descending order of their frequency ofoccurrence

Parato diagram is a Bar graph with height or value drawn by Arrangingdata in descending order Magnitude of defects


True/FalseQuestion Pie chart is also called as angular diagram.Correct Answer TrueYour Answer True

Page 18



exist when value of 'y' somewhat decreases as the value of 'x' increases.Correct Answer Weak negativeYour Answer Weak negative

Multiple Choice Single AnswerQuestion From scatter diagram the strength of relationship

between two variables or associated set of data can be inferred from theexamination of the shape of :-Correct Answer CloudYour Answer Cloud

Multiple Choice Multiple AnswerQuestion Product benchmarking requires, comparison of product

:-Correct Answer Performance , Features , CostYour Answer Performance , Features , Cost

Multiple Choice Multiple AnswerQuestion Steps in construction of scatter diagram :-Correct Answer Collect paired data (X,Y) from two variables who's

relationship is to be studied , Find out max & min values for both X & Y andthese values to scale X & Y axis & plot the paired data , Examine the shape ofthe cloud of points & discover type & strength of relationshipYour Answer Collect paired data (X,Y) from two variables who's

relationship is to be studied , Find out max & min values for both X & Y andthese values to scale X & Y axis & plot the paired data , Examine the shape ofthe cloud of points & discover type & strength of relationship


Select The BlankQuestion Each quality characteristic has permitted variation & is

equal to ________.Correct Answer USL - LSLYour Answer USL - LSL

Page 19

TechniquesForOperationsEfficiency_10Select The BlankQuestion Kaizen is ________ supported process.Correct Answer ManagementYour Answer Management


understanding of the process by indicating interrelationship within theprocess.Correct Answer TrueYour Answer False


monthly meeting.Correct Answer FalseYour Answer False








Multiple Choice Single AnswerPage 20

TechniquesForOperationsEfficiency_10Question Errors by armatures is :-Correct Answer Lack of experienceYour Answer Lack of experience

Multiple Choice Multiple AnswerQuestion While preparing scatter diagram following precautions

are to be taken :-Correct Answer Data should be properly stratified & should be collected

for full range , Scale selected should be right to avoid wrong conclusions ,Data should be free from bias or undue importanceYour Answer Data should be properly stratified & should be collected

for full range , Scale selected should be right to avoid wrong conclusions ,Data should be free from bias or undue importance



Multiple Choice Multiple AnswerQuestion If 'Annual saving in procurement expenses is managing

point', then checking points will be :-Correct Answer Price revision , Credit period , Transport expensesYour Answer Price revision , Credit period , Transport expenses


True/FalseQuestion Flow chart is pictorial representation of the steps in

production control.Correct Answer FalseYour Answer False

Multiple Choice Single AnswerQuestion It is essential to convey customer's expectations to :-Correct Answer Top ManagementYour Answer Supervisors & workmen

Page 21



Select The BlankQuestion Identification of non-value added operations & their

elimination is the first step to eliminate muda of ________.Correct Answer ProcessingYour Answer Processing


or weakness of the activity.Correct Answer RelativeYour Answer Relative




Multiple Choice Multiple AnswerQuestion Benefits of planned maintenance are :-Correct Answer Improved reliability mean time between failures ,

Improved maintainability mean time to repair , Improvement in breakdownYour Answer Improved reliability mean time between failures ,

Improved maintainability mean time to repair

Multiple Choice Multiple AnswerQuestion Gap analysis & problem identification is done during

converting internal setups into external setups in the areas like :-Correct Answer Equipment , Method , HumanYour Answer Equipment , Method , Human

Page 22

TechniquesForOperationsEfficiency_10Multiple Choice Single AnswerQuestion Some quantity in stock of item, is desirable if :-Correct Answer Manufacturing lead time is moreYour Answer Manufacturing lead time is more




inspection time

Page 23


Skip Questions.





level.Correct Answer False

Your Answer False




Multiple Choice Single AnswerQuestion Participants of the groups for quality circles should be decided by :-

Correct Answer Employees coming together by their own enthusiasm



















Select The BlankQuestion If some defective parts are discovered by the subsequent process they should be returned to

the ________ to prevent reoccurrence.Correct Answer Preceding process


Multiple Choice Multiple AnswerQuestion The results oriented efforts of the quality circle should also include :-

Correct Answer Efforts to avoid the problem permanently , Ultimate aim of the customers satisfaction ,Attacking the real root causes & all possibilities

Your Answer Efforts to avoid the problem permanently , Publication or advertisement of your contribution ,Attacking the real root causes & all possibilities




Philosophy of "vital few:trivial many" Philosophy of "vital few:trivial many"




Parato diagram is a Bar graph withheight or value drawn by

Arranging data in descending order Magnitude of defects


Correct Answer Brainstorming to enlist characteristics which require to be evaluated & draw the circle & divideit into 'slices' equal to number of characteristics , The first slice begins at 12 noon. Then drawvertical line & calibrate it equal to the number of levels required , Draw concentric circles fromeach gradiation using 'o' point as centre

Your Answer Brainstorming to enlist characteristics which require to be evaluated & draw the circle & divideit into 'slices' equal to number of characteristics , The first slice begins at 12 noon. Then drawvertical line & calibrate it equal to the number of levels required , Draw concentric circles fromeach gradiation using 'o' point as centre



Your Answer Monthly



Correct Answer True

Your Answer False





Correct Answer Approve six sigma projects , Remove road block in the path of six sigma implementation ,Monitor progress of six sigma projects

Your Answer Monitor progress of six sigma projects , Approve six sigma projects , Remove road block inthe path of six sigma implementation

Multiple Choice Multiple AnswerQuestion To draw control charts, sample must be representative of homogeneous segment of

production for which :-Correct Answer The items of the sample should be from the same machine setting , The items should be of

the same batch , Items should be made from the same raw material batchYour Answer The items of the sample should be from the same machine setting , The items should be of

the same batch , Items should be made from the same raw material batch

Multiple Choice Single AnswerQuestion Failure mode and effect analysis (FMEA) establish




Correct Answer Decide level of benchmarking , List down a few prospective candidates of partnership , Collectinformation of short listed partners

Your Answer Decide level of benchmarking , List down a few prospective candidates of partnership , Collectinformation of short listed partners




Multiple Choice Single AnswerQuestion Competitive benchmarking involves identifying key competitive product, services or processes

& comparing with those of :-Correct Answer Main competitor






Select The BlankQuestion Number of defects in an individual component, like gear, shaft, wheel etc can be monitored

through ________ type of control chart.Correct Answer c-chart

Your Answer c-chart

True/FalseQuestion Non-availability of files /document in time is a problem to be addressed by office TPM.

Correct Answer True

Your Answer True




Multiple Choice Single AnswerQuestion Benchmarking helps to identify the gap between the current performance of the organization

and the :-Correct Answer Performance of the best organization




Your Answer True





Select The BlankQuestion A control chart to exhibit counted data on number of defect is called ________.


Your Answer c-chart

Select The BlankQuestion Procedure for implementation of TPM consists of ________ numbers of steps.

Correct Answer 12

Your Answer 8









Your Answer True


Correct Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quick clampingdevice

Your Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quick clampingdevice






Correct Answer Worried about losing jobs , Afraid of being reprimanded if there are mistakes , Scared of theirbosses

Your Answer Worried about losing jobs , Afraid of being reprimanded if there are mistakes , Scared of theirbosses



Your Answer False


Correct Answer Equipment analysis , Setup change analysis , Preparation items (storage place , method)analysis

Your Answer Equipment analysis , Setup change analysis , Preparation items (storage place , method)analysis

True/FalseQuestion Daily work management can also be extended to non manufacturing areas like procurement,

QA, HRD etc.Correct Answer True

Your Answer True







True/FalseQuestion Along with problem solving tools experience and judgment is also used.

Correct Answer True

Your Answer False






Correct Answer True

Your Answer False


Correct Answer Defect in materials , Frequent adjustment of machines , Poorly trained operators


True/FalseQuestion Sample size for the construction of p-chart are larger than X bar-R chart.

Correct Answer True

Your Answer True


Correct Answer It shows cause which affects the process , An idea of what is happening to the process ,Whether the process is capable of meeting process or not i.e. around correct average & withinspecific limits

Your Answer An idea of what is happening to the process , Whether the process is capable of meetingprocess or not i.e. around correct average & within specific limits , A bird's eye view of thevariation




2nd Copy





Multiple Choice Multiple AnswerQuestion Histogram is an important diagnostic tool. Analysis of the histogram gives :-Correct Answer It shows cause which affects the process , An idea of what is happening to the process ,

Whether the process is capable of meeting process or not i.e. around correct average & within specific limitsYour Answer It shows cause which affects the process , An idea of what is happening to the process ,

Whether the process is capable of meeting process or not i.e. around correct average & within specific limits, A bird's eye view of the variation


Select The BlankQuestion Basic objective of control chart is to ________ the variation due to chance & assignable cause.Correct Answer Separate outYour Answer Separate out


inference , It helps to diagnose & localize problem , It helps to identify the influencing factorsYour Answer It helps to separate data into groups so that you can draw connect & meaningful inference ,

It helps to diagnose & localize problem , It helps to identify the influencing factors , Finding out differentreasons




Multiple Choice Single AnswerQuestion In cellular manufacturing system, the cells are designed so that the material flow within the cell

and between the cells are :-Correct Answer MinimizedYour Answer Minimized


parts is carried out at different locations.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Causes of Muda of transport are :-Correct Answer Faulty layout , Over productionYour Answer Faulty layout , Over production , Proper material handling equipment , Low rejection /

rework


Multiple Choice Multiple AnswerQuestion Types of meetings held in DWM are :-Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCA meetingYour Answer Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA meeting

Multiple Choice Multiple AnswerQuestion Customers complaints may be segregated by :-Correct Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantityYour Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity ,

Payment problem

Multiple Choice Multiple AnswerQuestion Cleaning your own area/equipments gives benefits of :-Correct Answer You know your self how to avoid dust , When you touch while cleaning you may find a

fault , Saving of further failure due to dustYour Answer You know your self how to avoid dust , When you touch while cleaning you may find a fault ,

Saving of further failure due to dust , Utilization of spare time

Multiple Choice Multiple AnswerQuestion Role of champions are :-Correct Answer Approve six sigma projects , Remove road block in the path of six sigma implementation

, Monitor progress of six sigma projectsYour Answer Approve six sigma projects , Remove road block in the path of six sigma implementation ,

Monitor progress of six sigma projects , Deliver presentation to teams on six sigma projects

Select The BlankQuestion Benchmarking shows how an organization is ________ in comparison to its competitors.Correct Answer PerformingYour Answer Performing





Multiple Choice Multiple AnswerQuestion Key principles of TQM :-Correct Answer Continuous improvement , People involvement , Cost of qualityYour Answer Continuous improvement , People involvement , Cost of quality , Competitor focus

Select The Blank


Question A histogram is a graphical display of distribution of measurements & reveals the amounts of________ within the process.Correct Answer VariationYour Answer Variation




Multiple Choice Single AnswerQuestion Setting & maintaining optimal process condition to get quality product is the aim of :-Correct Answer Quality maintenanceYour Answer Quality maintenance






Multiple Choice Single AnswerQuestion Recording of the entire setup operators focusing on hand, eye and body movements of the

person doing the setting is done through :-Correct Answer Video recordingYour Answer Video recording


In scatter diagram, the strength of relationship can be determined By "correlation coefficient" By"correlation coefficient"

The scatter diagram provides the technique to establish The possible relationship between a pair ofvariables The possible dependency between a pair of variables

The scatter diagram displays The pair of data as a cloud of points The possible relationship between a pairof variables






Multiple Choice Single AnswerQuestion Allowing worker's to stop machine / assembly line if they believe that product quality is below

standard' is an example of :-Correct Answer EmpowermentYour Answer Empowerment

Multiple Choice Single AnswerQuestion Kanban Signals are required when :-Correct Answer Set up time on the feeding operation is higher then the receiving operation.Your Answer Set up time on the feeding operation is higher then the receiving operation.





Multiple Choice Multiple AnswerQuestion Flow chart is required :-Correct Answer When trying to improve the process , At the time of review of the process , To

understand steps in a process by pictorial presentationYour Answer When trying to improve the process , At the time of review of the process , To understand

steps in a process by pictorial presentation , For defects finding of the products






Select The BlankQuestion Inspection activity for semi finished & finished component should be ________ to reduce muda

of transport .Correct Answer DecentralizedYour Answer Decentralized



3rd Copy



Correct Answer Reduce incoming inspection , Reduce inventory , Lower per unit cost



Correct Answer Minimization of transit damages , Ease in verification of quantity of parts , Automaticsignal to supplier to replenish stock

Your Answer Minimization of transit damages , Ease in verification of quantity of parts , Automaticsignal to supplier to replenish stock





Multiple Choice Single AnswerQuestion Competitive benchmarking involves identifying key competitive product, services or

processes & comparing with those of :-Correct Answer Main competitor



Correct Answer It helps to separate data into groups so that you can draw connect & meaningfulinference , It helps to diagnose & localize problem , It helps to identify the influencingfactors

Your Answer It helps to separate data into groups so that you can draw connect & meaningfulinference , It helps to diagnose & localize problem , Finding out different reasons


Correct Answer Men , Machine , Material


Multiple Choice Single AnswerQuestion The success indicators in quality, cost, delivery & product development are :-

Correct Answer Managing points



Correct Answer Team formation , Training , Recoding of activities on multiple activity charts

Your Answer Team formation , Recoding of activities on multiple activity charts , Convert externalsetups in to internal setups


Correct Answer Time management , Team participation and performance , Moral boosting

Your Answer Time management , Team participation and performance , Cost Management


Correct Answer Use team approach to track down root causes of the problem

Your Answer Maintenance of equipment condition by eliminating lubricant leakage.




Your Answer True


Correct Answer It shows cause which affects the process , An idea of what is happening to the process, Whether the process is capable of meeting process or not i.e. around correct average& within specific limits

Your Answer It shows cause which affects the process , An idea of what is happening to the process, Whether the process is capable of meeting process or not i.e. around correct average& within specific limits







Customer complaints per period Customer complaints per period



Correct Answer Breakdown of machine



Correct Answer Implementation of ideas



Correct Answer Visual control




Correct Answer True

Your Answer False

Select The BlankQuestion The shape of histogram can provide a clue about the ________ of the lot.

Correct Answer Quality




Your Answer Defect


Correct Answer Equal



Correct Answer True

Your Answer False


Correct Answer True

Your Answer True




True/FalseQuestion Customer wise outstanding is discussed in daily work management meeting by

operations head.Correct Answer False

Your Answer True


True/FalseQuestion Number of operation can change according to production requirement in U-Line

arrangement.Correct Answer False

Your Answer True



Your Answer True


Correct Answer 2

Your Answer 1.66

Select The BlankQuestion Range ( R ) is obtained as the difference between the highest and ________

measurement of a sample.Correct Answer Lowest



Correct Answer JIT Contract


True/FalseQuestion U-Line layout is better than straight lime layout.

Correct Answer True

Your Answer True


Correct Answer Marketing, design & manufacturing


Select The Blank


Question Bar graph is display of data that facilitates ________ of quality.

Correct Answer Comparison



Correct Answer P-kanban






Correct Answer Cleaning


Select The BlankQuestion Poka-Yoke devices under category use ________ to distinguish between similar parts

which may be assembled in wrong position.Correct Answer Color coding


Select The BlankQuestion Shitsuke means ________ all the previous 4-S throughout the month/year.

Correct Answer Sustaining



Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCA meeting

Your Answer Weekly PDCA meeting , Monthly PDCA meeting , Yearly PDCA meeting


Correct Answer True


Your Answer True


Correct Answer To develop easy to follow standards , Evolve standard operating procedure , Bettervisual management

Your Answer To develop easy to follow standards , Evolve standard operating procedure , Reductionof wastage



Your Answer True





Correct Answer Unity

Your Answer Six


Correct Answer (x - USL)/3 sigma , (x - LSL)/3 sigma


Select The BlankQuestion A histogram is a graphical display of distribution of measurements & reveals the

amounts of ________ within the process.Correct Answer Variation




To eliminate MUDA of processing To eliminate MUDA of overproduction


To eliminate MUDA of defect



To eliminate MUDA of stock To eliminate MUDA of stock

Flow / string diagram To eliminate MUDA of transport To eliminate MUDA of processing


Correct Answer Relative


4th Copy


True/FalseQuestion Performance benchmarking does not involves comparison of financial ratios at the

aggregate level.Correct Answer False

Your Answer False


Correct Answer Decide on the objective of flowchart & define boundaries of the process , Identify stepsin the process & construct a draft of the flowchart , Review the draft & connect thechanges as per review & name it & put the data & use it as 'Record'

Your Answer Decide on the objective of flowchart & define boundaries of the process , Identify stepsin the process & construct a draft of the flowchart , Review the draft & connect thechanges as per review & name it & put the data & use it as 'Record'


________.Correct Answer Checking






as the value of 'x' increases.Correct Answer Strong negative






Multiple Choice Single AnswerQuestion Poka-yoke for employee not performing work as per established method is :-







Correct Answer Decide level of benchmarking , List down a few prospective candidates of partnership ,Collect information of short listed partners

Your Answer Decide level of benchmarking , Collect information of short listed partners





Correct Answer True

Your Answer True















Correct Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quickclamping device

Your Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quickclamping device





Correct Answer Hyderabad unit of BHEL



Correct Answer Product development , Technology transfer , Environmental Management



Correct Answer Who produce the product


True/FalseQuestion Increase in defect rate is an example of 'Deviation from an established norms'

Correct Answer True


Your Answer True











Correct Answer True

Your Answer True

Select The BlankQuestion ________ waste is probably the biggest waste in most of the organizations.

Correct Answer Time

Your Answer Labor



Your Answer True


Correct Answer True

Your Answer True



Question An erratic patterns falling above & below the control limits indicates :-

Correct Answer Poorly trained operators , Defect in materials , Frequent adjustment of machines



Correct Answer 3.4

Your Answer 6210

Multiple Choice Single AnswerQuestion To provide flexibility to supervisors in allocation of task, JIT emphasizes :-

Correct Answer Multiskilled operators






Correct Answer Control chart



Ideally the histogram will have abell shape



Histogram is a graphical displayof distribution of measurementsand






The shape of histogram can Provide a clue about the qualityof the lot


True/FalseQuestion In single card kanban system production greater than quantity withdrawn is permitted.



Your Answer False

True/FalseQuestion Flow chart are drawn to document a process charting the tasks performed & the

sequence in which tasks are performed.Correct Answer True

Your Answer True


Correct Answer 1.5

Your Answer 1.5

True/FalseQuestion Seiso prevents the potential problems by discovering abnormalities while cleaning your

own area.Correct Answer True

Your Answer True


Correct Answer Define the problem & identify the stratification variables , Sort out data into categories& summarise information in each category , Present the information in graphical form &study, decide if further stratification is required?

Your Answer Define the problem & identify the stratification variables , Sort out data into categories& summarise information in each category , Present the information in graphical form &study, decide if further stratification is required?

True/FalseQuestion Processing cost of a product is mainly decided by conversion process.

Correct Answer True

Your Answer True


Correct Answer Output , Quality , Cost



Correct Answer Reducing process variability , Bringing target & average to fall at the same point ,Examine possibility of relaxing specification


Your Answer Reducing process variability , Bringing target & average to fall at the same point , Useof less precision machine


Correct Answer Express value of each category as percentage of total of all categories & calculate thedegree of angle form by each category by equation degree = Value of groups/Totalvalue * 360 , Draw the circle & segment the circle into angles calculated in step one ,Colour different segments & enter the percentage of each category into pie chart

Your Answer Express value of each category as percentage of total of all categories & calculate thedegree of angle form by each category by equation degree = Value of groups/Totalvalue * 360 , Draw the circle & segment the circle into angles calculated in step one ,Colour different segments & enter the percentage of each category into pie chart


Correct Answer Everyone, clerk to officer does cleaning his area , No sweeper or cleaner employees ,Every family does cleaning of pavement of their residence


Select The BlankQuestion Poka Yoke designed to help operators to know immediately ________ of the defeat

called detection type Poka-Yoke.Correct Answer On occurrence


Select The BlankQuestion Flow chart helps to dissect a process for better understanding & ________ of process.

Correct Answer Analysis



Correct Answer Employees of different department related to the problem





Multiple Choice Single AnswerQuestion Number of Kaizen projects suggested and implemented is checking point for :-


Correct Answer Continual Improvement


5th Copy



Correct Answer Material , Men , Machine



Correct Answer Measure the current pattern & extent of variation , Assess current conformance tospecification & scope of improvement , Determine whether or not the process is in thestate of control

Your Answer Measure the current pattern & extent of variation , Assess current conformance tospecification & scope of improvement , Determine whether or not the process is in thestate of control







Multiple Choice Single AnswerQuestion Identifying key preventive operational functions and comparing these operational

functions within the firm's own division & branches comes under :-Correct Answer Internal benchmarking






Select The BlankQuestion In scatter diagram "________" relationship is said to exist when there is positive

relationship upto certain level & negative thereafter or negative relationship uptocertain level & positive thereafter.




manufacturing at parts is carried out at different locations.Correct Answer True

Your Answer True


Correct Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity

Your Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity

True/FalseQuestion In case of more than one quality characteristics, separate chart is made for each

quality characteristics.Correct Answer True

Your Answer True

True/FalseQuestion Safety, hygiene and environment control is one of the pillar of TPM.

Correct Answer True

Your Answer True

























Parato diagram is a Bar graphwith height or value drawn by

Arranging data in descendingorder






Correct Answer True

Your Answer True

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when value of 'y' somewhat

decreases as the value of 'x' increases.Correct Answer Weak negative


Multiple Choice Single AnswerQuestion From scatter diagram the strength of relationship between two variables or associated

set of data can be inferred from the examination of the shape of :-Correct Answer Cloud

Your Answer Cloud






Correct Answer Collect paired data (X,Y) from two variables who's relationship is to be studied , Findout max & min values for both X & Y and these values to scale X & Y axis & plot thepaired data , Examine the shape of the cloud of points & discover type & strength ofrelationship

Your Answer Collect paired data (X,Y) from two variables who's relationship is to be studied , Findout max & min values for both X & Y and these values to scale X & Y axis & plot thepaired data , Examine the shape of the cloud of points & discover type & strength ofrelationship




Select The BlankQuestion Each quality characteristic has permitted variation & is equal to ________.

Correct Answer USL - LSL





True/FalseQuestion The flow charts are prepared to enhance the employees understanding of the process

by indicating interrelationship within the process.Correct Answer True

Your Answer False

True/FalseQuestion Gap analysis for production & dispatches is discussed in monthly meeting.


Your Answer False



as the value of 'x' increases.Correct Answer Strong negative


Select The BlankQuestion ________ is most difficult 'S' to implement & achieve.




Correct Answer True

Your Answer True








Correct Answer Data should be properly stratified & should be collected for full range , Scale selectedshould be right to avoid wrong conclusions , Data should be free from bias or undueimportance

Your Answer Data should be properly stratified & should be collected for full range , Scale selectedshould be right to avoid wrong conclusions , Data should be free from bias or undueimportance



Your Answer True



Question If 'Annual saving in procurement expenses is managing point', then checking points willbe :-

Correct Answer Price revision , Credit period , Transport expenses







Your Answer False







Select The BlankQuestion Identification of non-value added operations & their elimination is the first step to

eliminate muda of ________.Correct Answer Processing



Correct Answer Relative






True/FalseQuestion In single card kanban system production greater than quantity withdrawn is permitted.


Your Answer False


Correct Answer Improved reliability mean time between failures , Improved maintainability mean time torepair , Improvement in breakdown

Your Answer Improved reliability mean time between failures , Improved maintainability mean time torepair

Multiple Choice Multiple AnswerQuestion Gap analysis & problem identification is done during converting internal setups into

external setups in the areas like :-Correct Answer Equipment , Method , Human











5th Copy


Multiple Choice Multiple AnswerQuestion Advantages of JIT :-Correct Answer Reduce incoming inspection , Reduce inventory , Lower per unit costYour Answer Reduce incoming inspection , Reduce inventory , Lower per unit cost


Multiple Choice Multiple AnswerQuestion Benefits from the standardized containers areCorrect Answer Minimization of transit damages , Ease in verification of quantity of parts , Automatic

signal to supplier to replenish stockYour Answer Minimization of transit damages , Ease in verification of quantity of parts , Automatic

signal to supplier to replenish stock

Multiple Choice Multiple AnswerQuestion Benefits from SMED are :-Correct Answer Reduce work in process , Better average daily production , Increase capacityYour Answer Reduce work in process , Increase capacity

Multiple Choice Single AnswerQuestion Competitive benchmarking involves identifying key competitive product, services or processes

& comparing with those of :-Correct Answer Main competitorYour Answer Main competitor


inference , It helps to diagnose & localize problem , It helps to identify the influencing factorsYour Answer It helps to separate data into groups so that you can draw connect & meaningful

inference , It helps to diagnose & localize problem , Finding out different reasons

Multiple Choice Multiple AnswerQuestion Quality maintenance & pillar focuses on following production inputs :-Correct Answer Men , Machine , MaterialYour Answer Men , Machine , Management

Multiple Choice Single AnswerQuestion The success indicators in quality, cost, delivery & product development are :-Correct Answer Managing pointsYour Answer Accountability

Multiple Choice Multiple AnswerQuestion Steps in setup time reduction are :-Correct Answer Team formation , Training , Recoding of activities on multiple activity chartsYour Answer Team formation , Recoding of activities on multiple activity charts , Convert external

setups in to internal setups

Multiple Choice Multiple AnswerQuestion POM essentially consists of :-Correct Answer Time management , Team participation and performance , Moral boostingYour Answer Time management , Team participation and performance , Cost Management

Multiple Choice Single AnswerQuestion Activity under quality management is :-Correct Answer Use team approach to track down root causes of the problemYour Answer Maintenance of equipment condition by eliminating lubricant leakage.

True/FalseQuestion Every department should make their own rules of standardization.Correct Answer FalseYour Answer True



Question Histogram is an important diagnostic tool. Analysis of the histogram gives :-Correct Answer It shows cause which affects the process , An idea of what is happening to the process

, Whether the process is capable of meeting process or not i.e. around correct average & within specificlimitsYour Answer It shows cause which affects the process , An idea of what is happening to the process

, Whether the process is capable of meeting process or not i.e. around correct average & within specificlimits


Productivity performance measurement Turnover employee Sales of the months

Financial performance measurement Sales of the months Cash saving per department

Customer satisfaction measurement Customer complaints per period Customer complaints perperiod




Select The BlankQuestion Create as many ________ system as possible for better Seiketsu.Correct Answer Visual controlYour Answer Visual control

True/FalseQuestion Inadequate maintenance of machine leads to muda of defectsCorrect Answer TrueYour Answer False

Select The BlankQuestion The shape of histogram can provide a clue about the ________ of the lot.Correct Answer QualityYour Answer Distribution





Correct Answer TrueYour Answer False



True/FalseQuestion Customer wise outstanding is discussed in daily work management meeting by operations

head.Correct Answer FalseYour Answer True

True/FalseQuestion Number of operation can change according to production requirement in U-Line arrangement.Correct Answer FalseYour Answer True

True/FalseQuestion Automation can correct the basic faults of a improper setup process.Correct Answer FalseYour Answer True


Select The BlankQuestion Range ( R ) is obtained as the difference between the highest and ________ measurement of

a sample.Correct Answer LowestYour Answer Second highest

Select The BlankQuestion ________is an important step toward successful JIT purchasing.Correct Answer JIT ContractYour Answer JIT Contract



Select The BlankQuestion Bar graph is display of data that facilitates ________ of quality.Correct Answer Comparison



Multiple Choice Single AnswerQuestion Production kanban is presented by :-Correct Answer P-kanbanYour Answer R-kanban


Select The BlankQuestion Japanese believe that when they are ________ they are cleaning there minds too.Correct Answer CleaningYour Answer Repairing machines

Select The BlankQuestion Poka-Yoke devices under category use ________ to distinguish between similar parts which

may be assembled in wrong position.Correct Answer Color codingYour Answer Counting device

Select The BlankQuestion Shitsuke means ________ all the previous 4-S throughout the month/year.Correct Answer SustainingYour Answer Implementing

Multiple Choice Multiple AnswerQuestion Types of meetings held in DWM are :-Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCA meetingYour Answer Weekly PDCA meeting , Monthly PDCA meeting , Yearly PDCA meeting

True/FalseQuestion By TPM, consumption of electrical energy can be reduced.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion According to Seiketsu Standardization means :-Correct Answer To develop easy to follow standards , Evolve standard operating procedure , Better

visual managementYour Answer To develop easy to follow standards , Evolve standard operating procedure , Reduction

of wastage



Multiple Choice Single AnswerQuestion Total area under the normal curve isCorrect Answer Unity


Your Answer Six


Select The BlankQuestion A histogram is a graphical display of distribution of measurements & reveals the amounts of

________ within the process.Correct Answer VariationYour Answer Percentage defects


Value analysis / value engineering To eliminate MUDA of processing To eliminate MUDA of overproduction

SMED To eliminate MUDA of over production To eliminate MUDA of defect

VMI ( Vendor Management Inventory) system To eliminate MUDA of stock To eliminate MUDA of stock

Flow / string diagramTo eliminate MUDA of transport To eliminate MUDA of processing

Select The BlankQuestion A 'Radar chart' is used to portray ________ strength or weakness of the activity.Correct Answer RelativeYour Answer Comparative

------------------------------------------------------------



level.Correct Answer FalseYour Answer False

Multiple Choice Multiple AnswerQuestion Few steps to construct a flow chart are :-Correct Answer Decide on the objective of flowchart & define boundaries of the process , Identify steps

in the process & construct a draft of the flowchart , Review the draft & connect the changes as per review &name it & put the data & use it as 'Record'Your Answer Decide on the objective of flowchart & define boundaries of the process , Identify steps

in the process & construct a draft of the flowchart , Review the draft & connect the changes as per review &name it & put the data & use it as 'Record'

Select The BlankQuestion In PDCA cycle for benchmarking 'Identification of performance gap' is done in ________.Correct Answer CheckingYour Answer Checking

Select The Blank


Question 5 S audit result is discussed in ________ meeting.Correct Answer MonthlyYour Answer Shift beginning

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when value of 'y' decreases as the

value of 'x' increases.Correct Answer Strong negativeYour Answer Strong negative


Multiple Choice Single AnswerQuestion Poka-yoke for employee not performing work as per established method is :-Correct Answer Implement work standardYour Answer Implement work standard


Multiple Choice Multiple AnswerQuestion What are the steps in deciding the benchmarking partner?Correct Answer Decide level of benchmarking , List down a few prospective candidates of partnership ,

Collect information of short listed partnersYour Answer Decide level of benchmarking , Collect information of short listed partners




Reduce clamping & declamping time Use U-shaped washer Use U-shaped washer

Reduce time of external setup Improve work aids positioning method Improve work aids positioningmethod

Convert internal setup into external setup Preparation of tools / dies as off line activity Preparation oftools / dies as off line activity

Eliminate adjustmentPre setting of tool Pre setting of tool

Multiple Choice Single AnswerQuestion Muda of defect is very serious in case of:-Correct Answer High speed automatic machines



Multiple Choice Multiple AnswerQuestion To reduce clamping & declamping time, following actions are desirable :-Correct Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quick

clamping deviceYour Answer Standardize clamping bolts / screws , Cut off unnecessary threads , Use quick

clamping device



Multiple Choice Multiple AnswerQuestion 3M' is world class benchmarking ' candidates in the field of :-Correct Answer Product development , Technology transfer , Environmental ManagementYour Answer Product development , Technology transfer , Environmental Management


True/FalseQuestion Increase in defect rate is an example of 'Deviation from an established norms'Correct Answer TrueYour Answer True

Select The BlankQuestion ________ are implemented for defect detection & prevention.Correct Answer Poka-YokesYour Answer Poka-Yokes



True/FalseQuestion Presentation of graphs in pictorial form of data collection are for easy understanding.Correct Answer TrueYour Answer True

Select The BlankQuestion ________ waste is probably the biggest waste in most of the organizations.Correct Answer TimeYour Answer Labor



& more competitive and customer driven.Correct Answer TrueYour Answer True


Multiple Choice Multiple AnswerQuestion An erratic patterns falling above & below the control limits indicates :-Correct Answer Poorly trained operators , Defect in materials , Frequent adjustment of machinesYour Answer Defect in materials , Frequent adjustment of machines , Poorly trained operators

Multiple Choice Single AnswerQuestion Defects per million for the process at six sigma level are :-Correct Answer 3.4Your Answer 6210

Multiple Choice Single AnswerQuestion To provide flexibility to supervisors in allocation of task, JIT emphasizes :-Correct Answer Multiskilled operatorsYour Answer Multiskilled operators


Select The BlankQuestion ________ should be used to exercise control on the process.Correct Answer Control chartYour Answer Latest checking instruments


Ideally the histogram will have a bell shape Tapering away on the both sides from average valueTapering away on the both sides from average value

Histogram is a graphical display of distribution of measurements and Reveals the amount of variationwithin the process Reveals the amount of variation within the process

Histogram is a diagrammatic presentation of The frequency distribution of a characteristics Thefrequency distribution of a characteristics

The shape of histogram can Provide a clue about the quality of the lot Provide a clue about the quality ofthe lot

True/FalseQuestion In single card kanban system production greater than quantity withdrawn is permitted.Correct Answer FalseYour Answer False


True/FalseQuestion Flow chart are drawn to document a process charting the tasks performed & the sequence in

which tasks are performed.Correct Answer TrueYour Answer True


True/FalseQuestion Seiso prevents the potential problems by discovering abnormalities while cleaning your own

area.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Some steps for stratification are :-Correct Answer Define the problem & identify the stratification variables , Sort out data into categories

& summarise information in each category , Present the information in graphical form & study, decide iffurther stratification is required?Your Answer Define the problem & identify the stratification variables , Sort out data into categories

& summarise information in each category , Present the information in graphical form & study, decide iffurther stratification is required?

True/FalseQuestion Processing cost of a product is mainly decided by conversion process.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Work standards enable management to minimize variation in :-Correct Answer Output , Quality , CostYour Answer Output , Quality , Cost

Multiple Choice Multiple AnswerQuestion Process can be made capable by :-Correct Answer Reducing process variability , Bringing target & average to fall at the same point ,

Examine possibility of relaxing specificationYour Answer Reducing process variability , Bringing target & average to fall at the same point , Use

of less precision machine

Multiple Choice Multiple AnswerQuestion Few steps in construction of Pie chart are :-Correct Answer Express value of each category as percentage of total of all categories & calculate the

degree of angle form by each category by equation degree = Value of groups/Total value * 360 , Draw thecircle & segment the circle into angles calculated in step one , Colour different segments & enter thepercentage of each category into pie chartYour Answer Express value of each category as percentage of total of all categories & calculate the

degree of angle form by each category by equation degree = Value of groups/Total value * 360 , Draw thecircle & segment the circle into angles calculated in step one , Colour different segments & enter thepercentage of each category into pie chart

Multiple Choice Multiple AnswerQuestion As benchmark in Japan seiso activities means :-Correct Answer Everyone, clerk to officer does cleaning his area , No sweeper or cleaner employees ,

Every family does cleaning of pavement of their residence



Select The BlankQuestion Poka Yoke designed to help operators to know immediately ________ of the defeat called

detection type Poka-Yoke.Correct Answer On occurrenceYour Answer Before Occurrence

Select The BlankQuestion Flow chart helps to dissect a process for better understanding & ________ of process.Correct Answer AnalysisYour Answer Analysis

Multiple Choice Single AnswerQuestion Small groups forming a circle should consist of :-Correct Answer Employees of different department related to the problemYour Answer Employees of same department

Select The BlankQuestion Graphs convey a situation more ________ than summary of data or figures.Correct Answer Effectively & clearlyYour Answer Effectively & clearly

Multiple Choice Single AnswerQuestion Number of Kaizen projects suggested and implemented is checking point for :-Correct Answer Continual ImprovementYour Answer Continual Improvement

--------------------------------------------------------------------


Multiple Choice Multiple AnswerQuestion Quality maintenance & pillar focuses on following production inputs :-Correct Answer Material , Men , MachineYour Answer Material , Men , Machine

Multiple Choice Multiple AnswerQuestion Histograms are useful to :-Correct Answer Measure the current pattern & extent of variation , Assess current conformance to

specification & scope of improvement , Determine whether or not the process is in the state of controlYour Answer Measure the current pattern & extent of variation , Assess current conformance to

specification & scope of improvement , Determine whether or not the process is in the state of control





Question Identifying key preventive operational functions and comparing these operational functionswithin the firm's own division & branches comes under :-Correct Answer Internal benchmarkingYour Answer Internal benchmarking


________.Correct Answer Over ProductionYour Answer Over Production

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when there is positive relationship

upto certain level & negative thereafter or negative relationship upto certain level & positive thereafter.Correct Answer CurvilinearYour Answer Curvilinear


parts is carried out at different locations.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion Customers complaints may be segregated by :-Correct Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantityYour Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity

True/FalseQuestion In case of more than one quality characteristics, separate chart is made for each quality

characteristics.Correct Answer TrueYour Answer True




Reduce time of external setup Improve work aids positioning method Improve work aids positioningmethod

Convert internal setup into external setup Preparation of tools / dies as off line activity Preparation oftools / dies as off line activity

Eliminate adjustmentPre setting of tool Pre setting of tool

Reduce clamping & declamping time Use U-shaped washer Use U-shaped washer




Parato diagram always indicates Magnitude of defects Philosophy of 20% of the activity causes 80% ofthe effect

Parato analysis underlines & operates on Philosophy of "vital few:trivial many" Philosophy of "vitalfew:trivial many"

Parato analysis is technique of identifying vital causes byArranging data according to the descending orderof their frequency of occurrence Arranging data according to the descending order of their frequency ofoccurrence

Parato diagram is a Bar graph with height or value drawn by Arranging data in descending orderMagnitude of defects


True/FalseQuestion Pie chart is also called as angular diagram.Correct Answer TrueYour Answer True

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when value of 'y' somewhat

decreases as the value of 'x' increases.Correct Answer Weak negativeYour Answer Weak negative

Multiple Choice Single AnswerQuestion From scatter diagram the strength of relationship between two variables or associated set of

data can be inferred from the examination of the shape of :-Correct Answer CloudYour Answer Cloud

Multiple Choice Multiple AnswerQuestion Product benchmarking requires, comparison of product :-Correct Answer Performance , Features , CostYour Answer Performance , Features , Cost

Multiple Choice Multiple AnswerQuestion Steps in construction of scatter diagram :-Correct Answer Collect paired data (X,Y) from two variables who's relationship is to be studied , Find

out max & min values for both X & Y and these values to scale X & Y axis & plot the paired data , Examinethe shape of the cloud of points & discover type & strength of relationshipYour Answer Collect paired data (X,Y) from two variables who's relationship is to be studied , Find

out max & min values for both X & Y and these values to scale X & Y axis & plot the paired data , Examinethe shape of the cloud of points & discover type & strength of relationship



Select The BlankQuestion Each quality characteristic has permitted variation & is equal to ________.Correct Answer USL - LSLYour Answer USL - LSL

Select The BlankQuestion Kaizen is ________ supported process.Correct Answer ManagementYour Answer Management

True/FalseQuestion The flow charts are prepared to enhance the employees understanding of the process by

indicating interrelationship within the process.Correct Answer TrueYour Answer False

True/FalseQuestion Gap analysis for production & dispatches is discussed in monthly meeting.Correct Answer FalseYour Answer False

Select The BlankQuestion In scatter diagram "________" relationship is said to exist when value of 'y' decreases as the

value of 'x' increases.Correct Answer Strong negativeYour Answer Strong negative


True/FalseQuestion Presentation of graphs in pictorial form of data collection are for easy understanding.Correct Answer TrueYour Answer True

Select The BlankQuestion Graphs convey a situation more ________ than summary of data or figures.Correct Answer Effectively & clearlyYour Answer Effectively & clearly

Multiple Choice Single AnswerQuestion Errors by armatures is :-Correct Answer Lack of experienceYour Answer Lack of experience

Multiple Choice Multiple AnswerQuestion While preparing scatter diagram following precautions are to be taken :-Correct Answer Data should be properly stratified & should be collected for full range , Scale selected

should be right to avoid wrong conclusions , Data should be free from bias or undue importanceYour Answer Data should be properly stratified & should be collected for full range , Scale selected

should be right to avoid wrong conclusions , Data should be free from bias or undue importance



& more competitive and customer driven.Correct Answer TrueYour Answer True

Multiple Choice Multiple AnswerQuestion If 'Annual saving in procurement expenses is managing point', then checking points will be :-Correct Answer Price revision , Credit period , Transport expensesYour Answer Price revision , Credit period , Transport expenses


True/FalseQuestion Flow chart is pictorial representation of the steps in production control.Correct Answer FalseYour Answer False

Multiple Choice Single AnswerQuestion It is essential to convey customer's expectations to :-Correct Answer Top ManagementYour Answer Supervisors & workmen


Select The BlankQuestion Identification of non-value added operations & their elimination is the first step to eliminate

muda of ________.Correct Answer ProcessingYour Answer Processing

Select The BlankQuestion A 'Radar chart' is used to portray ________ strength or weakness of the activity.Correct Answer RelativeYour Answer Relative


True/FalseQuestion In single card kanban system production greater than quantity withdrawn is permitted.Correct Answer FalseYour Answer False

Multiple Choice Multiple AnswerQuestion Benefits of planned maintenance are :-Correct Answer Improved reliability mean time between failures , Improved maintainability mean time

to repair , Improvement in breakdown


Your Answer Improved reliability mean time between failures , Improved maintainability mean timeto repair

Multiple Choice Multiple AnswerQuestion Gap analysis & problem identification is done during converting internal setups into external

setups in the areas like :-Correct Answer Equipment , Method , HumanYour Answer Equipment , Method , Human

Multiple Choice Single AnswerQuestion Some quantity in stock of item, is desirable if :-Correct Answer Manufacturing lead time is moreYour Answer Manufacturing lead time is more


Multiple Choice Multiple AnswerQuestion Benefits of Quality maintenance are :-Correct Answer Reduction in customer quality complaints , Reduction in inspection timeYour Answer Reduction in customer quality complaints , Reduction in inspection time

6th Copy

1) What are the basics steps in the problem solving process? Explain them briefly.Ans:INTRODUCTION: Systematic problem solving provides a structured approach toproblem solving. Depending upon the nature of problem (i.e. maintenance orimprovement problem), some steps may be different.

SOLVING A MAINTENANCE PROBLEM: Maintenance problems as mentionedearlier, surface when the status quo is distributed and decision make needs torecommend/take measures to restore and maintain the status quo.

Fig: Steps to solve a maintenance problem.

(a) Diagnose (define) the problem:Sound diagnosis is the crucial step in the problem solving process. Defining the problemsets the boundaries for that follows. Decision maker, like a doctor, must take into accountall symptoms before prescribing the medicines (i.e. recommending the decision). PeterDrucker rightly states, “The books and articles on leadership are full of advice on how tomake fast, forceful and useful decisions, but there is no more foolish and no more timewasting advice than to decide quickly what a problem really is. Defining the problem inmost instances is a time-consuming task, but it is time well spent.”

Identify a maintenance problem

Collect data on “causes”

Perform Pareto Analysis

Identify root causes

Evolve alternatives & select(Brain storming)

Implement best alternative

Monitor effect

Is the problemresolved?

End

No

Sound diagnosis requires

(i) Measurement of the gap between the desired performance and the actualperformance.

(ii) Identification of the root cause for the gap.

(iii) Identification of the restraints in the decision making process.

(b) Secure and analyse pertinent facts:Once the problem has been diagnosed (defined), the next step is to collect data. Datacollection implies collecting background material, pertinent facts, decision taken in thepast and their outcome, previous solutions to similar problems etc.

General rules are:

(i) The information should be collected from the most reliable source.

(ii) All relevant facts, regardless of how disorganized or unrelated they seem atthe time of data gathering, should be recorded.

(iii) The information should be subjected to checks and cross checks. Theconflicting data must be resolved. The temptation to accept first response toinquiries should be avoided.

(iv) The facts wherever possible should be supported by tangible evidence in theform of copies of the appropriate documents. Facts when cannot be supportedby documentary evidence (i.e. facts which are bases on opinion of theindividuals) should carry the names of the contributors so that they(individuals) can be contacted later if required.

Facts are next analysed to establish:

(i) The length of time to which the decision should apply.(ii) Effect of the decision on other functional areas.(iii) Qualitative considerations to take overall view of the business.

(c) Develop alternative solutions:This step concerns looking for the possible solutions and listing them down. Mostcommon sources of collecting and listing of alternatives include experience, superiors,juniors, consultants, research, creativity, brain storming, critical examination, literatureetc.

It is also the most important step and therefore good amount of time, effort and moneyshould be spent /invested to get good alternative solutions.

Generally, for every problem, alternative solutions exist and efforts need to put to unearththese alternatives. Usually, a brain storming or interaction session with those, concernedwith the problem can highlight several alternatives. For example, the company wasconsidering purchase of a CNC machine. The general manager held a series of brainstorming session of his engineers and following alternatives got identified:

(a) continue to make the part by present method, or

(b) buy the proposed CNC machine, or

(c) buy a machine other than the proposed one, or

(d) improvise the current method of making part (e.g retrofitting the existingmachine improves tooling and gauging method etc.), or

(e) subcontract CNC – compatible operations to a good quality vendor, or

(f) discontinue manufacturing the part at company’s own plant and buy thepart from an outside source.

After evaluating all the alternatives for their merits and demerits, the general manageropted for alternatives ‘d’, ‘e’ and ‘f’ and got the best results.

(d) Evaluate alternatives:Once all the alternative solutions have been enumerated, they are next evaluated. This isusually done by testing each alternative against a set of objectives or specified criteriawhich the solution must meet. The steps involved are:

(i) Each alternative is analysed to see whether or not it meets the “must”objectives. An alternative which does not meet the “must” objective isimmediately removed from further study.

(ii) Alternatives which meet the “must” objectives are next checked for “want”objectives and those which are good in terms of “want” objectives areexamined for adverse consequences. Since each alternative usually entailssome risk, the decision maker next assesses the risk, the probability of risk,the probability or risk, and /or seriousness of the risk.

(iii) Every attempt is made to eliminate or minimize risk (or disadvantages). Tchart analysis is usually helpful.

(iv) Alternatives are next weighed for their effectiveness by identifying their longterm and short term consequences. The advantages of the alternatives arequantified in terms of common denominator, usually the money.

(e) Select the best alternative:

The alternative cleared at the evaluation stage are ranked according to their worth. Finalselection is then made of the alternative which provides the maximum advantages whileentailing acceptance risk (i.e. the alternative that best meets the solution criteria isselected)

(f) Implement the selected decision:Once the final choice has been made the next step is to implement the decision andfollow up for verification of the consequences (or effect of the decision)

Though the steps mentioned above are sequential and separate but usually there isrecycling among the steps. For example, while trying to evaluate alternatives, thedecision maker may have to ho back to data collection step if he finds that he does nothave all the information.

STEPS FOR SOLVING AN IMPROVEMENT PROBLEM:

The Japanese have provided a structured methodology for solving “improvement”problem. The methodology is also known as QC story and it comprises of the followingsix steps based on famous Deming Plan-Do-Check-Act (PDCA) cycle.

Fig: Steps to solve an improvement problem

Define improvement problem

Measure current status

Decide on desired level

Find gap in performance

Set Target

Prepare action plan(counter measure)

Implement countermeasure

Measure /analyseachievement

Satisfactoryperformance?

New target

Stabilize/standardize (SDCA)

Maintain status quo

End

Plan (P)

Do (D)

Check (C)

No

Yes

No

Yes

2. (a) What is “Cause and effect” diagram? How is it useful in analyzing a problem?How is it constructed?Ans: INTRODUCTION: Every organization has contributory causes. The causes need tobe identified to eliminate problems or minimize the effect of the problems. All causesincluding probable causes (i.e. which have not occurred earlier) should be identified sothat preventive action can be taken (After all, prevention is better than cure)

After the causes have been identified, they should be put into a systematic form thatfacilitates presentation and analysis.

Cause and effect diagram is also called as “Ishikawa Diagram” or a fishbone diagram(due to its shape) – an effective tool for diagnosis to a problem – was developed by Dr.Kaoru Ishikawa, a professor of Tokyo University.

The diagram lists out in a classified and systematic manner all causes which areresponsible for the problem (called effect). The diagram consists of a main line torepresent the actual problem and few lines to represent the major causes – materials, men,methods and machines – and horizontal or slanting arrows to represent sub-causes undrelying each main cause.

Procedure:

Step1 : Specify the problem to be solvedFor eg:

(i) Accidents(ii) Process defectives(iii) Employer – employee relations(iv) Delayed delivery(v) Defective bills(vi) Labour efficiency

Step2: Brain storm to find all possible causes of the problem.

Step3: Organize/ arrange these causes in few major themes (i.e. rational categories)

Step4: Construct a cause and effect diagram that accurately displays the relationship ofall data in each category. Steps in the construction of the diagram are as follows:

(a) Draw a box on the far right hand side of a large sheet of paper and write inside thebox the description of the problem to be solved. Also draw a thick arrow thatpoints to the box and look up on this as a main trunk of a tree.

Problem

(b) Enter the titles of the categories (also called themes) above and below thehorizontal line and connect them to horizontal line by vertical or standing arrows.Think of these as branches of the main truck of the tree.

(c) Enter the detailed cause data for each category / theme by arrows meeting thehorizontal or slanting lines (i.e. lines representing the main theme). Look uponthese as limbs or twigs of the branches.

(d) Review diagram drawn above to ensure that no cause has been missed.

Problem

Man Machine

Method Materials

Cause A

Cause B

Cause B

Cause D

Cause A

Cause C

Cause A

Cause C

Cause A

Cause C

Cause C

Cause B Cause B

Cause D

Problem

Man Machine

MaterialsMethod

A cross function team constituted to study problem of employees’ poor morale haveconducted on following probable causes. Draw a “cause and effect” diagram fromthe given data…Ans:


Lack of communication

Improper management training

EMPLOYEE

HIRING REWARD/RECOGNITION

MANAGEMENT WORKING CONDITIONS

Poor selection

Incomplete job description

Recruiting errors


Low pay level

Wage differentials

Poor benefits

Favoritism

Lack of discipline methods

Public reprimands

Unclear company goals

Faulty working assignment

Bad Lighting

Noise

Temperature

Long working hours

Excessive Criticism

3. a) What is Pie-Chart? How is it constructed?Ans: INTRODUCTION: Pie chart is also called an angular diagram. It is the graph ofpercentage breakdown of data.

Steps in Construction of a PIE CHART:

i. Express value of each category of component group as a percentage of total ofall categories or components or groups.

ii. Calculate degree of the angle formed by each category/component/group asunder

Degree of particular category = Value of the group X 360Total Value

iii. Draw a circle of a suitable diameter (say diameter of 3”)iv. Segment the circle into angles calculated in step 2 with the help of a protractor

v. Shade or color different segments suitable to make distinction betweendifferent categories.

vi. Enter the percentage of each category in to the pie chart.

b) Draw a Pie Chart to represent the following population in a village.

Males Females Girls Boys Total2000 1800 4200 2000 10000

Sol:

S.No Gender Population Population % Degree1. Males 2000 20% 72o

2. Females 1800 18% 64.8o

3. Girls 4200 42% 151.2o

4. Boys 2000 20% 72o

Total 10000 100%

POPULATION

Girls42%

Females18%

Males20%

Boys20%

Males Females Girls Boys

4. a) What is Pareto’s analysis? How is it used for problem solving?Ans: Introduction: Every problem is the result of few causes and all causes are notequally important. Some causes are more significant than others. Pareto’s analysisunderlines and operates his philosophy of “vital few: trivial many”. It is a technique ofidentifying vital causes by arranging the data according to the descending order of theirfrequency of occurrence.

Pareto’s diagram is the outcome of the study conducted by Vilfredo Pareto to study thephenomenon of wealth in his country. Pareto observed that in his native country 80% ofthe wealth was held by 20% of the population. He eventually realized that he haddiscovered a universal law – around 20% of the activity causes 80% of the effect.

For Example: 80% to 90% of the Italy’s wealth lay in the hands of 10% to 20% of the

population. 80% of the accidents occur on 20% of the roads (i.e. some roads are more

dangerous than others) 80% of the shopping that takes place is done in 20% of the time of the store are

open.(i.e. people try to shop at the same time). 80% of the absenteeism in a company is generally on account of 20% of the work

force. 20% of the machines are responsible for 80% of the total down time. 20% of the end products generate 80% of sales revenue. 20% of the clerks make 80% of the clerical errors. 20% of the employees create 80% of the troubles.

20% of the customers are responsible for 80% of the bad debts. 20% of the total items in the stock account for 80% of the annual expenditure on

materials.

U.S Economist M.C. Lorenz presented this lop sided distribution in the form oftheoretical curve, called Lorenz’s curve. Dr. J. M. Juran observed similar phenomenon inmany other fields including quality. He names this phenomenon as Pareto Analysis inhonor of the originator of the concept.

We need to follow few steps in order to solve the problems using Pareto’s Chart. Theyare listed as follows:

1) Select the problem and identify causes into a handful of categories. For example,for a problem of “late coming to works”, possible categories of causes may beheavy traffic oversleeping, sickness, vehicle problem, family problem etc.

2) Select the standard unit for measurement (e.g. frequency, cost, sales etc.)3) Select the time period over which data will be collected (e.g. 8 hours, 5 days, 2

weeks, etc.)4) Collect necessary data on each category and summarize results.

It is generally convenient to create a three-column-table having heading as “errorcategory”. “frequency (or cost)”, and “percentage of total”. This information canbe directly taken from the check sheet.

5) Rearrange the data in the descending order of the frequency or cost.6) Organize the Pareto’s chart

(a) Draw two vertical axis, one on either side of a horizontal side axis (leavingenough space on the horizontal axis to list the problem categories). Markthe frequency of occurrence of the problem along left vertical axis andpercentage along right vertical axis.

(b) Divide the horizontal axis into intervals equal to the number of categories.(c) List down the categories from left to right in their order of decreasing

frequency or cost.(d) Construct a bar or rectangle above each category with height equal to

frequency or cost.

7) Draw the cumulative line /curve (Pareto’s curve) by plotting each point at theright hand corner of each bar and them connecting these points.

8) Write all necessary information concerning the diagram.

b) Shrivastive, an administrative officer, working with Dattatreya Chemicals Ltd.has been receiving frequent complaints from internal customers regarding late andwrong receipt of mail delivered by his department. In order to correct the problem,he called a meeting of a small group of his internal customers and with their helpidentified five error categories, namely mail behind schedule, wrong deliveries, andlate delivery of outgoing mail to post office, rude clerks and incorrect charges.

The administrative officer then started tracking complaints. The data collected byhim in a 30-day span in the form of a check-sheet reproduced below.

Error Category Tally Mark FrequencyBehind schedule mail lllll ll 7Wrong delivery of mail lllll lllll lllll 20Late delivery of outgoing mail to P.O lllll lllll ll 12Rude clerks l 1Incorrect charges lllll 5

Total 45Draw a Pareto’s Chart.Sol:

1. Collect the data concerning the problem under study.2. Rearrange the data in the descending order.

Error Category Frequency %of Error to total Cumulative%Wrong delivery of mail 20 44.44 44.44Late delivery… 12 26.67 72.1Behind schedule mail 7 15.55 86.65Incorrect charges 5 11.11 97.76Rude clerks 1 2.22 100.00

PARETO's DIAGRAM

2012 7 5 1

44.44

26.6715.55 11.11

2.22

44.44

72.1

86.6597.76 100

0

20

40

60

80

100

120

0 2 4 6

Frequency

%of Error to total

Cumulative%

Log. (Cumulative%)

5. What are the quality circles? How are they formed? Explain briefly theorganization of quality circles.Ans:Introduction: Quality circle is basically a small group of employees – who volunteer tomeet regularly to undertake work related projects – quality, productivity, safety,efficiency, cost, working conditions, etc., - and evolve recommendations to improveeffectiveness in the selected functional area.

The size of quality circle is important. Too big a size 9 (too many members) may notprovide enough time to each member to effectively participate and too small a size maymake a circle dormant. An ideal size of the circle is eight to ten members but in any caseit should not exceed fifteen members.

More than one circle may be formed if too many employees in a particular work area arewilling to participate in the quality circle activities. For example, if there are 25 clerks inthe organization doing identical jobs, 2 to 3 circles may be formed.

Participation in the circle activities is absolutely voluntary. Members are not selected/nominated. They are not elected or rotated either. Employees, however, are encouragedto form circles.Ideally, members of a particular circle should be from the same area or who do similarwork so that problems that they select /analyse / discuss will be familiar to all of them.

Brief History: Japanese Union of Scientists and Engineers (JUSE) was established in1946 after the World War II in which Japanese industries were completely destroyed.JUSE worked for growth and development of quality and in 1950 it invited Dr. EdwardDeming, a renowned American expert on quality to visit Japan. Dr. Deming delivered aseries of lectures on various aspects of quality control to the top management of severalcompanies of Japan.These circles have lifted war-ravaged Japan to its present dominant position and haveendangered even the very existence of American industry. A quality circle in Japan onthe average saves $56, 000. All this is achieved without any monetary incentives. Around25% of the profitability of the Japanese industries is attributed to the quality circles.Nissan motor, for example works with 57,000 employees, has 4,200 quality circles whichhave helped the company to double its productivity in ten years.

Quality circles in India were first launched in the Hyderabad unit of BHEL in 1980 whichhas now around 100 quality circles in its various branches throughout India. Qualitycircles forum of India was formed in 1982 to propagate concept. The concept of qualitycircles is gaining momentum and quite a few firms in the private and public sector –Kirloskars, Alwayns, Tata’s, H.A., Bharat Forge, Balaji Auto, Vulcan Laval, RourkelaSteel plant etc., have instituted quality circles.

Organization for quality circles: The Organization of circles consists of:

i. Steering Committee: Steering committee is the apex body at the highest level

of the plant which is made up of heads of the major departments likeProduction, Finance, Materials, Marketing, Engineering, Quality Assurance,etc, and is headed by the Chief Executive of the plant. The committee meetperiodically and it-o Evolves policies and guidelines for the formation, functioning and growth

of quality circles.o Appoints facilitators and a co-coordinator.o Identifies overall quality and productivity problems in the organization.o Authorizes budget for quality circle activitieso Takes part in top management presentation and annual get-togetherso Demonstrates, in visible manner, management commitment and supporto Reviews performance of the quality circles regularly on the basis of

reports from the coordinator and facilitators.o Evolves guidelines for recognizing the good performance of quality

circles.

The head of the Quality Assurance department takes the responsibility of convening themeeting of the committee.

ii. Facilitators: The facilitators are selected by the steering committee tosupervise the activities of two, three or more circles. Facilitator is usually asenior officer nominated by the management who is incharge of shop ordepartment. The facilitator acts as a teacher, a promoter, a catalyst, and aguide to the quality circles. The responsibilities of the facilitators include:o To co-ordinate the activities of quality circles under their supervision and

guidanceo To train QC leaders and lend help in training QC members.o To interface between circleso To render support and assistance to the circles under his control.o To encourage employees to form more QC’so To demonstrate support of the management.

iii. Leaders: A leader acts as an integral part of the quality circle. The leadersshould have good knowledge of statistical methods and approaches to be usedto identify and analysis problems. The leaders also, like other regularmembers, participate in the discussions. The leader should preferably be thefirst line supervisor but it not essential. Supervisors taking over the task ofleaders ensure some leadership quality inputs are already available.

Responsibilities of the leader are:o To conduct training of members of the circle with the help of facilitator

and other agencies.o To prepare agenda for the meetings.o To organize and conduct meetingo To evolve action plans and milestone charts to compare actual progress

with targets by periodic reviews and take mid-course correction.

o To assign roles to members and to guide them for effective contributiontowards the achievement of goals.

o To ensure participation and involvement of all members in the activities ofthe circle.

o To ensure records and liaison with other agencies to obtain help in solvingthe problem

o To catalyse attitudinal changes in his own and other related areas.o To make management presentationso To take sincere interest individually by active involvement in the progress

of quality circle movement.o To endeavour to promote quality circles as a way of life in the

organization.

iv. Members: Members form hard core of the quality circles; Members areselected on “purely voluntarily basis” and are from the same or similarfunctional areas. The group should basically be small, between 8 to 10members. The members should have adequate education and experience in theconcerned field and should have the ability to express clearly and freely.

v. Co-ordinator: In a large manufacturing organization, some agency – usuallyQuality Assurance – is required to co-ordinate the activities of the qualitycircles. The responsibility of the coordinating department includes:o Rendering assistance as request by circleso Disseminating literature relating to circle activities elsewhereo Organizing training programmeso Publishing newsletter to communicate circle activitieso Providing circles with necessary facilities for the meetingo Organizing social get-together for circle members and senior executives

6. “5-S is an excellent technique to achieve good house-keeping”. Discuss.Ans: Introduction: Good housekeeping is the foundation for and first step towardsquality achievement in a manufacturing organization. It boosts employee morale andinspires customer confidence.

Good quality of work place is essential as –1. Good environment has a strong influence on the people and the quality of product

they produce.2. A customer visiting the plant sees in a quality work place a guarantee for the

product quality.3. Good housekeeping helps to eliminate waste by identifying non-value added

activities, such as searching for tools, time lost in reaching out to retrieve items,over production, etc.

4. Housekeeping reflects management’s general attitude towards work in theorganization.

Housekeeping is measured the way- Factory floor are swept and machines are cleaned- Tools are stored- Scarp and chips from machines are handled- Work tables are organized- Personal items are stored- Records are maintained- Targets and achievements are displayed or communicated to employees.

Good housekeeping is simply the basic to a better workplace and to –

- Reduce cost of products and service- Achieve discipline in manufacturing- Bring improvement in quality and productivity

5-S (Seiri, Seiton, Seiso, Seiketsu and Shitsuke) are considered in Japan the basics of anyjob. 5-S principles have been practiced in Japan the basics of any job. 5-S principles havebeen practiced in Japan to establish and maintain quality environment in the organization.Japanese managements are of the view that if the housekeeping in a plant is weak, nofurther diagnosis is needed to know as to why that plant produces poor quality products.5-S technique has been defined as –

“A systematic and rational approach to work place organization and methodicalhousekeeping with a sense of purpose”

Relationship between 5-S’s:

Japanese English Meaning How to apply it to the work place?

Seiri Structurise Sorting Classify items into necessary and unnecessary,retain only those which are required anddispose off others. (i.e. those not needed)

Seiton Systematise Re-organise Store things systematically to ensure safety,quality and efficiency. Storage methods mustpermit efficient use of space-accident freestage, long shelf and easy retrievability ofitems within pre-fixed target retrieval time.

Seiso Sanitise Cleanup Maintain work place free of dirt/ dust andgarbage by fixing individuals’ cleaningresponsibility.

Seiketsu Standardize Standardization Maintain cleanliness through Seiri, Seiton andSeiso by ensuring transparency and uniformlyof everything that is done in the organization.

Shitsuke Self-discipline Sustain Make a habit of doing things the way they aresupposed to be done (i.e. developing habit offollowing rules/ practices) including 5-Spractices.

SEIRI(Organisation

)

SEIKETSU(Standardisation)

SHITSUKE(Discipline)

SEITON(Maintenance)

SEISO(Clean Up)

7. What is SMED? How is it used to reduce setup time of an operation?Ans: Introduction: Every organization must increase line of its products, accept lowvolume orders, shorten delivery lead time, and keep its cost low to maintain its marketshare in a competitive market. The organization must cut production lead time anddecrease production batch sizes. It should also reduce inventory levels in the productionand inventory systems. Since small batches require frequent changeovers, productioncapacity is expected to shrink unless setup times are reduced. Set up time reduction,therefore, is the key to developing or monitoring a company’s competitiveness in today’smarket where more diversified products are desired at short production lead time.

Quick Die/ set up change is not restricted to set-up reduction of press shop alone, it canbe extended to all areas of manufacturing wherever there is requirement of tool change/set up on a machine prior to manufacturing.

i. Pressesii. Multi-spindle automatsiii. Lathes, turret lathesiv. Milling machinesv. Drilling machinesvi. Broaching machines.vii. Forging machinesviii. Paint manufacturing equipmentix. Powder coating machinesx. Oil extracting mill

Meaning:Set up time is the time required to prepare a machine or a group of machines tochangeover from one job to another. Time of a conventional set up consists of followingtasks.

(a) The time to study blue print , including time spent on receiving instructions fromsupervisor or foreman.

(b) The time to go to tool crib to get necessary tools and gauges, etc and to return thetools used to previous job.

(c) The time to select fixture (Vice, mandrel, suitable sized collets, face plate, etc)and secure it to the bed of the machines.

(d) The time to install/ mount necessary tools on to the machine, make adjustments,set longitudinal or traverse feed stoppers wherever necessary to ensure that eachtool cuts properly and to dimensions.

(e) The time to call the inspector and get inspection done (pilot piece inspection).Alternatively it is the time necessary to deliver the part to the inspection booth forinspection. Inspection time, however, does not include time to manufacture thepart.

(f) The time spent by the operative, over and above the unit standard time, to producefirst few pieces.

(g) The time to physically count the jobs produced, including time to sign thecompleted work-order.

(h) The time to remove tools from their tool-holders after required quantity has beenmanufactured, clean each tool and put it away in proper place.

(i) The time to clean measuring instruments and put them away in proper places.(j) The time to release and remove fixture blow or brush it clean and keep it aside.(k) The time to remove borings, turning, drilling etc, from the bed of the machine.

Normally, turnings/ drillings/ borings should be removed by a helper (even whenthe production is in progress) when these gather in large quantity. However, burnsremoval, would have to be considered part of set up operation if different materialis required on the next job (e.g. Steel for the job just completed and brass for thejob to be loaded).

Traditional set up operations involve several kinds of waste and SMED technique wasdeveloped to eliminate waste and to reduce set up time from hours to minutes. SMEDalso has interesting history of development.

Reduction in set up time results in the following benefits:o Reduction in batch sizeso Lowering of manufacturing lead timeso Drop in inventory levelso Reduction in set-up scrapo Increase in machine efficiencyo Increased flexibility to respond to changes.

The firm desiring to reduce change-over time may not achieve its target figure in oneattempt, but after a series of improvements. From its current level of set up time ofdouble digit on a particular machine, it may be able to reduce to single digit hours. Andsubsequently on the same machine from single digit hours to double digit minutes, stilllater from double digit minutes to single-digit ones and finally in to few extremesituations one touch change over.

Step-by-step reduction of set-up time

8 a) What is meaning of MUDA? What are the various types of MUDAS?Ans:Introduction: MUDA is a Japanese word for waste and waste means anything (or anyactivity) which does not add value to the product.

o A worker looking, even though affectionately, at an automatic machine does notadd any value while machine does (MUDA of Waiting)

o A maintenance engineer who walks over a long distance with tool in his hand,does not add any value (value is added when he uses the tool to fix the machine) (MUDA of Transport)

o Piles of material lying in racks in the stores don’t add any value but add to cost(MUDA of Stock)

o A material handler while pushing a heavy trolley full of parts, even thoughperspiring, adds no value (MUDA of Transport)

o An assembly operator, overstretching his hand to pick up parts for assembly, addsno value but causes fatigue to himself (MUDA of Motion)

o A welding operation, performed to join metal parts of assembly constituent, doesadd value but the welding operation performed to repair weld a blowhole in job isa non-value added activity (MUDA of Processing)

Waste (MUDA) is the major element of company’s product cost and must becontinually identified and eliminated from its processes to stay competitive.

Since labour cost is hardly 8-10% of total cost (which also is on the decline due torecent advances in manufacturing technologies), we also need to look at various otherhidden wastages, besides human waste, to improve productivity.

Elimination of sampleruns, inspection,adjustments

Comp.A run

Studyblueprint

Removeexisting

Replacetoo at thecrib store

Install toolsfor the newjob

Samplerun

Adjust

Run forcomponentA

SETUP Run forcomponentB

ComponentB

ComponentA

Setup

Samplerun

Types of MUDA:

There are seven types of MUDA in manufacturing:

1. MUDA of Over Production.

2. MUDA of Stock (inventory)

3. MUDA of Waiting

4. MUDA of Transport

5. MUDA of Defects

6. MUDA of Motion

7. MUDA of Processing

b) What Causes MUDA of “Motions”? How can it be eliminated?Ans: Introduction: A workman while performing a task makes use of a number ofmotions. The scrutiny of these motions may reveal that some of these motions –

o Are unnecessary and can be eliminatedo Can be combined / modified by changing their sequenceo Can be simplified by effecting changes in work bench layouto Can be performed efficiently by other members of the body.

In the absence of the above mentioned actions, the workman makes motions which don’tadd any value. Typical examples are –

o Walking to reach objects/ parts. Toolso Lifting or carrying objectso Picking up and putting down a work pieceo Transferring objects from one hand to anothero Searching to find the required object

While dealing with MUDA of motion it is recommended to get rid of operations that aredifficult dirty and / or dangerous (3D’s). such actions include –

o Work that makes and employee move over long distanceso Work that causes physical strain (i.e. use of undue physical effort)o Work that causes mental strain (e.g. work that needs memorizing lot of details)o Work that involves search or unnecessary sorting.

Tools and techniques to eliminate MUDA of Motion:

i) Improvement in layout: Lifting or carrying a heavy object is undesirable ontwo counts, firstly because it represents MUDA and secondly it causesphysical exertion. The need for the operator to carry a heavy object can beeliminated by rearranging the work place.

ii) Motion economy principles: Motions of the hands/ legs can be shortened andsome of them can be eliminated by rearranging the parts on work table anddevelopment of tools and jigs.

iii) Effective supervision: Finding workmen busy with their jobs may givesupervisor satisfaction but it may do no good to the company. A supervisormust watch closely his people to find as to –- What are they doing?- How are they doing?- Do they need to do what they are doing?- Are they doing the right way?- Are they doing work which adds value?- Are they using motions of the lowest classification?

List down different kinds of human errors. How can they be eliminated? How isPokaYoke technique useful to eliminate human errors?

Ans:Description of the

errorTypical examples Remedial action

Forgetting to do athing

3. Operator skipping anoperation.

4. Operator forgetting totighten bolts

5. station master forgetting tolower the crossing gate

6.Misunderstanding

Jumping to thewrong conclusiondue to poorfamiliarity with thesituation

1. Putting foot on clutchthinking it is brake

1. Training2. Checking in advance3. Standardizing work

procedures.

Mistakenidentity

Misjudging asituation

1. Mistaking Rs.500 note asRs.100 note

1. Improving attentiveness.

Errors byamateurs

Lack of experience 1. Improper welding2. Wrong measurements

1. On-the-job training2. Work Standardisation

Willful errors Ignoring rules/deliberate wrongactions

1. Ignoring safety rules2. Crossing a street against

a red light just becausethere are no vehicles insight at the moment.

3. Not replacing blunt toolon time

1. Attitude change.2. Education

Inadvertenterrors

Absent mindednessi.e. not knowing howthe problem / errorhas occurred

1. Removing job beforecompleting drilling of allholes

2. Crossing street withoutnoticing that the light is red

1. Improving attentiveness2. Work standardization

Judgmentalerrors

Errors due to absenceof instructions ofwork standards

1. Difference in method ofmeasurement used byvendor and by buyer’sinspection

2. Operator deciding his own

1. Works instructions2. Work standardization.

Errors due toabsence ofstandards

Lack of instructionsor absence of workinstructions

Measurements left to thediscretion of the workman

1. Works instructions2. Work standardization.

Type ofError

Forgetfulness 1. Altering operator in advance

2. Checking at regular intervals

3. Verification by anotheremployee

1.

“Poka-Yoke” is a combination of two Japanese words, “Poka” meaning “inadvertenterrors” and “Yoke” (derived from Japanese word Yokerie) meaning “to avoid” andtogether they translate as “Error/ mistake proofing” or “Fool proofing” or “Failsafing” awork process system to eliminate inadvertent errors.

Poka-Yoke is a powerful and comprehensive tool for identification, measurement andanalysis of mistakes/ defects at the Gemba (real piece of work) and implementation ofmeasure that prevent the activity from being incorrectly performed, thereby ensuringproduction of quality goods and services.

Errors are inevitable but can be eliminated, using Poka-Yoke technique. This is thetechnique that can help to analyse the kinds of mistakes employees make and to eliminatethese mistakes by implementing / installing simple Poka-Yoke devices.

Poka-Yoke Devices:Poka-Yoke may be designed either to help the operator to recognize the defect before it isabout to occur called “Prevention type Poka-Yoke” or to help the operator to knowimmediately on occurrence of the defect called “Detection type Poka-Yoke”.

Some of the Poka-Yoke devices which can help to avoid defects are –

1. Guide Pins / locators2. Error detection buzzers/ alarms and blinking lights3. Limit switches4. Counters5. Color coding6. Checklist

9.a) What is Kaizen? What are different types of Kaizen?Ans: Introduction: Kaizen is a combination of two Japanese words, “Kai” and “Zen”,Kai means “to change or modify” and Zen means “to improve or make better” andtogether they translate as “improvement”. Kaizen when used in the context of amanagement process, has come to mean as continual and slow improvement in everyaspect of management (i.e. improvement in whatever company does and the way it doesthings) through the active involvement of all company’s employees. Kaizen does not justmerely mean doing things better but it is an unending process to eliminate muda, improvequality, cost and delivery, thereby creating more and more customers.

Few Definitions:

Kaizen is a management supported, employee driven process, where employees seekdevelopment of their own capabilities by challenging existing system and findingimprovement in them - R.R. Asawa & Dr. D. R. Baheti

Kaizen is a program, a philosophy and a strategy to improve quality of goods andservices or an organization - Samuel KHO

Kaizen means making a great number of continuous lasting improvements by discoveringsmall problems and eliminating them permanently (attacking root causes of theproblems) thereby helping the organization in setting and reaching higher standards ofperformance. - Surindra Narang

The Spirit of kaizen is that whatever you are doing, you can do better. Kaizen thus helpsin setting and reaching higher standards of performance.

The word “Kaizen” was used for the first time by Maasaki Imai, who wrote a look ofsame name. although a registered name of Kaizen Institute, the work is now widely usedand understood all over the world to mean “continuous improvement”. The word“Kaizen” also now appears in the English dictionary. Recently, Imai has elaborated onKaizen in his book titled “Gemba Kaizen”

Types of Kaizen:Kaizen depending upon the complexity and level, can be placed into one of threecategories

1) Management Kaizen2) Group Kaizen3) Individual Kaizen

1) Management oriented Kaizen: Concentrates on strategic issues and ofteninvolves people from different departments working together on cross-functionalproblems as project teams. Typical examples of management oriented Kaizen are:

Identification and elimination of waste in workers motions Charges in plant layout for better efficienvy Reduction in buffer stocks Just-in-time production System improvement

2) Group oriented Kaizen: Concentrates on improvement within the sameworkplace or department brought about by employees working in small groups,called quality circles. Typical areas of group Kaizen generally include –

Productivity improvement Defect prevention Accident prevention Absenteeism

3) Individual oriented Kaizen: Concentrates on issues concerning worker’s ownwork area and improvements are brought about through worker’s ownsuggestions. Problems solved through individual Kaizen generally include –

Improvement in machines and processes

Improvement in jigs and fixtures Reduction in defect level Customer service and customer complaints Improvements in working environment.

b) Discuss in brief the Kaizen process and its steps.

Ans: Introduction:Kaizen process provides a disciplined and analytical approach, sometimes called thekaizen story to problems solving. It consists of a series of sequential steps that can beused to guide a group (say an improvement team) for the process of identifying andfixing problems. The Kaizen story (or Kaizen process) is built on PDCA mnemonic –Plan, Do, Check and Act. The Kaizen process is a seven step basic procedure whichallows any individual or team to solve problems scientifically, rationally, effectively andefficiently. These seven steps are –

1. Defining the problem

2. Understanding/ assessing the current status

3. Finding the root cause.

4. Planning counter measures

5. Implementing counter measure

6. Verifying results

7. Standardising and establishing control.

A brief of each of the steps in the Kaizen process is given.

Fig: Problem definition phase

When Deming cycle is used as a tool for systematic problem solving (improvement), thePDCA activities take the form as shown below…

Poka-yoke forfailsafing

Model machineexercises in TPM

Exercises to identify MURA,MUDA and MURI

Spotting abnormalities atGemba

Internal customer’scomplaints

External customer’scomplaints

Cost of Quality

SMED/ JITTargets

5-S Audits

ISO-9000, QS-9000and ISO-14000 non-conformities

Problems

Define Problems

Enlist problems

Prioritize problems

Select topics for Kaizen

Assign themes toKaizen teams

problems

Conduct PDCA-SDCAimprovement cycles

Process Steps Objective Element of PDCAcycle

Defining the problem Identification of the problem The “PLAN” element

Understanding /Assessing Current status

Establishing the base from whichyou are trying to improve


Finding the root cause Identifying underlying causes ofthe problem


The “PLAN” elementPlanning countermeasures

Preparing action plan to fix theproblem

The “DO” elementImplementing countermeasures

Verifying results

Standardizing andestablishing control

Implementing the action plan

Confirming the effect ofimplementation

Consolidating the change

The “CHECK” element

The “ACT” element ofPDCA and / or + theSTANDARDIZEelement of SDCA


Select The BlankQuestion Due to SMED, ________ time cuts down.

Correct Answer Waiting

Your Answer Operation

Multiple Choice Multiple AnswerQuestion Actions that can be thought for the process having process

capability is smaller than specification tolerance are:-Correct Answer Use of less precision machine , Possibility of squeezing

tolerances , Reduction in inspectionYour Answer Possibility of squeezing tolerances , Reduction in inspection ,

100% inspection , Use of less precision machine

Multiple Choice Single AnswerQuestion A control chart is also called as :-

Correct Answer Run chart

Your Answer Flow chart

Select The BlankQuestion Ideally the histogram will have a symmetrical ( i.e. also called as

bell) shape tapering away on both sides from ________ value.Correct Answer Average

Your Answer Maximum






Your Answer Defect


Question Customers complaints may be segregated by :-

Correct Answer Nature of compliant i.e. defective product , Delayed delivery ,Short/excess quantity

Your Answer Nature of compliant i.e. defective product , Delayed delivery ,Short/excess quantity , Payment problem

Select The BlankQuestion JIT helps to ________ the waste in the purchasing process.

Correct Answer Eliminates

Your Answer Eliminates


Correct Answer True

Your Answer False

True/FalseQuestion Review is important step in problem solving.

Correct Answer True

Your Answer True

Select The BlankQuestion To assess effectiveness of training ________ is essential.

Correct Answer Evaluation

Your Answer Re training

Select The BlankQuestion Quality improvement team consists of departmental head with a

chairperson who has easy access to the ________.Correct Answer Top management

Your Answer Workmen

Multiple Choice Single AnswerQuestion The area enclosed under normal distribution curve between

mean +3standard deviation is :-Correct Answer 0.9973

Your Answer 0.9545

Multiple Choice Single AnswerQuestion In autonomus modules or cells, rate of production increases :-

Correct Answer Number of operators increases

Your Answer Number of operators increases



Your Answer Measure the current pattern & extent of variation , Assesscurrent conformance to specification & scope of improvement ,Determine whether or not the process is in the state of control ,Do the analysis as per "parato diagram"

Multiple Choice Single AnswerQuestion DOE stands for

Correct Answer Design of Experiments

Your Answer Degree of Evaluation

True/FalseQuestion Automation can correct the basic faults of a improper setup

process.Correct Answer False

Your Answer True

Multiple Choice Multiple AnswerQuestion Limitation of quality circles are :-

Correct Answer Problems headed by worker group must be simple & within theirlimit , Unions in India are reluctant , Management is also notopen for union

Your Answer Problems headed by worker group must be simple & within theirlimit , Unions in India are reluctant , Management is also notopen for union , Worker attitude only for financial benefit



Correct Answer True

Your Answer True

True/FalseQuestion Safety, hygiene and environment control is one of the pillar of

TPM.Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion During the steps of Deming cycle of PDCA what is important?

Correct Answer Plan unitedly for the target within reach , Make plan active by"doing it" i.e. everyone working , After some time check theresults for success

Your Answer Plan unitedly for the target within reach , Make plan active by"doing it" i.e. everyone working , After some time check theresults for success , Make your own methods for individualsuccess

Multiple Choice Multiple AnswerQuestion Initial list of prospective partners can be drawn on feedback

information gathered from :-Correct Answer Winners of excellence award , Top rated companies in industry

survey , ConsultantYour Answer Winners of excellence award , Top rated companies in industry

survey , Consultant , Employees

Multiple Choice Single AnswerQuestion For customer satisfaction, checking point will be :-

Correct Answer Obtaining feedback from concerned department

Your Answer Obtaining feedback from concerned department

True/FalseQuestion Graph is a tabulated representation of the data which is easily

understandable at a glance.Correct Answer False

Your Answer True

Multiple Choice Multiple AnswerQuestion Examples of Muda are :-

Correct Answer Muda of over production , Muda of stock , Muda of defeat

Your Answer Muda of over production , Muda of stock , Muda of defeat ,Muda of competition

Multiple Choice Multiple AnswerQuestion Causes of Muda of transport are :-

Correct Answer Faulty layout , Over production

Your Answer Faulty layout , Over production , Proper material handlingequipment , Low rejection / rework

True/FalseQuestion Process capability refers to ability of the process to meet the

design specification for a product or a service.Correct Answer True

Your Answer True

Select The BlankQuestion ________ is the root cause of the problems.

Correct Answer Variation

Your Answer Duplicating

Multiple Choice Single AnswerQuestion Seiri means :-

Correct Answer Destroying unwanted items after classifying the necessity

Your Answer Destroying unwanted items after classifying the necessity

Select The BlankQuestion Poka Yoke is ________.

Correct Answer Simple technique

Your Answer Simple technique

Multiple Choice Single AnswerQuestion Kaizen process is built on PDCA cycle, where P represents :-

Correct Answer PLAN

Your Answer PLAN

Multiple Choice Single AnswerQuestion For normal distribution curve, skewness & kurtosis are :-

Correct Answer Zero

Your Answer One






Your Answer Japanese unit of scientist & engineers(JVSE)


abnormalities while cleaning your own area.Correct Answer True

Your Answer True


Kanban Pull system Statistical process control

Work standards Best way of doing job Best way of doing job

TPM Reducing breakdown ofmachines

Reducing breakdown ofmachines

JIT Waste elimination Waste elimination

Select The BlankQuestion Basic objective of control chart is to ________ the variation due

to chance & assignable cause.Correct Answer Separate out

Your Answer Separate out



Your Answer Reduce work in process , Better average daily production ,Increase capacity , Reduce productivity

Multiple Choice Multiple AnswerQuestion Quality problems may be segregated by & regrouped by :-

Correct Answer Machines , Workers , Materials

Your Answer Machines , Workers , Materials , Suggestion

Select The BlankQuestion Histogram is a diagrammatic presentation of the ________

distribution of characteristics such as strength, diameter, etc.Correct Answer Frequency

Your Answer Frequency


Correct Answer True

Your Answer False



Your Answer Customer

Multiple Choice Single AnswerQuestion Theoretically, the normal curve can extend :-

Correct Answer From - Infinity to + Infinity

Your Answer From 0 to+ infinity


Control chart can be used As process monitoringtool

Stability of the process

Control chart is agraphical method ofchecking

Stability of the process For quality monitoring

Control chart can be used How much variability in How much variability in the

to determine the process is due torandom causes & howmuch is due to assignablecauses

process is due to randomcauses & how much is dueto assignable causes

Control chart is a chartwith UCL & LCL placed

At 3 Sigma distance oneither side of the processaverage

At 6 Sigma distance oneither side of the processaverage

Multiple Choice Multiple AnswerQuestion Few main steps to construct a Histogram after deciding classes,

class width & class boundaries are :-Correct Answer Compute mid-point of the class (cell) & fill up the tally sheet

determining the cell or class into which each value falls , Countthe tally marks i.e. frequency in each class & construct ahistogram by plotting a bar graph for each class , Analyze &conclude whether process is is meeting the requirement or not &take connective actions if needed.

Your Answer Compute mid-point of the class (cell) & fill up the tally sheetdetermining the cell or class into which each value falls , Countthe tally marks i.e. frequency in each class & construct ahistogram by plotting a bar graph for each class , Analyze &conclude whether process is is meeting the requirement or not &take connective actions if needed. , Do the Parato analysis asper 80%=20% rule

True/FalseQuestion Exercise to identify MURA, MUDA & MURI is not helpful to

identify problems.Correct Answer False

Your Answer False


Correct Answer Decide on the objective of flowchart & define boundaries of theprocess , Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes as perreview & name it & put the data & use it as 'Record'

Your Answer Decide on the objective of flowchart & define boundaries of theprocess , Identify steps in the process & construct a draft of theflowchart , Review the draft & connect the changes as perreview & name it & put the data & use it as 'Record' , Circulateflowchart


Select The BlankQuestion ________ is management skill.

Correct Answer Delegation

Your Answer Delegation




Your Answer Data should be properly stratified & should be collected for fullrange

True/FalseQuestion In cellular manufacturing system cell may consist of a single

machine or more than one machine arranged in line.Correct Answer True

Your Answer True






Correct Answer True

Your Answer True



Your Answer Only height

Multiple Choice Single AnswerQuestion Flow charts are drawn to document a process by charting the

task performed and :-Correct Answer The sequence in which tasks are performed

Your Answer The sequence in which tasks are performed

Multiple Choice Multiple AnswerQuestion Best practices for standardization in implementing Seiketsu are

:-Correct Answer Create as many visual control systems as possible , Use colour

code system for easy control , Fix one colour (e.g. Red) fordanger zones/out of controls

Your Answer Create as many visual control systems as possible , Use colourcode system for easy control , Display warning notices

Multiple Choice Single AnswerQuestion Empowerment means making best use of the firm's most

valuable resource, namely:-Correct Answer Human

Your Answer Human


Correct Answer Examine possibility of relaxing specification , Reducing processvariability , Bringing target & average to fall at the same point

Your Answer Reducing process variability , Bringing target & average to fall atthe same point , Examine possibility of relaxing specification



Your Answer Approve six sigma projects , Remove road block in the path ofsix sigma implementation , Monitor progress of six sigmaprojects



Your Answer Place of maximum physical labour

Select The Blank

Question By improving layout MUDA, due to ________ can be eliminated.

Correct Answer Motion

Your Answer Over production

Multiple Choice Multiple AnswerQuestion Remedial actions for error of misunderstanding is :-

Correct Answer Training , Checking in advance , Standardizing work procedures

Your Answer Training , Checking in advance , Standardizing work procedures

Multiple Choice Single AnswerQuestion JIT manufacturing emphasizes workplace improvement through

:-Correct Answer 5 'S'

Your Answer 5 'S'

True/FalseQuestion Without review PDCA cycle not completed.

Correct Answer True

Your Answer True

Select The BlankQuestion To eliminate muda of processing, ________ exercise is

essential.Correct Answer ECRS

Your Answer ECRS



Your Answer True



Your Answer GM, operation heads, corporate functional heads

Select The BlankQuestion Suppliers may________ their prices to cover for cost of delivery,

small production run etc.Correct Answer Raise

Your Answer Raise

True/FalseQuestion Create as many visual controls as possible to achieve visual

management is the principle of "Shitsuke"Correct Answer True

Your Answer False

True/FalseQuestion Flow charts are used to train new employees by providing

documented description of the task involved.Correct Answer True

Your Answer True

Select The BlankQuestion Poka-Yoke devices under category use ________ to distinguish

between similar parts which may be assembled in wrongposition.

Correct Answer Color coding

Your Answer Color coding





Any thing misplacedshould be visualimmediately

Seiketsu Display Colour codesmeanings

Unrepairable tool orequipments

To be scrapped underSeiri

To be scrapped under Seiri

Colour coding essentialthroughout but

Display Colour codesmeanings

Colour codes as perdepartments

Surprise Audit any timeshould shout consistentgood housekeeping

Shitsuke for maintenanceof 4-S

Seiketsu




Multiple Choice Single AnswerQuestion Zero loss concept means :-

Correct Answer Zero accident, zero defect, zero breakdown

Your Answer Zero accident, zero defect, zero breakdown






Your Answer False

Multiple Choice Single AnswerQuestion The area enclosed under normal distribution curve between

mean +3standard deviation is :-Correct Answer 0.9973

Your Answer 0.9973

Select The BlankQuestion Poka Yoke is ________.

Correct Answer Simple technique

Your Answer Simple technique


Question The JIT Philosophy recommends attainment of flexibility by :-

Correct Answer Contracting all lead times

Your Answer Contracting all lead times

Multiple Choice Multiple AnswerQuestion Causes of Muda of transport are :-

Correct Answer Faulty layout , Over production

Your Answer Faulty layout , Over production

Multiple Choice Multiple AnswerQuestion For the presentation of the quality circle project what is required

is :-Correct Answer Presentation skills , Graphical data , Progressive efforts of the

team workYour Answer Presentation skills , Graphical data

Select The BlankQuestion ________ is responsible for effective implementation of action

plan's under TPM.Correct Answer Steering committee

Your Answer Steering committee


4 th level in six sigmaorganization

Green Belts Green Belts

1 st level in six sigmaorganization

Champions Champions

2 nd level in six sigmaorganization

Master Black Belts Master Black Belts

3 rd level in six sigmaorganization

Black Belts Black Belts

Multiple Choice Multiple AnswerQuestion Benefits of TQM are :-

Correct Answer Greater customer satisfaction , Lower manufacturing cost

Your Answer Greater customer satisfaction , Lower manufacturing cost

Multiple Choice Single AnswerQuestion Vilfredo Pareto had discovered a universal law as :-

Correct Answer "around 20% of the activity causes 80% of the effect"

Your Answer "around 20% of the activity causes 80% of the effect"

Multiple Choice Multiple AnswerQuestion Implementation of TPM in Indian industries is difficult due to :-

Correct Answer Lack of knowledge of the TPM , Resistance to change , Fear toloss of job

Your Answer Lack of knowledge of the TPM , Resistance to change , Fear toloss of job


Correct Answer Define the problem & identify the stratification variables , Sort outdata into categories & summarise information in each category ,Present the information in graphical form & study, decide iffurther stratification is required?

Your Answer Define the problem & identify the stratification variables , Sort outdata into categories & summarise information in each category ,Present the information in graphical form & study, decide iffurther stratification is required?

Select The BlankQuestion Each quality characteristic has permitted variation & is equal to

________.Correct Answer USL - LSL




Your Answer Process

True/FalseQuestion Automation can correct the basic faults of a improper setup

process.Correct Answer False

Your Answer True


Question In problem solving the best alternative is that :-



True/FalseQuestion Benefits of DWN is faster response to customer needs.

Correct Answer True

Your Answer True






Your Answer True


Multiple Choice Multiple Answer Question Quality maintenance & pillar focuses on following production

inputs :- Correct Answer Material , Men , Machine


Multiple Choice Multiple Answer Question Histograms are useful to :-

Correct Answer Measure the current pattern & extent of variation , Assess current conformance to specification & scope of improvement , Determine whether or not the process is in the state of control

Your Answer Measure the current pattern & extent of variation , Assess current conformance to specification & scope of improvement , Determine whether or not the process is in the state of control

Multiple Choice Single Answer Question In problem solving the best alternative is that :-



Multiple Choice Single Answer Question "Cause & effect" diagram was developed by :-



Multiple Choice Single Answer Question Identifying key preventive operational functions and comparing

these operational functions within the firm's own division & branches comes under :-



Select The Blank Question JIT advocates the philosophy at elimination of waste from

system which occurs due to ________. Correct Answer Over Production


Select The Blank Question In scatter diagram "________" relationship is said to exist when

there is positive relationship upto certain level & negative thereafter or negative relationship upto certain level & positive thereafter.



True/False Question Kanban signals are required when assembly work, subassembly

work and manufacturing at parts is carried out at different locations.

Correct Answer True

Your Answer True

Multiple Choice Multiple Answer Question Customers complaints may be segregated by :-

Correct Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity

Your Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity

True/False Question In case of more than one quality characteristics, separate chart

is made for each quality characteristics. Correct Answer True

Your Answer True

True/False Question Safety, hygiene and environment control is one of the pillar of

TPM. Correct Answer True

Your Answer True

Multiple Choice Single Answer Question 5-S technique is useful to:



Match The Following

Question Correct Answer Your Answer Reduce time of external setup

Improve work aids positioning method

Improve work aids positioning method

Convert internal setup into external setup

Preparation of tools / dies as off line activity

Preparation of tools / dies as off line activity

Eliminate adjustment Pre setting of tool Pre setting of tool Reduce clamping & declamping time


Multiple Choice Single Answer Question The facilitator should be normally :-



Match The Following Question Correct Answer Your Answer Parato diagram always indicates

Magnitude of defects Philosophy of 20% of the activity causes 80% of the effect

Parato analysis underlines & operates on

Philosophy of "vital few:trivial many"

Philosophy of "vital few:trivial many"

Parato analysis is technique of identifying vital causes by

Arranging data according to the descending order of their frequency of occurrence

Arranging data according to the descending order of their frequency of occurrence

Parato diagram is a Bar graph with height or value drawn by

Arranging data in descending order


Multiple Choice Single Answer Question Quality problem solving tool is used to :-



True/False Question Pie chart is also called as angular diagram.

Correct Answer True

Your Answer True


value of 'y' somewhat decreases as the value of 'x' increases. Correct Answer Weak negative


Multiple Choice Single Answer Question From scatter diagram the strength of relationship between two

variables or associated set of data can be inferred from the examination of the shape of :-


Your Answer Cloud

Multiple Choice Multiple Answer Question Product benchmarking requires, comparison of product :-



Multiple Choice Multiple Answer Question Steps in construction of scatter diagram :-

Correct Answer Collect paired data (X,Y) from two variables who's relationship is to be studied , Find out max & min values for both X & Y and these values to scale X & Y axis & plot the paired data , Examine the shape of the cloud of points & discover type & strength of relationship

Your Answer Collect paired data (X,Y) from two variables who's relationship is to be studied , Find out max & min values for both X & Y and these values to scale X & Y axis & plot the paired data , Examine the shape of the cloud of points & discover type & strength of relationship

Multiple Choice Single Answer Question Implication of Quality problem is:-



Select The Blank Question Each quality characteristic has permitted variation & is equal to

________. Correct Answer USL - LSL


Select The Blank Question Kaizen is ________ supported process.



True/False Question The flow charts are prepared to enhance the employees

understanding of the process by indicating interrelationship within the process.

Correct Answer True

Your Answer False

True/False Question Gap analysis for production & dispatches is discussed in monthly

meeting. Correct Answer False

Your Answer False


value of 'y' decreases as the value of 'x' increases. Correct Answer Strong negative


Select The Blank Question ________ is most difficult 'S' to implement & achieve.



True/False Question Presentation of graphs in pictorial form of data collection are for

easy understanding. Correct Answer True

Your Answer True

Select The Blank

Question Graphs convey a situation more ________ than summary of data or figures.



Multiple Choice Single Answer Question Errors by armatures is :-



Multiple Choice Multiple Answer Question While preparing scatter diagram following precautions are to be

taken :- Correct Answer Data should be properly stratified & should be collected for full

range , Scale selected should be right to avoid wrong conclusions , Data should be free from bias or undue importance

Your Answer Data should be properly stratified & should be collected for full range , Scale selected should be right to avoid wrong conclusions , Data should be free from bias or undue importance

True/False Question Globalization of trade and industrial operations have forced

Indian companies to become more & more competitive and customer driven.

Correct Answer True

Your Answer True

Multiple Choice Multiple Answer Question If 'Annual saving in procurement expenses is managing point',

then checking points will be :- Correct Answer Price revision , Credit period , Transport expenses


Multiple Choice Single Answer Question Number of kaizen in Group kaizen categories are :-



True/False Question Flow chart is pictorial representation of the steps in production

control.


Your Answer False

Multiple Choice Single Answer Question It is essential to convey customer's expectations to :-



Multiple Choice Single Answer Question Check sheet is easy to use because it is :-



Select The Blank Question Identification of non-value added operations & their elimination is

the first step to eliminate muda of ________. Correct Answer Processing


Select The Blank Question A 'Radar chart' is used to portray ________ strength or

weakness of the activity. Correct Answer Relative


Multiple Choice Single Answer Question Pareto's analysis underlines & operates philosophy of :-



True/False Question In single card kanban system production greater than quantity

withdrawn is permitted. Correct Answer False

Your Answer False


Question Benefits of planned maintenance are :-

Correct Answer Improved reliability mean time between failures , Improved maintainability mean time to repair , Improvement in breakdown

Your Answer Improved reliability mean time between failures , Improved maintainability mean time to repair

Multiple Choice Multiple Answer Question Gap analysis & problem identification is done during converting

internal setups into external setups in the areas like :- Correct Answer Equipment , Method , Human


Multiple Choice Single Answer Question Some quantity in stock of item, is desirable if :-



Multiple Choice Single Answer Question Sorting of usable items should be



Multiple Choice Multiple Answer Question Benefits of Quality maintenance are :-



1. TPM

1. Waste elimination

2. JIT

2. Visual management

3. Kanban

3. Best way of doing job

4. Work standards

4. Reducing breakdown of machines

5. Pull system 6. Statistical process control

1. Parato analysis underlines & operates on

1. Arranging data according to the descending order of their frequency of occurrence

2. Parato analysis is technique of identifying vital causes by

2. Philosophy of 20% of the activity causes 80% of the effect

3. Parato diagram is a Bar graph with height or value drawn by


4. Parato diagram always indicates


5. Arranging data in descending order 6. Philosophy of "vital few:trivial many"


a)

b)

c)

d)

Unity

Zero

Infinity

Six

U shape arrangement of layout provides the operator degree of mobility. 48. Quality problems may be segregated by & regrouped by :-

a)

b)

c)

Machines

Workers

Materials

d)

Suggestion LIST OF ATTEMPTED QUESTIONS AND ANSWERS

Multiple Choice Multiple Answer Question TQM can never flourish if the staff are:-

Correct Answer Scared of their bosses , Worried about losing jobs , Afraid of being reprimanded if there are mistakes

Your Answer Scared of their bosses , Worried about losing jobs , Afraid of being reprimanded if there are mistakes

Multiple Choice Single Answer Question Quality problem solving tool is used to :-



Multiple Choice Single Answer Question The concept of quality circle was mooted by :-



Match The Following Question Correct Answer Your Answer SMED Setup time reduction Setup time reduction 5 'S Cleanliness Total productive

maintenance Muda elimination Waste elimination Waste elimination Poka-Yoke Error proofing Error proofing

Multiple Choice Single Answer Question Allowing worker's to stop machine / assembly line if they believe

that product quality is below standard' is an example of :- Correct Answer Empowerment


Select The Blank Question Kaizen is ________ supported process.


Your Answer Workmen

Select The Blank Question Ratio of ________ to the number of pieces inspected is called

fraction defectives. Correct Answer Number of item rejected


Multiple Choice Single Answer Question Histogram always indicates :-



Multiple Choice Single Answer Question List of customers, to carry out parato analysis to identify

customers who gives business includes :- Correct Answer Present & past customers


Multiple Choice Single Answer Question Implication of Quality problem is:-



Multiple Choice Multiple Answer Question Steps to six sigma process consists of :-

Correct Answer Identify the work you do , Identify your customers , Map the process

Your Answer Identify the work you do , Identify your customers , Map the process

Multiple Choice Single Answer Question From scatter diagram the strength of relationship between two

variables or associated set of data can be inferred from the examination of the shape of :-


Your Answer Cloud

True/False Question Non-availability of files /document in time is a problem to be

addressed by office TPM. Correct Answer True

Your Answer True

Select The Blank Question ________ used to detect drop in air pressure.



Multiple Choice Single Answer Question TQM is a way to improve quality of product and service :-



Multiple Choice Multiple Answer Question The aim of education & training under TPM is :-

Correct Answer To develop abilities to respond quickly to abnormalities , To develop abilities to discover analyze malfunction

Your Answer To develop abilities to respond quickly to abnormalities , To develop abilities to discover analyze malfunction , To have multiskilled employees in all departments

Match The Following Question Correct Answer Your Answer In scatter diagram, the strength of relationship can be determined


The scatter diagram provides the technique to establish

The possible relationship between a pair of variables

The possible relationship between a pair of variables

The scatter diagram displays

The pair of data as a cloud of points

The pair of data as a cloud of points

The scatter is also known as


True/False Question Flow chart is pictorial representation of the steps in production

control. Correct Answer False

Your Answer True

Multiple Choice Single Answer Question Pareto's analysis underlines & operates philosophy of :-



Multiple Choice Single Answer Question Pareto diagram always indicate magnitude of :-



True/False Question By cutting the cost of quality, profitability decreases.


Your Answer False

Multiple Choice Single Answer Question Check sheet is easy to use because it is :-



True/False Question The flow charts are prepared to enhance the employees

understanding of the process by indicating interrelationship within the process.

Correct Answer True

Your Answer True

Multiple Choice Single Answer Question Abnormal variations can occur if :-



Multiple Choice Multiple Answer Question Types of Poka-Yoke are :-


Your Answer Prevention type Poka-Yoke , Detection type Poka-Yoke , Standards type Poka-Yoke

True/False Question Control limits of control charts should be revised from time to

time as additional data is accumulated. Correct Answer True

Your Answer True

Select The Blank Question Kaizen is an excellent method to involve ________ to unearth &

eliminate hidden waste. Correct Answer Employees


Multiple Choice Multiple Answer Question To reduce Muda of transport, techniques used are :-



Select The Blank Question Cp for six sigma process is ________

Correct Answer 2

Your Answer 2

Select The Blank Question ________ participants in monthly meeting(MRM)



True/False

Question Processing cost of a product is mainly decided by conversion process.

Correct Answer True

Your Answer True

Select The Blank Question Production in last shift & production plan for next shift is

discussed during ________. Correct Answer Shift beginning & shift end/change meeting


Multiple Choice Multiple Answer Question Material Supply on DSL basis helps :-

Correct Answer To eliminate handling , To reduce transporting , To reduce inspection

Your Answer To eliminate handling , To reduce transporting , To reduce inspection

True/False Question Inadequate maintenance of machine leads to muda of defects

Correct Answer True

Your Answer True

True/False Question Most of the external setups are treated as internal setup.

Correct Answer True

Your Answer False

Multiple Choice Multiple Answer Question Benefits from SMED are :-


Your Answer Reduce work in process , Better average daily production , Increase capacity

Multiple Choice Multiple Answer Question Typical examples of process benchmark are :-



True/False Question Low level of delegation is an example of muda in office.

Correct Answer True

Your Answer False

Multiple Choice Multiple Answer Question Histograms are useful to :-

Correct Answer Measure the current pattern & extent of variation , Assess current conformance to specification & scope of improvement , Determine whether or not the process is in the state of control

Your Answer Measure the current pattern & extent of variation , Assess current conformance to specification & scope of improvement , Determine whether or not the process is in the state of control

Multiple Choice Multiple Answer Question While preparing scatter diagram following precautions are to be

taken :- Correct Answer Data should be properly stratified & should be collected for full

range , Scale selected should be right to avoid wrong conclusions , Data should be free from bias or undue importance

Your Answer Data should be properly stratified & should be collected for full range , Scale selected should be right to avoid wrong conclusions , Data should be free from bias or undue importance

Multiple Choice Single Answer Question Through continuous improvement in the process & procedures,

kobetsu-kaizen is continuously improve utilization of :- Correct Answer Worker, equipment & material


True/False Question Every department should make their own rules of

standardization. Correct Answer False

Your Answer False

Multiple Choice Single Answer Question Quality circle should consist adequate experienced members

between :- Correct Answer 8 to 10

Your Answer 8 to 10

Multiple Choice Single Answer Question Number of kaizen in Group kaizen categories are :-



Select The Blank Question Flow chart helps to provide clarity of the ________ without

visiting actual spot. Correct Answer Process

Your Answer Process

Multiple Choice Single Answer Question Gap in performance = Ideal situation minus :-



Select The Blank Question Seminar talks and video show are organized to introduce TPM

concept to ________ Correct Answer General employees


Documents

SOLVING A MAINTENANCE PROBLEM - SCDL C …scdlpgdba.weebly.com/uploads/4/6/5/9/4659319/techniques_for... · INTRODUCTION: Systematic problem solving provides a structured approach