Techniques for Operations Efficiency ALL

8/3/2019 Techniques for Operations Efficiency ALL

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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 Answer

Question 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

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

Multiple Choice Multiple Answer Question 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 Answer Question 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 for financial 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

Match The Following

Question Correct Answer Your Answer

Hidden faults come out

while implementing.

Cleaning yourself your

equipments

shitsuke

Fix the place of items,tools as per frequency of use

Seiri Seiton

Responsibility same fromtop to bottom

Seiso Cleaning yourself your equipments

Evolve standard operatingprocedure & implement.

Seiketsu Seiketsu

Multiple Choice Single Answer Question 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

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

Correct Answer 20 employees

Your Answer 20 employees

Select The BlankQuestion _______ is the critical element of TQM.



Correct Answer Focus on customer

Your Answer Focus on customer

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

Correct Answer Muda of overproduction

Your Answer Muda of overproduction

Multiple Choice Single Answer Question Accountability means :-

Correct Answer Responsibility of Business Results

Your Answer Responsibility Execution or Action

Select The BlankQuestion Benchmarking allows exchange of ________ between the

benchmarking partners.Correct Answer Information

Your Answer Information

Multiple Choice Multiple Answer Question 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 Answer Question To provide flexibility to supervisors in allocation of task, JIT

emphasizes :-Correct Answer Multiskilled operators

Your Answer Multiskilled operators

Multiple Choice Multiple Answer Question 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 Answer Question Typical examples of process benchmark are :-

Correct Answer Procurement procedures , Budgeting , Recruitment

Your Answer Procurement procedures , Budgeting , Recruitment

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

also used.Correct Answer True

Your Answer True

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

eakness 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 Answer Question Control chart can be used as :-

Correct Answer Process monitoring tool

Your Answer Process monitoring tool

Multiple Choice Single Answer Question Productivity improves by :-

Correct Answer oluntary participants of everyone



Your Answer oluntary participants of everyone

Multiple Choice Multiple Answer Question 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

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

Correct Answer Wear & tear of parts while disassembling

Your Answer Wear & tear of parts while disassembling

Multiple Choice Single Answer Question 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 Answer Question 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 Answer Question 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

Multiple Choice Multiple Answer Question 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 & allpossibilitiesYour Answer Efforts to avoid the problem permanently , Ultimate aim of the

customers 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

Multiple Choice Multiple Answer 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 & withinspecific limits

Your Answer It shows cause which affects the process , An idea of what ishappening to the process , Whether the process is capable of meeting 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 Answer Question 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 for successYour 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 Answer Question Discussion on people, problem & role play exercise helps to

develop :-Correct Answer Counseling skill

Your Answer Counseling skill

Match The Following


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 Answer Question TPM implementation is done through:-

Correct Answer Small group

Your Answer Small group

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

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

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

Multiple Choice Multiple Answer Question 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 , Convertinginternal setup into external setup

True/False

Question Everyone in the team of quality should target his own benefitsi.e. promotion, etc.


Your Answer False



Techniques for Operations Efficiency assgn :01: Naresh

Multiple 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 :-

Correct

Answer

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

Your Answer Main 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


Question Quality maintenance & pillar focuses on following production inputs :-

Correct

Answer

Men , Machine , Material

Your Answer Men , Machine , Management

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

Correct

Answer

Managing points

Your Answer Accountability

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



CorrectAnswer

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

Your 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 :-

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/False

Question 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 :-

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

Match The Following


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:-

Correct

Answer

Breakdown of machine

Your Answer Breakdown of machine



Multiple Choice Single AnswerQuestion Kaizen emphasizes :-

CorrectAnswer

Implementation of ideas

Your Answer Collection of ideas

Select The Blank

Question 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 Answer

Question 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



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

Answer

False

Your Answer True

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

arrangement.

CorrectAnswer

False

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

Answer

Lowest

Your Answer Second highest

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

CorrectAnswer

JIT Contract

Your Answer JIT Contract

True/False



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.

Correct

Answer

Comparison

Your Answer Performance

Multiple Choice Single AnswerQuestion Production kanban is presented by :-

CorrectAnswer

P-kanban

Your Answer R-kanban


Question 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.

Correct

Answer

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.

CorrectAnswer

Color coding

Your Answer Counting device

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

CorrectAnswer

Sustaining



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/False

Question Flow chart helps to stop an old process.

CorrectAnswer

False

Your Answer True

Multiple Choice Multiple AnswerQuestion Training related to Quality includes:-

Correct

Answer

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



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

Correct

Answer

Variation

Your Answer Percentage defects

Match The Following


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 assignment

Techniques for Operations Efficiency assgn :02: Naresh

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

aggregate level.

CorrectAnswer

False

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 , Identify

steps 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

Select The Blank

Question 5 S audit result is discussed in ________ meeting.



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


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

CorrectAnswer

Implement work standard

Your Answer Implement work standard

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

Correct

Answer

Procurement procedures , Budgeting , Recruitment


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

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.

Correct

Answer

True

Your Answer True



Match The Following


Reduce clamping & declampingtime

Use U- shaped washer Use U- shaped washer

Reduce time of external setup Improve work aids positioning

method

Improve work aids positioning

method

Convert internal setup intoexternal 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

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

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

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:-

Correct

Answer

Who produce the product

Your Answer Quality control department



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

CorrectAnswer

True

Your Answer True

Select The Blank

Question ________ are implemented for defect detection & prevention.

CorrectAnswer

Poka-Yokes

Your Answer Poka-Yokes

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

Correct

Answer

Improve quality

Your Answer Improve quality

Multiple Choice Single AnswerQuestion Implication of Quality problem is:-

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.

Correct

Answer

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

True/False

Question TQM improves the quality by improving processes.



CorrectAnswer

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

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 :-

Correct

Answer

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

Match The Following


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 quality

of the lot

Provide a clue about the quality of

the lot

True/False



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

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.

CorrectAnswer

True

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.

Correct

Answer

True

Your Answer True

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

Correct

Answer

Output , Quality , Cost

Your Answer Output , Quality , Cost

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



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 , Use

of 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/Total

value * 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.

Correct

Answer

Analysis

Your Answer Analysis

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

Correct

Answer

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 :-



CorrectAnswer

Continual Improvement

Your Answer Continual Improvement

3rd assignment

Techniques 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


Question Identifying key preventive operational functions and comparing theseoperational 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

Your Answer Over Production

Select The Blank

Question In scatter diagram "________" relationship is said to exist when there ispositive relationship upto certain level & negative thereafter or negativerelationship upto certain level & positive thereafter.



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

Match The Following


Reduce time of external setup Improve work aids positioningmethod

Improve work aids positioningmethod

Convert internal setup intoexternal setup

Preparation of tools / dies as off line activity




Use U- shaped washer Use U- shaped washer

Multiple Choice Single AnswerQuestion The facilitator should be normally : -



Correct Answer Senior officer /Shop incharge

Your Answer Senior officer /Shop incharge

Match The Following


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:trivial

many"

Philosophy of "vital few:trivial

many"

Parato analysis is technique of identifying vital causes by

Arranging data according to thedescending order of theirfrequency of occurrence

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

Magnitude of defects


Question Quality problem solving tool is used to :-

Correct Answer Improve quality

Your Answer Make work easy

True/False

Question 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




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 AnswerQuestion Implication of Quality problem is:-

Correct Answer Gap in performance

Your Answer Gap in performance

Select The Blank

Question 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



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

Select The Blank

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

Correct Answer Effectively & clearly


Multiple Choice Single AnswerQuestion Errors by armatures is :-

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 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 frombias or undue importance

True/False

Question Globalization of trade and industrial o erations have forced Indian com anies tobecome 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


Question Number of kaizen in Group kaizen categories are :-

Correct Answer Two to three per year



Your Answer Two to three per year

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


Your Answer False


Question It is essential to convey customer's expectations to :-

Correct Answer Top Management

Your Answer Supervisors & workmen

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

Correct Answer Simplest tool

Your Answer Simplest tool

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


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

Correct Answer Vital few = trivial many

Your Answer Vital few = trivial many

True/False

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


Your Answer False

Multiple Choice Multiple AnswerQuestion Benefits of planned maintenance are : -



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 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 , 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


Question 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


Question If defects found at own process, the cost to the company is :-Correct Answer Very littleYour Answer Very high


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 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 , A bird's eye view of the variation

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



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 factors

Your 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 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 day

Your 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


Question In cellular manufacturing system, the cells are designed so that the material flow withinthe cell and between the cells are :-

Correct Answer MinimizedYour Answer Minimized

True/False

Question Kanban signals are required when assembly work, subassembly work and manufacturingat parts is carried out at different locations.

Correct Answer TrueYour Answer True


Question 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 meeting

Your 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 sigmaimplementation , Monitor progress of six sigma projects

Your Answer Approve six sigma projects , Remove road block in the path of six sigmaimplementation , Monitor progress of six sigma projects , Deliver presentation to teams on six sigma

projects

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

True/False

Question Inspection is poor method of assuring 100% quality.Correct Answer TrueYour Answer False


Question 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 Management

Your 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 amountsof ________ 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-Yokes

Your Answer TPM



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


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

Match The FollowingQuestion Correct Answer Your Answer

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 recording

Your 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 of variables 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


Question Allowing worker's to stop machine / assembly line if they believe that product quality isbelow 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 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 verification

Your Answer The check list for verification

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

Your 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 True

Your Answer True

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

muda of transport .Correct Answer Decentralized

Your Answer Decentralized



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

Select The Blank

Question 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 Answer Question Setup time includes :-

Correct Answer Internal setup time & External setup time

Your Answer Internal setup time & External setup time

Multiple Choice Single Answer Question 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

Multiple Choice Single Answer Question Check sheet are also used as :-

Correct Answer Data gathering & interpretation tool

Your Answer Data gathering & interpretation tool


Question SMED means :-

Correct Answer Single minute exchange of dies

Your Answer Single minute exchange of dies

Match The Following



Turnover employee Cost of quality

Financial performancemeasurement

Sales of the months Sales of the months





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


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 prevent reoccurrence.Correct Answer Preceding process

Your Answer Return to stores

Multiple Choice Multiple Answer Question 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

Match The Following



Parato analysis underlines &operates on

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


Question Few steps in construction in Radar chart are :-

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

Select The Blank


Correct Answer Monthly



Your Answer Monthly

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

Correct Answer True

Your Answer False





Question 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 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 Answer Question 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 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 Answer Question What are the steps in deciding the benchmarking partner?

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 Answer Question One Master Black Belt may head a team of :-

Correct Answer 15-20 Black Belts

Your Answer 15-20 Black Belts




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

Correct Answer Main competitor


Multiple Choice Single Answer Question Implication of Quality problem is:-



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 Answer Question Check sheet is easy to use because it is :-



Multiple Choice Single Answer Question 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



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)



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


Question Pareto's analysis underlines & operates philosophy of :-



True/False

Question Kanban signals are required when assembly work, subassembly work and manufacturing atparts is carried out at different locations.

Correct Answer True

Your Answer True

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

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


Multiple Choice Multiple Answer Question 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 bosses



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



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

Multiple Choice Multiple Answer Question 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 Answer Question Quality problem solving tool is used to :-


Your Answer Save time

True/False

Question 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


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



Correct Answer True

Your Answer False

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

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

Multiple Choice Multiple Answer 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 & 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


Correct Answer Voluntary participants of everyone

Your Answer Voluntary participants of everyone

6th

assignments

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

Answer

Identify 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

Match The Following


Review your efforts & successachieved

Check Check

Act about the causes found out Do ActCollect the initial data for the Plan Control



problem

Actions further after reviewingthe progress

Act Repeat

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

person.CorrectAnswer

False

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

CorrectAnswer

Maintaining 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 is

CorrectAnswer

High

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 :-

Correct

Answer

Stability of the process

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

AnswerIncorrect positioning

Match The Following


n scatter diagram, the strengthof relationship can be

determined

By "correlation coefficient" By "correlation coefficient"

The scatter diagram provides The possible relationship The possible dependency



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"


Question Time required to prepare machine to change over from one job to another iscalled :-

CorrectAnswer

Setup time

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

CorrectAnswer

15


Question 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 theinfluencing factors


Correct

Answer

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 :-

Correct

Answer

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

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

CorrectAnswer

True

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

CorrectAnswer

Procurement procedures , Budgeting , Recruitment

Select The Blank

Question uppliers may________ their prices to cover for cost of delivery, small productionrun etc.



CorrectAnswer

Raise

Multiple Choice Single AnswerQuestion Benefits of Seiton means

Correct

Answer

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 theelationship between two variables , To confirm anticipated relationship between

two variables / associated sets of dataSelect 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.

Correct

Answer

True

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

defeat called detection type Poka-Yoke.Correct

Answer

On 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




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

CorrectAnswer

ou 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 :-

Correct

Answer

Can be eliminated

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

Correct

Answer

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

Multiple Choice Multiple AnswerQuestion According to Seiketsu Standardization means :-

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


Question To draw control charts, sample must be representative of homogeneous segmentof 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 materialbatch

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

AnswerC- kanban

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



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

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

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


_______.CorrectAnswer

Checking

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

Answer

True

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

CorrectAnswer

True

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

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








Multiple Choice Multiple Answer Question Flow chart is prepared when :-

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

root causesYour Answer Defining the problem , Trying to know the activities involved in the process , Identifying the

root causes

Multiple Choice Multiple Answer Question Benefits of stratification are :-

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 , It

helps to diagnose & localize problem , It helps to identify the influencing factors


orld class benchmarking companyin assembly automation

Ford Ford

orld class benchmarking companyin marketing

Microsoft Microsoft

World class benchmarking companyin quality

Motorola Motorola

orld class benchmarking companyin training

General Electric General Electric

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

Correct Answer Product development , Technology transfer , Environmental Management



Correct Answer True

Your Answer True

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

Correct Answer Process control

Your Answer Process control


Question The area enclosed under normal distribution curve between mean +1standard deviation is :-



Correct Answer 0.6826

Your Answer 1

Multiple Choice Single Answer Question Quality maintenance means :-

Correct Answer Incorporating quality into product

Your Answer Incorporating quality into product

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

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

Correct Answer True

Your Answer True

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

Correct Answer Study of staff attitudes

Your Answer Developing basic skill

Match The Following


Ideall the histogram will have a bellshape



Histogram is a graphical display of distribution of measurements and



Histogram is a diagrammatic

presentation of

The frequency distribution of a

characteristics

The frequency distribution of a

characteristicsThe shape of histogram can Provide a clue about the quality of

the lotProvide a clue about the quality of the lot

Multiple Choice Multiple Answer Question 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 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



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/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 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

Multiple Choice Multiple Answer Question Histograms are useful to :-

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 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 Training related to Quality includes:-

Correct Answer Quality measures , Quality failure

Your Answer Quality measures , Quality failure






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

Multiple Choice Single Answer Question To maintain smoothness in production :-

Correct Answer Elimination of buffer stock is recommended

Your Answer Elimination of buffer stock is recommended

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



Correct Answer Poka-Yokes


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

Correct Answer High speed automatic machines


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 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 Answer Question 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 Blank

Question Range ( R ) is obtained as the difference between the highest and ________ measurement of a sample.

Correct Answer Lowest

Your Answer Lowest

True/False

Question Automation can correct the basic faults of a improper setup process.


Your Answer False

Multiple Choice Single Answer Question 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



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

Correct Answer True

Your Answer False

Multiple Choice Single Answer Question 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


Correct Answer Evaluation

Your Answer Evaluation

Multiple Choice Multiple Answer Question Benefits from SMED are :-

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 Answer Question Line graph is also called as :-

Correct Answer Run chart

Your Answer Radar chart

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

Correct Answer Width

Your Answer Width

Multiple Choice Multiple Answer Question 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



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 of Low 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)

Greater

attention tocentering of the process

Keepmean &standarddeviationunder strictcontrol

Putefforts to

reducevariability



Use of lessprecisionmachine

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

arrow diagram is called as

36. .

True

False




Multiple Choice Multiple Answer Question Advantages of JIT :-

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


Multiple Choice Multiple Answer Question Benefits from the standardized containers are

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

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


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


Multiple Choice Single Answer Question 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 &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 ou can draw connect &meaningful inference , It helps to diagnose & localize problem ,

Finding out different reasons

Multiple Choice Multiple Answer Question Quality maintenance & pillar focuses on following production inputs

:-Correct Answer Men , Machine , Material


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

development are :-



Correct Answer Managing points


Multiple Choice Multiple Answer Question Steps in setup time reduction are :-

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

Multiple Choice Multiple Answer Question POM essentially consists of :-

Correct Answer Time management , Team participation and performance , Moralboosting

Your Answer Time management , Team participation and performance , CostManagement

Multiple Choice Single Answer Question Activity under quality management is :-

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

Your Answer Maintenance of equipment condition by eliminating lubricantleakage.

True/False

Question Every department should make their own rules of standardization.


Your Answer True

Multiple Choice Multiple Answer 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 specificlimits

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

Match The Following





Sales of the months Cash saving per department




Customer complaints per period


Staff attitude measurement Employee satisfactionindex

Employee satisfaction index

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

Correct Answer Breakdown of machine


Multiple Choice Single Answer Question Kaizen emphasizes :-

Correct Answer Implementation of ideas


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

Correct Answer Visual control


True/False

Question Inadequate maintenance of machine leads to muda of defects

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


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

Correct Answer Defect

Your Answer Defect

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



Correct Answer Equal



Correct Answer True

Your Answer False


Correct Answer True

Your Answer True

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

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

Multiple Choice Single Answer Question TQM applicable to :-

Correct Answer Marketing, design & manufacturing


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

Correct Answer Comparison


Multiple Choice Single Answer Question Production kanban is presented by :-

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 Blank

Question Shitsuke means ________ all the previous 4-S throughout themonth/year.

Correct Answer Sustaining


Multiple Choice Multiple Answer Question Types of meetings held in DWM are :-

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

meeting

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


Correct Answer True

Your Answer True

Multiple Choice Multiple Answer Question According to Seiketsu Standardization means :-

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

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


Your Answer True






Multiple Choice Single Answer Question Total area under the normal curve is

Correct Answer Unity

Your Answer Six

Multiple Choice Multiple Answer Question Cpk =

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


Match The Following



To eliminate MUDA of processing

To eliminate MUDA of over production

SMED To eliminate MUDA of over production



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.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 system

6. Statistical process control

1. Parato analysis underlines &operates on

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

occurrence2. Parato analysis is technique of

identifying vital causes by2. Philosophy of 20% of the activity causes

80% 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 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 The concept of quality circle was mooted by :-

Correct Answer Prof. Kaoishikawa

Your Answer Prof. Kaoishikawa

Match The Following


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 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

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 Answer Question Histogram always indicates :-

Correct Answer Only height

Your Answer Percentage defect

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

Your Answer Present & past customers




Multiple Choice Multiple Answer Question 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 Answer Question 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

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

addressed by office TPM.Correct Answer True

Your Answer True


Correct Answer Buzzers / alarms

Your Answer Locators

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

Correct Answer Continuously

Your Answer Continuously




Match The Following


In scatter diagram, thestrength of relationshipcan be determined


The scatter diagramprovides the technique toestablish

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



True/FalseQuestion 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 :-

Correct Answer ital few = trivial many

Your Answer ital few = trivial many

Multiple Choice Single Answer Question 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 employeesunderstanding of the process by indicating interrelationship

ithin the process.Correct Answer True

Your Answer True

Multiple Choice Single Answer Question 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 Answer Question 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 Answer Question 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 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 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 wrongconclusions , Data should be ree 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 wrongconclusions , 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

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

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


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 Answer Question 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

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

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


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




value of 'y' decreases as the value of 'x' increases.

Correct Answer Strong negative



Correct Answer Cross functional team





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

Correct Answer Implement work standard






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

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

Multiple Choice Single Answer Question Errors by armatures is :-


Your Answer Absent mindedness

True/False

Question Control chart is also called as run-chart.

Correct Answer True

Your Answer True

Match The Following


Reduce clamping &declamping time

Use U-shaped washer Use U-shaped washer

Reduce time of externalsetup

Improve work aidspositioning method



Preparation of tools / diesas off line activity

Preparation of tools / dies asoff line activity


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





Multiple Choice Multiple Answer Question 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





Question In India quality circle was first launched by :-

Correct Answer Hyderabad unit of BHEL



Question 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

Multiple Choice Single Answer Question Responsibility for Quality should rest on:-

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 customer driven.

Correct Answer True

Your Answer True

True/False

Question TQM improves the quality by improving processes.

Correct Answer True

Your Answer True

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

:-

Correct Answer Poorly trained operators , Defect in materials , Frequent adjustmentof machines



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

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

Correct Answer 3.4

Your Answer 6210

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

emphasizes :-Correct Answer Multiskilled operators






Correct Answer Control chart


Match The Following


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 of

measurements and

Reveals the amount of variation within the process

Reveals the amount of variation within the process

Histogram is adiagrammatic presentationof

The frequency distributionof a characteristics

The frequency distribution of a 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/False

Question Seiso prevents the potential problems by discovering abnormalitieswhile 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 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


Question Work standards enable management to minimize variation in :-

Correct Answer Output , Quality , Cost


Multiple Choice Multiple Answer Question Process can be made capable by :-



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

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

Correct Answer Express value of each category as percentage of total of allcategories & 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 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

Multiple Choice Multiple Answer Question 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

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 Answer On occurrence


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

________ of process.

Correct Answer Analysis


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

Correct Answer Employees of different department related to the problem

Your Answer Employees of same department

Select The Blank






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

point for :-Correct Answer Continual Improvement





Multiple Choice Multiple Answer Question Quality maintenance & pillar focuses on following production

inputs :-Correct Answer Material , Men , Machine



Correct Answer Measure the current pattern & extent of variation , Assess


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 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 :-Correct Answer Internal benchmarking


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

system which occurs due to ________.Correct Answer Over Production





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



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

ork and manufacturing at parts is carried out at differentlocations.

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/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 Answer Question 5-S technique is useful to:



Match The Following




Reduce time of externalsetup







Reduce clamping &declamping time


Multiple Choice Single Answer Question The facilitator should be normally :-



Match The Following


Parato diagram alwaysindicates

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

Parato analysis

underlines & operates on

Philosophy of "vital

few:trivial many"

Philosophy of "vital

few:trivial many"

Parato analysis istechnique of identifyingvital causes by

Arranging data accordingo the descending order of

their frequency of occurrence

Arranging data accordingto the descending order of their frequency of occurrence

Parato diagram is a Bar graph with height or valuedrawn by

Arranging data indescending order





True/FalseQuestion 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





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 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


Question Implication of Quality problem is:-



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 interrelationshipithin the process.

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 In scatter diagram "________" relationship is said to exist whenvalue of 'y' decreases as the value of 'x' increases.



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 While preparing scatter diagram following precautions are to betaken :-

Correct 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

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/False

Question Globalization of trade and industrial operations have forcedIndian companies to become more & more competitive andcustomer 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





True/False



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


Your Answer False

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




Question Check sheet is easy to use because it is :-



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

eakness of the activity.Correct Answer Relative






ithdrawn is permitted.Correct Answer False

Your Answer False



Multiple Choice Multiple Answer Question Benefits of planned maintenance are :-

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 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 Sorting of usable items should be



Multiple Choice Multiple Answer Question Benefits of Quality maintenance are :-

Correct Answer Reduction in customer quality complaints , Reduction ininspection time

Your Answer Reduction in customer quality complaints , Reduction ininspection time



Sem – 3rd Techniques for Operations Efficiency 1


True/False

Question Performance benchmarking does not involves comparison of financial ratios at the aggregate level.Correct Answer False

Your Answer False




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

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





Multiple Choice Single Answer Question SMED means :-














Staff attitudemeasurement

Employee satisfactionindex


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



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


Multiple Choice Multiple Answer Question 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 or advertisement of your contribution , Attacking the real rootcauses & all possibilities


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"

Philosophy of "vitalfew:trivial many"

Parato analysis istechnique of identifyingvital causes by

Arranging data accordingto the descending order of their frequency of

occurrence

Arranging data accordingto the descending order of their frequency of

occurrenceParato diagram is a Bar graph with height or valuedrawn by

Arranging data indescending order


Multiple Choice Multiple Answer Question 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 of levels required , Draw concentric circles from each gradiationusing 'o' point as centre



Your Answer Monthly

True/False

Question Fishbone analysis is used both in analysis & planning.

Correct Answer True

Your Answer False




Multiple Choice Multiple Answer Question Role of champions are :-

Correct Answer Approve six sigma projects , Remove road block in the path of six 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 Answer Question 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 machinesetting , 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




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


Question One Master Black Belt may head a team of :-



Multiple Choice Single Answer 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,

heel etc can be monitored through ________ type of controlchart.


Your Answer c-chart






Your Answer True




Multiple Choice Single Answer Question 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)

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












Correct Answer True

Your Answer True

Multiple Choice Multiple Answer Question 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



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





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



Correct Answer True

Your Answer False

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

indicates :-







Correct Answer Quality measures , Quality failureYour Answer Negotiation skill , Goal of business , Quality measures , Quality failure

Multiple Choice Single Answer Question If defects found at own process, the cost to the company is :-

Correct Answer Very littleYour Answer Very high


Correct Answer It shows cause which affects the process , An idea of what ishappening 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. aroundcorrect average & within specific limits , A bird's eye view of the variation



Select The Blank

Question Basic objective of control chart is to ________ the variation due to chance &assignable cause.

Correct Answer Separate out

Your Answer Separate out

Multiple Choice Multiple Answer Question 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 &


influencing factors , Finding out different reasons

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




Multiple Choice Single Answer Question 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 Blank Question JIT helps to ________ the waste in the purchasing process.

Correct Answer EliminatesYour Answer Eliminates


Question In cellular manufacturing system, the cells are designed so that the materialflow within the cell and between the cells are :-

Correct Answer Minimized

Your Answer Minimized


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


Question Causes of Muda of transport are :-Correct Answer Faulty layout , Over production

Your Answer Faulty layout , Over production , Proper material handling equipment ,Low rejection / rework


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

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


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

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

Correct Answer You know your self how to avoid dust , When you touch whilecleaning 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


Question 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 projects

Your Answer Approve six sigma projects , Remove road block in the path of six sigmaimplementation , Monitor progress of six sigma projects , Deliver presentation to teams

on six sigma projects

Select The Blank Question Benchmarking shows how an organization is ________ in comparison to its

competitors.

Correct Answer PerformingYour Answer Performing

True/False



Question Benefits of TQM are :-Correct Answer Greater customer satisfaction , Lower manufacturing cost

Your Answer Greater customer satisfaction , Lower manufacturing cost

Select The Blank Question ________ ensures that communication is simple & effective.Correct Answer Visual Management


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

Your Answer True

Multiple Choice Multiple Answer Question 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 & revealsthe amounts of ________ within the process.




Select The Blank

Question To assess effectiveness of training ________ is essential.Correct Answer EvaluationYour Answer Evaluation

Select The Blank

Question ________ are implemented for defect detection & prevention.Correct Answer Poka-Yokes

Your Answer TPM

True/False

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

Your Answer True

Multiple Choice Single Answer Question Setting & maintaining optimal process condition to get quality product is the

aim of :-

Correct Answer Quality maintenanceYour Answer Quality maintenance

Match The Following




Customer satisfaction measurement Customer complaints per period Customer

complaints per period


Multiple Choice Single Answer Question 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 recording


Match The Following




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 between

a 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 possible

relationship between a pair of variables




True/False

Question Flow chart helps to stop an old process.Correct Answer FalseYour Answer False

Select The Blank

Question Create as many ________ system as possible for better Seiketsu.Correct Answer Visual control

Your Answer Labeling

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 :-


Multiple Choice Single Answer Question 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 quality


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


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


Multiple Choice Multiple Answer Question 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 presentation

Your 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 Blank

Question ________ is the critical element of TQM.Correct Answer Focus on customer


Multiple Choice Multiple Answer Question Management skill includes :-Correct Answer Leadership , Motivation , Performance appraisals

Your Answer Leadership , Motivation , Performance appraisals , Quality measurement

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




Select The Blank Question Inspection activity for semi finished & finished component should be

________ to reduce muda of transport .Correct Answer Decentralized





Correct Answer FalseYour Answer True

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

Correct Answer Teamwork Your Answer Teamwork





Correct Answer Quality measures , Quality failureYour Answer Negotiation skill , Goal of business , Quality measures , Quality failure

Multiple Choice Single Answer Question If defects found at own process, the cost to the company is :-

Correct Answer Very littleYour Answer Very high


Correct Answer It shows cause which affects the process , An idea of what ishappening 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. aroundcorrect average & within specific limits , A bird's eye view of the variation



Select The Blank

Question Basic objective of control chart is to ________ the variation due to chance &assignable cause.



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


influencing factorsYour Answer It helps to separate data into groups so that you can draw connect &


influencing factors , Finding out different reasons

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




Multiple Choice Single Answer Question 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 Blank Question JIT helps to ________ the waste in the purchasing process.

Correct Answer EliminatesYour Answer Eliminates


Question In cellular manufacturing system, the cells are designed so that the materialflow within the cell and between the cells are :-

Correct Answer Minimized

Your Answer Minimized


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


Question Causes of Muda of transport are :-Correct Answer Faulty layout , Over production

Your Answer Faulty layout , Over production , Proper material handling equipment ,Low rejection / rework


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

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


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

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

Correct Answer You know your self how to avoid dust , When you touch whilecleaning 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


Question 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 projects

Your Answer Approve six sigma projects , Remove road block in the path of six sigmaimplementation , Monitor progress of six sigma projects , Deliver presentation to teams

on six sigma projects

Select The Blank Question Benchmarking shows how an organization is ________ in comparison to its

competitors.


True/False



Question Benefits of TQM are :-Correct Answer Greater customer satisfaction , Lower manufacturing cost


Select The Blank Question ________ ensures that communication is simple & effective.Correct Answer Visual Management


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

Your Answer True

Multiple Choice Multiple Answer Question 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 & revealsthe amounts of ________ within the process.




Select The Blank

Question To assess effectiveness of training ________ is essential.Correct Answer EvaluationYour Answer Evaluation

Select The Blank

Question ________ are implemented for defect detection & prevention.Correct Answer Poka-Yokes

Your Answer TPM

True/False


Your Answer True

Multiple Choice Single Answer Question Setting & maintaining optimal process condition to get quality product is the

aim of :-


Match The Following




Customer satisfaction measurement Customer complaints per period Customer

complaints per period


Multiple Choice Single Answer Question 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 recording


Match The Following




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 between

a 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 possible

relationship between a pair of variables




True/False

Question Flow chart helps to stop an old process.Correct Answer FalseYour Answer False

Select The Blank

Question Create as many ________ system as possible for better Seiketsu.Correct Answer Visual control


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 :-


Multiple Choice Single Answer Question 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 quality


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


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


Multiple Choice Multiple Answer Question 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 presentation

Your 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 Blank

Question ________ is the critical element of TQM.Correct Answer Focus on customer


Multiple Choice Multiple Answer Question Management skill includes :-Correct Answer Leadership , Motivation , Performance appraisals


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




Select The Blank Question Inspection activity for semi finished & finished component should be

________ to reduce muda of transport .Correct Answer Decentralized






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

Correct Answer Teamwork Your Answer Teamwork



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 thedescending order of their frequency of

occurrence2. Parato analysis is technique of

identifying vital causes by2. Philosophy of 20% of the activity causes

80% 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 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






Your Answer Prof. Kaoishikawa

Match The Following


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 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

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



Your Answer Percentage defect


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

Your Answer Present & past customers




Multiple Choice Multiple Answer Question 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


Correct Answer Buzzers / alarms

Your Answer Locators

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

Correct Answer Continuously

Your Answer Continuously




Match The Following


In scatter diagram, thestrength of relationshipcan be determined


The scatter diagramprovides the technique toestablish



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 Answer Question Pareto diagram always indicate magnitude of :-


Your Answer Influence of defect



Your Answer False




True/FalseQuestion The flow charts are prepared to enhance the employeesunderstanding of the process by indicating interrelationship

ithin the process.Correct Answer True

Your Answer True

Multiple Choice Single Answer Question 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



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 Answer Question 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



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 Answer Question 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


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 controlYour Answer Measure the current pattern & extent of variation , Assess




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


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

Your Answer Workers & materials


standardization.Correct Answer False

Your Answer False





Your Answer 8 to 10



Your Answer As many as management decides



Your Answer Process

Multiple Choice Single Answer Question 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



TechniquesForOperationsEfficiency_8 LIST OF ATTEMPTED QUESTIONS AND ANSWERS

Select The Blank

Question 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 Answer Question 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 Answer Question 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

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

Multiple Choice Multiple Answer Question 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 projects

Your Answer Approve six sigma projects , Remove road block in the path of Page 1



TechniquesForOperationsEfficiency_8six sigma implementation , Monitor progress of six sigma projects


Question For 'Control on PPM and rework level;, checking points' will be :-Correct Answer PPM level , Initiate corrective actions on rejection/rework ,nitiate preventive action on rejection / reworkYour Answer PPM level , Initiate corrective actions on rejection/rework ,nitiate preventive action on rejection / rework

Multiple Choice Single Answer Question POP is :-Correct Answer Process Oriented Management Your 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 True

Your Answer True

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

important job is :-Correct Answer Prepare for the presentation of your work , Explain thero ress b resentation to steerin committee , Convince committee or

inancial help for running the project Your Answer Prepare for the presentation of your work , Explain the

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


n 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 of variables The possible relationship between a Page 2



TechniquesForOperationsEfficiency_8air of variables

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

data 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 Answer Question While assessing the current status during problem solving Go to

Gamba and look at gembustu is :-

Correct Answer Essential Your Answer Essential depends upon situation

Multiple Choice Multiple Answer Question In absence of P-kanban the workman may :-Correct Answer Carry out machine clean up , Work on improvement ro ect. , Receive traininYour Answer Carry out machine clean up , Work on improvement project.

Multiple Choice Single Answer Question 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 Answer Page 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 rocessCorrect Answer FalseYour Answer True

Select The BlankQuestion ________ participants in monthly meeting(MRM)Correct Answer GM, operation heads, corporate functional headsYour Answer Department heads & supervisors


Question 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 Answer Question 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 Answer Question 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/False

Question TQM organizations also harness the goodwill and interest of the Page 4



TechniquesForOperationsEfficiency_8amily 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 Answer Question 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 Answer Question Bulk production, to reduce setup time is an example of :-Correct Answer Over productionYour Answer Machine utilization


Question SWOT analysis is an important step in :-Correct Answer Deciding what to benchmarkYour Answer Deciding what to benchmark

Multiple Choice Multiple Answer Question Remedial actions for error of misunderstanding is :-Correct Answer Training , Checking in advance , Standardizing workroceduresYour Answer Training , Checking in advance , Standardizing work

rocedures

Select The BlankQuestion ________ is a must in meeting of quality circles.Correct Answer BrainstormingYour Answer Brainstorming

Multiple Choice Single Answer Question The Steering committee as apex body should be :-Correct Answer Only one for all the groups in organization

Your Answer Only one for all the groups in organization Page 5



TechniquesForOperationsEfficiency_8

Multiple Choice Single Answer Question 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 Answer Question Statistical process control is application of statistical technique to

control :-Correct Answer ProcessYour Answer Process

Multiple Choice Single Answer Question 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 Answer Question Examples of Muda of motion are :-Correct Answer Lifting objects , Walking to reach object , Searching for

object Your Answer Lifting objects , Walking to reach object , Searching for object

True/False Page 6



TechniquesForOperationsEfficiency_8Question 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 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 Answer Question Product benchmarking requires, comparison of product :-Correct Answer Performance , Features , Cost Your Answer Performance , Features , Cost

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

Select The BlankQuestion Poka Yoke is ________.Correct Answer Simple techniqueYour Answer Simple technique



Question 5-S technique is useful to: Page 7



TechniquesForOperationsEfficiency_8Correct Answer To all places including homesYour Answer To all places including homes

Multiple Choice Single Answer Question Empowerment means making best use of the firm's most valuableresource, namely:-

Correct Answer HumanYour Answer Human

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

Multiple Choice Single Answer Question TQM is a way to improve quality of product and service :-Correct Answer ContinuouslyYour Answer Continuously

Multiple Choice Multiple Answer Question Best practices for standardization in implementing Seiketsu are :-

Correct Answer Create as many visual control systems as possible , Usecolour code system for easy control , Fix one colour (e.g. Red) for danger

zones/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 True

Your 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 Answer Question Customer's return is an indicators of the MUDA of :-Correct Answer Defect Your Answer Defect


Evolve standard operating procedure & implement. Seiketsu Seiketsu

Hidden faults come out while implementing. Cleaning yourself your equipments Seiso

Fix the place of items, tools as per frequency of use Seiri Seiton

Responsibility same from top to bottom Seiso shitsuke


Question Accountability means :-Correct Answer Responsibility of Business ResultsYour Answer Responsibility Execution or Action

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

True/FalseQuestion Performance benchmarking does not involves comparison of inancial ratios at the aggregate level.Correct Answer FalseYour Answer False

Multiple Choice Single Answer Question Competitive benchmarking is usually conducted :-Correct Answer Through third party researchYour Answer Through third party research

Page 9



TechniquesForOperationsEfficiency_8 Multiple Choice Single Answer

Question Small groups forming a circle should consist of :-Correct Answer Employees of different department related to the problem

Your 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 Answer Question 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 control

Your Answer Measure the current pattern & extent of variation , Assesscurrent 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

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

called ________.Correct Answer c-chart Your 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 Decentralized

Your Answer Decentralized Page 10




Multiple Choice Multiple Answer Question 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 data

Your Answer To discover relationship between two associated sets of data ,To display the relationship between two variables , To confirm anticipated relationship 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


Question 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 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 the results for success


Question Benefits of Quality maintenance are :-Correct Answer Reduction in customer quality complaints , Reduction ininspection time

Your Answer Reduction in customer quality complaints , Reduction ininspection time

Multiple Choice Multiple Answer Question Causes of Muda of transport are :-Correct Answer Faulty layout , Over productionYour Answer Faulty layout , Over production

Page 11



TechniquesForOperationsEfficiency_8 Multiple Choice Multiple Answer

Question 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 , Standards type Poka-Yoke

Multiple Choice Single Answer Question Pie chart is also called as :-Correct Answer Angular diagramYour Answer Angular diagram

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 malfunctionYour Answer To develop abilities to respond quickly to abnormalities , To

develop abilities to discover analyze malfunction , To have multiskilled employees in all departments

Multiple Choice Multiple Answer Question 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 _______ o the de eat called detection t e Poka-Yoke.Correct Answer On occurrenceYour Answer On occurrence

Multiple Choice Multiple Answer Question Typical examples of process benchmark are :-Correct Answer Procurement procedures , Budgeting , Recruitment Your Answer Procurement procedures , Budgeting , Recruitment

Multiple Choice Single Answer Question The area enclosed under normal distribution curve between mean

+2standard deviation is :-Correct Answer 0.9545

Your Answer 1 Page 12




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

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 TQM Correct Answer ISO-9000 quality standard Your Answer TPM

Select The Blank

Question 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 & material Your Answer Worker, equipment & material

Page 13




Question Frequencies, values, tabulated in the frequency table, can berepresented pictorially in the form of bar graph & this graph of frequency is

called as :-Correct Answer HistogramYour Answer Histogram

Multiple Choice Multiple Answer Question 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 Answer Question Management skill includes :-Correct Answer Leadership , Motivation , Performance appraisalsYour Answer Leadership , Motivation


Question 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 ANSWERS Page 14





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 Answer Question Toyota, Honda & Nissan are world class benchmarking

candidates in :-Correct Answer Employee selectionYour Answer Employee selection

Multiple Choice Single Answer Question The leader of the circle should be selected by :-Correct Answer Circle membersYour Answer Steering committee

Multiple Choice Multiple Answer Question Missing parts is due to :-Correct Answer Willful errors , Inadvertent error , Judgment error

Your Answer Willful errors , Inadvertent error

Multiple Choice Single Answer Question Rushing to complete a job is considered symptom of :-Correct Answer Poor planningYour Answer Poor planning

Multiple Choice Multiple Answer Question The purpose of Shitsuke is especially for :-

Correct Answer Maintaining the 4-S consistently , Develop disciplineattitude 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 Answer Question Few typical shapes of histograms are :-Correct Answer Symmetrical (or bell shaped) , Asymmetrical skewed ositive , Double peaked Your Answer Symmetrical (or bell shaped) , Asymmetrical skewed positive ,

Double peaked Page 15




Multiple Choice Single Answer Question 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 Answer Question Breakdown problem may be stratified by :-Correct Answer Sections , Machines , Type of breakdown (e.g mech. Or


electrical)

Multiple Choice Multiple Answer Question Advantages of JIT :-Correct Answer Reduce inventory , Lower per unit cost , Reduce incoming

inspectionYour Answer Reduce inventory , Lower per unit cost , Reduce incoming

inspection


Question Assignable causes :-Correct Answer Can be eliminated Your Answer Can be eliminated

Multiple Choice Multiple Answer Question If 'Inventory investment' is managing point, then checking point

will be :-Correct Answer Stores inventory , Vendor stock , WIP Your Answer WIP , Stores inventory , Vendor stock

True/False Page 16



TechniquesForOperationsEfficiency_8Question Globalization of trade and industrial operations have forced ndian companies to become more & more competitive and customer driven.Correct Answer True

Your Answer True

Multiple Choice Single Answer Question Flow charts are used to train new employees by :-Correct Answer Providing a documented description of the tasks involved Your Answer Providing a documented description of the tasks involved

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


Review your efforts & success achieved Check Check

ct about the causes found out Do Act

Collect the initial data for the problem Plan Plan

ctions further after reviewing the progress Act Repeat

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

Multiple Choice Single Answer Question A flow chart is a pictorial representation of the steps in a :-Correct Answer ProcessYour Answer Process

Multiple Choice Multiple Answer Question 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 the circle & segment the Page 17



TechniquesForOperationsEfficiency_8circle into angles calculated in step one , Colour different segments & enter the

ercentage of each category into pie chart Your 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 the

ercentage of each category into pie chart


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

Multiple Choice Single Answer Question Benefits of Seiton meansCorrect Answer Easy irretrievability of material Your Answer Cost saving in unwanted items

Multiple Choice Multiple Answer Question 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

Your Answer Everyone, clerk to officer does cleaning his area , Everyamily does cleaning of pavement of their residence , Separate department for

cleaning supervision

True/FalseQuestion Six sigma process requires 100 % inspectionCorrect Answer False

Your Answer False

True/FalseQuestion Graph is a tabulated representation of the data which is easily

understandable at a glance.Correct Answer FalseYour Answer True


Correct Answer Decide level of benchmarking , List down a few prospective Page 18



TechniquesForOperationsEfficiency_8candidates of partnership , Collect information of short listed partners

Your Answer Decide level of benchmarking , List down a few prospectivecandidates 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 Answer Question According to Seiketsu Standardization means :-Correct Answer To develop easy to follow standards , Evolve standard

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

operating procedure , Better visual management

Select The BlankQuestion Ford, general electric & Motorola are word class benchmarkingor ________Correct Answer TrainingYour Answer Training

Select The BlankQuestion Cpk for six sigma process is ________Correct Answer 1.5

Your Answer 1.5

Multiple Choice Single Answer Question 5 'S rating after audit is check point for :-Correct Answer Work place improvement Your Answer Work place improvement

True/FalseQuestion Process capability index Cp is a measure of capability of therocess to meet the s eci ication limits.

Correct Answer True Page 19



TechniquesForOperationsEfficiency_8Your Answer True

Select The Blank

Question ________ should be used to exercise control on the process.Correct Answer Control chart Your 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 cost Your Answer Low production cost

Multiple Choice Multiple Answer Question Example of mechanizations are :-Correct Answer Use of fork-lifts / cranes for die - movements , Using

moving bolster , Using roller die carts

Your Answer Use of fork-lifts / cranes for die - movements , Using movingbolster , Using roller die carts

Multiple Choice Single Answer Question To maintain smoothness in production :-Correct Answer Elimination of buffer stock is recommended Your Answer Maintenance of buffer stock is recommended.

Match The Following


onthly meeting Discussion for capital expenditure & customer outstanding. Discussion or ca ital ex enditure & customer outstandin .

Shift begining & shift end / change meeting Discussion on production in last shift & plan for next shift Discussion on production in last shift & plan for next shift

Dail work mana ement meetin Discussion on a anal sis or roduction

maintenance, dispatch Discussion on gap analysis for production Page 20



TechniquesForOperationsEfficiency_8maintenance, dispatch

Weekly meeting Discussion for customer complaints Discussion for customer

complaints

True/FalseQuestion TQM improves manufacturing as well as clerical activities.Correct Answer TrueYour Answer True

Select The BlankQuestion To find out root cause ________used Correct Answer Why-why TechniqueYour Answer Why-why Technique

Multiple Choice Single Answer Question 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 of

Your 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






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 Answer Question 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 valuealls , 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 if needed.

Your Answer Compute mid-point of the class (cell) & fill up the tallysheet determining the cell or class into which each valuealls , 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 if needed.

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

Correct Answer Study of staff attitudes

Your Answer Staff empowerment

Multiple Choice Single Answer Question Poka-yoke for employee not performing work as per

established method is :-



Correct Answer Implement work standard


Multiple Choice Multiple Answer Question 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 Answer Question 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





Question The purpose of Shitsuke is especially for :-

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

Your Answer Maintaining the 4-S consistently , Develop disciplineattitude in everyone , Any day throughout the year sustain 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 & construct

a 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

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


Multiple Choice Single Answer Question Whatever you are doing you can do better by :-

Correct Answer Kaizen

Your Answer Kaizen

Multiple Choice Single Answer Question 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 Answer Question Number of Kaizen projects suggested and implemented

is checking point for :-Correct Answer Continual Improvement


Match The Following


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 which

tasks 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


Question 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 , Reduce

incoming inspectionYour Answer Reduce inventory , Lower per unit cost

Multiple Choice Multiple Answer Question 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 Answer Question Difference between the specification limits is called as :-

Correct Answer Design tolerance

Your Answer Design tolerance

Match The Following


Productivity

performancemeasurement

Turnover employee Turnover employee




Customer complaintsper period

Customer complaintsper period

Staff attitudemeasurement



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 FrequencyYour Answer Frequency

Multiple Choice Single Answer Question 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 Answer Question Competitive benchmarking is usually conducted :-



Correct Answer Through third party research

Your Answer Through third party research

Multiple Choice Single Answer Question 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 Answer Question 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 Answer Question 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 Answer Question 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 Answer Question 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 employees

to improve their qualification

1. SMED 1. To eliminate MUDA of transport

2. VMI ( Vendor ManagementInventory) system

2. To eliminate MUDA of processing

3. Flow / string diagram 3. To eliminate MUDA of

defect4. Value analysis / value

engineering4. To eliminate MUDA of stock

5. To eliminate MUDA of over production

6. To eliminate MUDA of office

1. Control chart is a

graphical method of checking

1. How much variability in the process is due

to 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 of distribution of measurements and

1. Tapering away on the bothsides from average value

2. Histogram is a diagrammaticpresentation of

2. The frequency distribution of defects in the process

3. The shape of histogram can 3. The frequency distribution of a characteristics

4. Ideally the histogram will have a bellshape

4. Provide a clue about thequality of the lot

5. Reveals the amount of variation 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 sister company.

3. Weekly meeting 3. Discussion for capital expenditure &customer outstanding.

4. Monthly meeting 4. Discussion on production in last shift &plan for next shift

5. Discussion on Competitors progress

6. Discussion on gap analysis for production 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 ensuring

defect free equipment2. Quality management 2. To achieve zero breakdown.

3. Safety, hygiene andenvironment

3. To improve product features

4. Planned maintenance 4. To achieve zero accident &zerocontamination

5. To ensure easy to manufacture productdevelopment

6. 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, the

equally 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 Answer Question Advantages of JIT :-Correct Answer Reduce incoming inspection , Reduce inventory , Lower er unit cost Your Answer Reduce incoming inspection , Reduce inventory , Lower er unit cost




Multiple Choice Multiple Answer Question Benefits from SMED are :-Correct Answer Reduce work in process , Better average dailyroduction , Increase capacityYour Answer Reduce work in process , Increase capacity

Multiple Choice Single Answer Question Competitive benchmarking involves identifying key

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


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

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

Multiple Choice Multiple Answer Question Quality maintenance & pillar focuses on followingroduction in uts :-

Correct Answer Men , Machine , Material Page 1



TechniquesForOperationsEfficiency_9Your Answer Men , Machine , Management


Question The success indicators in quality, cost, delivery & roduct development are :-Correct Answer Managing pointsYour Answer Accountability

Multiple Choice Multiple Answer Question 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 Answer Question POM essentially consists of :-Correct Answer Time management , Team participation and erformance , Moral boostingYour Answer Time management , Team participation and erformance , Cost Management

Multiple Choice Single Answer Question Activity under quality management is :-Correct Answer Use team approach to track down root causes of theroblemYour Answer Maintenance of equipment condition by eliminating

lubricant leakage.


standardization.Correct Answer FalseYour Answer True

Multiple Choice Multiple Answer 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 meetingrocess or not i.e. around correct avera e & within s eci ic limits

Your 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 meeting

rocess 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 savinger department


Staff attitude measurement Employee satisfaction index Employeesatisfaction index

Multiple Choice Single Answer Question TPM helps to reduce down time due to:-Correct Answer Breakdown of machine


Multiple Choice Single Answer Question 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 control Your Answer Visual control

True/FalseQuestion Inadequate maintenance of machine leads to muda of

defectsCorrect Answer TrueYour Answer False

Select The Blank Page 3



TechniquesForOperationsEfficiency_9Question The shape of histogram can provide a clue about the _______ of the lot.Correct Answer Quality



Multiple Choice Single Answer Question In bar graph the interval (gap) between the bars is :-Correct Answer Equal Your Answer Symmetrical

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



Multiple Choice Single Answer Question A workshop is to be treated as :-Correct Answer Place where one's creativity can be applied Your Answer Place where one's creativity can be applied

True/False

Question Customer wise outstanding is discussed in daily workmanagement meeting by operations head.Correct Answer FalseYour Answer True

True/FalseQuestion Number of operation can change according toroduction 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.


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 Lowest Your Answer Second highest

Select The BlankQuestion ________is an important step toward successful JIT urchasing.Correct Answer JIT Contract Your Answer JIT Contract


Multiple Choice Single Answer Question TQM applicable to :-Correct Answer Marketing, design & manufacturing


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

of quality.Correct Answer ComparisonYour Answer Performance


Correct Answer P-kanban Page 5



TechniquesForOperationsEfficiency_9Your Answer R-kanban


Question Check sheet are also used as :-Correct Answer 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.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 Answer Question Types of meetings held in DWM are :-Correct Answer Daily PDCA meeting , Weekly PDCA meeting , Monthly

PDCA meetinYour 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 management Page 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 Answer Question Training related to Quality includes:-Correct Answer Quality measures , Quality failureYour Answer Quality measures , Quality failure , Goal of business

Multiple Choice Single Answer Question Total area under the normal curve isCorrect Answer UnityYour Answer Six

Multiple Choice Multiple Answer Question 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 of defect

VMI ( Vendor Management Inventory) system To eliminate MUDA of stock To eliminate MUDA of stock

Flow / string diagram To eliminate MUDA of transport To Page 7



TechniquesForOperationsEfficiency_9eliminate MUDA of processing

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


Question 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 thelowchart , Review the draft & connect the changes as per review & name it & ut 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 thelowchart , Review the draft & connect the changes as per review & name it & ut the data & use it as 'Record'

Select The BlankQuestion In PDCA cycle for benchmarking 'Identification of er ormance a ' is done in ________.Correct Answer CheckingYour Answer Checking

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

Your 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 standard Your Answer Implement work standard


Multiple Choice Multiple Answer Question What are the steps in deciding the benchmarkingartner? Correct Answer Decide level of benchmarking , List down a fewrospective candidates of partnership , Collect information of short listed artnersYour Answer Decide level of benchmarking , Collect information of

short listed partners

Multiple Choice Single Answer Question 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_9 Match 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 method mprove 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


Multiple Choice Single Answer Question Muda of defect is very serious in case of:-Correct Answer High speed automatic machinesYour Answer High speed automatic machines

Multiple Choice Multiple Answer Question 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 Answer Question Requirement of more machines, is an example of :-Correct Answer Muda of overproduction




of :-

Correct Answer Product development , Technology transfer , Page 10



TechniquesForOperationsEfficiency_9 Environmental Management


Multiple Choice Single Answer Question Responsibility for Quality should rest on:-Correct Answer Who produce the product Your 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 & revention.Correct Answer Poka-YokesYour Answer Poka-Yokes


Question Quality problem solving tool is used to :-Correct Answer Improve qualityYour Answer Improve quality

Multiple Choice Single Answer Question Implication of Quality problem is:-Correct Answer Gap in performanceYour Answer Lower efficiency

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


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

of the organizations.Correct Answer Time

Your Answer Labor Page 11




True/FalseQuestion Globalization of trade and industrial operations have

orced Indian companies to become more & more competitive and customer driven.Correct Answer TrueYour Answer True


Multiple Choice Multiple Answer Question 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


Question Defects per million for the process at six sigma level are:-

Correct Answer 3.4Your Answer 6210

Multiple Choice Single Answer Question To provide flexibility to supervisors in allocation of task, IT emphasizes :-Correct Answer Multiskilled operators



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

Correct Answer Control chart Page 12



TechniquesForOperationsEfficiency_9Your Answer Latest checking instruments

Match The Following


deally 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 and Reveals the amount of variation within the process Reveals the amount of variation 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 lot Provide 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

Select The BlankQuestion Cpk for six sigma process is ________Correct Answer 1.5 Your Answer 1.5



Your Answer True Page 13





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 TrueYour Answer True

Multiple Choice Multiple Answer Question Work standards enable management to minimize

variation in :-Correct Answer Output , Quality , Cost


Multiple Choice Multiple Answer Question 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 Answer Question 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 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 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


Question As benchmark in Japan seiso activities means :-Correct Answer Everyone, clerk to officer does cleaning his area , Nosweeper or cleaner employees , Every family does cleaning of pavement of their residence

Your Answer Everyone, clerk to officer does cleaning his area , Nosweeper 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 Answer Question Small groups forming a circle should consist of :-Correct Answer Employees of different department related to theroblemYour 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 Improvement Your Answer Continual Improvement

Page 15



TechniquesForOperationsEfficiency_9--------------------------------------------------------------------


Multiple Choice Multiple Answer Question Quality maintenance & pillar focuses on followingroduction inputs :-Correct Answer Material , Men , MachineYour Answer Material , Men , Machine

Multiple Choice Multiple Answer Question Histograms are useful to :-Correct Answer Measure the current pattern & extent of variation ,ssess 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 ,ssess 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 :-Correct Answer Which best meets the criteria


Multiple Choice Single Answer Question "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 wasterom system which occurs due to ________.Correct Answer Over ProductionYour Answer Over Production

Page 16



TechniquesForOperationsEfficiency_9 Select The Blank

Question In scatter diagram "________" relationship is said toexist when there is positive relationship upto certain level & negative

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


Multiple Choice Multiple Answer Question 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/False

Question In case of more than one quality characteristics,separate chart is made for each quality characteristics.


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

Your Answer True

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


Reduce time of external setup Improve work aids positioning method Page 17



TechniquesForOperationsEfficiency_9mprove 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



Multiple Choice Single Answer Question The facilitator should be normally :-Correct Answer Senior officer /Shop inchargeYour Answer Senior officer /Shop incharge


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

Parato anal sis underlines & o erates on Philosophy of "vital few:trivial many" 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 occurrence

rranging 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 Magnitude of defects

Multiple Choice Single Answer Question Quality problem solving tool is used to :-Correct Answer Improve qualityYour Answer Make work easy






Select The Blank

Question In scatter diagram "________" relationship is said toexist when value of 'y' somewhat decreases as the value of 'x' increases.Correct Answer Weak negativeYour 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 theexamination of the shape of :-

Correct Answer Cloud Your Answer Cloud

Multiple Choice Multiple Answer Question Product benchmarking requires, comparison of product

:-Correct Answer Performance , Features , Cost Your Answer Performance , Features , Cost


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'srelationship 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:-Correct Answer Gap in performanceYour Answer Gap in performance

Select The BlankQuestion Each quality characteristic has permitted variation & is

equal to ________.Correct Answer USL - LSL

Your Answer USL - LSL Page 19





Correct Answer Management Your Answer Management


understanding of the process by indicating interrelationship within therocess.Correct Answer TrueYour Answer False


monthly meeting.Correct Answer FalseYour Answer False


exist when value of 'y' decreases as the value of 'x' increases.

Correct Answer Strong negativeYour Answer Strong negative

Select The BlankQuestion ________ is most difficult 'S' to implement & achieve.Correct Answer ShitsukeYour Answer Shitsuke

True/False

Question Presentation of graphs in pictorial form of datacollection are for easy understanding.Correct Answer TrueYour Answer True



Page 20




Question Errors by armatures is :-Correct Answer Lack of experience


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 or 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 or full range , Scale selected should be right to avoid wrong conclusions ,

Data should be free from bias or undue importance

True/FalseQuestion Globalization of trade and industrial operations haveorced Indian companies to become more & more competitive and customer

driven.Correct Answer TrueYour Answer True

Multiple Choice Multiple Answer Question If 'Annual saving in procurement expenses is managingoint', then checking points will be :-Correct Answer Price revision , Credit period , Transport expensesYour Answer Price revision , Credit period , Transport expenses

Multiple Choice Single Answer Question Number of kaizen in Group kaizen categories are :-Correct Answer Two to three per year


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


Correct Answer Top Management Page 21



TechniquesForOperationsEfficiency_9Your Answer Supervisors & workmen


Question Check sheet is easy to use because it is :-Correct Answer Simplest tool Your 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

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

or weakness of the activity.Correct Answer RelativeYour Answer Relative

Multiple Choice Single Answer Question Pareto's analysis underlines & operates philosophy of :-Correct Answer Vital few = trivial many





Question Benefits of planned maintenance are :-Correct Answer Improved reliability mean time between failures ,mproved maintainability mean time to repair , Improvement in breakdownYour Answer Improved reliability mean time between failures ,mproved 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

Your Answer Equipment , Method , Human Page 22





Correct Answer Manufacturing lead time is moreYour Answer Manufacturing lead time is more

Multiple Choice Single Answer Question Sorting of usable items should beCorrect Answer Planned storage based on frequency of useYour Answer Within visual reach method

Multiple Choice Multiple Answer Question 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

Page 23



TechniquesForOperationsEfficiency_10 LIST OF ATTEMPTED QUESTIONS AND ANSWERS


Question Advantages of JIT :-Correct Answer Reduce incoming inspection , Reduce inventory , Lower er unit cost Your Answer Reduce incoming inspection , Reduce inventory , Lower er unit cost




Multiple Choice Multiple Answer Question Benefits from SMED are :-Correct Answer Reduce work in process , Better average dailyroduction , Increase capacityYour Answer Reduce work in process , Increase capacity

Multiple Choice Single Answer Question Competitive benchmarking involves identifying key

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

Multiple Choice Multiple Answer Question 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 Answer Question Quality maintenance & pillar focuses on followingroduction inputs :-Correct Answer Men , Machine , Material

Your Answer Men , Machine , Management Page 1




Multiple Choice Single Answer Question The success indicators in quality, cost, delivery &

roduct development are :-Correct Answer Managing pointsYour Answer Accountability

Multiple Choice Multiple Answer Question 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 Answer Question POM essentially consists of :-Correct Answer Time management , Team participation and erformance , Moral boostingYour Answer Time management , Team participation and erformance , Cost Management


Question Activity under quality management is :-Correct Answer Use team approach to track down root causes of theroblemYour Answer Maintenance of equipment condition by eliminating

lubricant leakage.


standardization.


Multiple Choice Multiple Answer 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 meetingrocess 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 Page 2





TechniquesForOperationsEfficiency_10 _______ of the lot.Correct Answer QualityYour Answer Distribution


Multiple Choice Single Answer Question In bar graph the interval (gap) between the bars is :-Correct Answer Equal Your Answer Symmetrical

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

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

Your Answer True

Multiple Choice Single Answer Question A workshop is to be treated as :-Correct Answer 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 Answer FalseYour Answer True

True/FalseQuestion Number of operation can change according toroduction requirement in U-Line arrangement.Correct Answer FalseYour Answer True

True/False Page 4



TechniquesForOperationsEfficiency_10Question Automation can correct the basic faults of a improper

setup process.Correct Answer False

Your 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 Lowest Your Answer Second highest

Select The BlankQuestion ________is an important step toward successful JIT urchasing.Correct Answer JIT Contract Your Answer JIT Contract


Multiple Choice Single Answer Question 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 Answer Question Production kanban is presented by :-Correct Answer P-kanban

Your Answer R-kanban Page 5





Correct Answer 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.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 Sustaining


Multiple Choice Multiple Answer Question 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 bereduced.



operating procedure , Better visual management

Your Answer To develop easy to follow standards , Evolve standard Page 6



TechniquesForOperationsEfficiency_10operating procedure , Reduction of wastage

True/False

Question Flow chart helps to stop an old process.Correct Answer FalseYour Answer True

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

Multiple Choice Single Answer Question Total area under the normal curve isCorrect Answer UnityYour Answer Six

Multiple Choice Multiple Answer Question 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



Flow / strin dia ram To eliminate MUDA of transport To

eliminate MUDA of processing Page 7




Select The Blank

Question A 'Radar chart' is used to portray ________ strengthor 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


Correct Answer Decide on the objective of flowchart & define boundariesof the process , Identify steps in the process & construct a draft of thelowchart , Review the draft & connect the changes as per review & name it & ut 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 thelowchart , Review the dra t & connect the chan es as er review & name it & ut the data & use it as 'Record'

Select The BlankQuestion In PDCA cycle for benchmarking 'Identification of erformance 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




Question In scatter diagram "________" relationship is said toexist when value of 'y' decreases as the value of 'x' increases.


Select The BlankQuestion Kaizen projects are managed by ________Correct Answer Cross functional teamYour Answer Management


established method is :-Correct Answer Implement work standard Your Answer Implement work standard


Multiple Choice Multiple Answer Question What are the steps in deciding the benchmarkingartner? Correct Answer Decide level of benchmarking , List down a fewrospective candidates of partnership , Collect information of short listed artnersYour Answer Decide level of benchmarking , Collect information of

short listed partners

Multiple Choice Single Answer Question 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

Match The Following Page 9



TechniquesForOperationsEfficiency_10Question Correct Answer Your Answer

Reduce clamping & declamping time Use U-shaped washer Use

U-shaped washer

Reduce time of external setup Improve work aids positioning method mprove work aids positioning method



Multiple Choice Single Answer Question Muda of defect is very serious in case of:-Correct Answer High speed automatic machinesYour Answer High speed automatic machines

Multiple Choice Multiple Answer Question To reduce clamping & declamping time, following

actions are desirable :-

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

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

Multiple Choice Single Answer Question Requirement of more machines, is an example of :-Correct Answer Muda of overproductionYour Answer Muda of waiting



of :-Correct Answer Product development , Technology transfer ,

Environmental Management Page 10



TechniquesForOperationsEfficiency_10Your Answer Product development , Technology transfer ,

Environmental Management

Multiple Choice Single Answer Question Responsibility for Quality should rest on:-Correct Answer Who produce the product Your 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 & revention.Correct Answer Poka-YokesYour Answer Poka-Yokes


Correct Answer Improve qualityYour Answer Improve quality

Multiple Choice Single Answer Question Implication of Quality problem is:-Correct Answer Gap in performanceYour Answer Lower efficiency

True/False

Question Presentation of graphs in pictorial form of datacollection 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



TechniquesForOperationsEfficiency_10True/FalseQuestion Globalization of trade and industrial operations haveorced Indian companies to become more & more competitive and customer



Multiple Choice Multiple Answer Question 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 Answer Question Defects per million for the process at six sigma level are

:-Correct Answer 3.4Your Answer 6210

Multiple Choice Single Answer Question To provide flexibility to supervisors in allocation of task, IT em hasizes :-Correct Answer Multiskilled operatorsYour Answer Multiskilled operators


Select The BlankQuestion ________ should be used to exercise control on therocess.Correct Answer Control chart

Your Answer Latest checking instruments Page 12





deally 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 and Reveals the amount of variation within the process Reveals the amount of variation 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 lot Provide a clue about the quality of the lot


quantity withdrawn is permitted.


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

Select The BlankQuestion Cpk for six sigma process is ________Correct Answer 1.5 Your Answer 1.5


abnormalities while cleaning your own area.Correct Answer TrueYour Answer True

Page 13



TechniquesForOperationsEfficiency_10 Multiple Choice Multiple Answer

Question 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 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 TrueYour Answer True

Multiple Choice Multiple Answer Question Work standards enable management to minimize

variation in :-Correct Answer Output , Quality , Cost Your Answer Output , Quality , Cost

Multiple Choice Multiple Answer Question 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


Question 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 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 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

segments & enter the percentage of each category into pie chart Page 14




Multiple Choice Multiple Answer Question As benchmark in Japan seiso activities means :-

Correct Answer Everyone, clerk to officer does cleaning his area , Nosweeper or cleaner employees , Every family does cleaning of pavement of their residence

Your Answer Everyone, clerk to officer does cleaning his area , Nosweeper 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 Answer Question Small groups forming a circle should consist of :-Correct Answer Employees of different department related to theroblemYour Answer Employees of same department


summary of data or figures.

Correct Answer Effectively & clearlyYour Answer Effectively & clearly


is checking point for :-Correct Answer Continual Improvement Your Answer Continual Improvement

-------------------------------------------------------------------- Page 15





Multiple Choice Multiple Answer Question Quality maintenance & pillar focuses on followingroduction inputs :-Correct Answer Material , Men , MachineYour Answer Material , Men , Machine

Multiple Choice Multiple Answer Question Histograms are useful to :-Correct Answer Measure the current pattern & extent of variation ,ssess 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 ,ssess 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 :-Correct Answer Which best meets the criteriaYour Answer Which best meets the criteria

Multiple Choice Single Answer Question "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 wasterom system which occurs due to ________.Correct Answer Over ProductionYour Answer Over Production

Select The Blank Page 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 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.


Multiple Choice Multiple Answer Question 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 theillar o TPM.Correct Answer TrueYour Answer True

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


Reduce time o external setu Improve work aids positioning method

mprove work aids positioning method Page 17







Multiple Choice Single Answer Question The facilitator should be normally :-Correct Answer Senior officer /Shop inchargeYour Answer Senior officer /Shop incharge


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 Arrangingdata according to the descending order of their frequency of occurrence

rranging data according to the descending order of their frequency of occurrence

Parato diagram is a Bar graph with height or value drawn by Arrangingdata in descending order Magnitude of defects

Multiple Choice Single Answer Question 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

Your 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 Answer Question 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

Multiple Choice Multiple Answer Question Product benchmarking requires, comparison of product

:-Correct Answer Performance , Features , Cost Your Answer Performance , Features , Cost


Correct Answer Collect paired data (X,Y) from two variables who'srelationship 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'srelationship 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:-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




Question Kaizen is ________ supported process.Correct Answer Management



understanding of the process by indicating interrelationship within therocess.Correct Answer TrueYour Answer False


monthly meeting.Correct Answer FalseYour Answer False


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


Select The BlankQuestion ________ is most difficult 'S' to implement & achieve.Correct Answer ShitsukeYour Answer Shitsuke

True/FalseQuestion Presentation of graphs in pictorial form of data

collection are for easy understanding.Correct Answer TrueYour Answer True



Multiple Choice Single Answer Page 20



TechniquesForOperationsEfficiency_10Question Errors by armatures is :-Correct Answer Lack of experienceYour Answer Lack of experience

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 or 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 or full range , Scale selected should be right to avoid wrong conclusions ,

Data should be free from bias or undue importance

True/FalseQuestion Globalization of trade and industrial operations haveorced Indian companies to become more & more competitive and customer



Question If 'Annual saving in procurement expenses is managingoint', then checking points will be :-Correct Answer Price revision , Credit period , Transport expensesYour Answer Price revision , Credit period , Transport expenses

Multiple Choice Single Answer Question Number of kaizen in Group kaizen categories are :-Correct Answer Two to three per year Your Answer Two to three per year

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

Multiple Choice Single Answer Question It is essential to convey customer's expectations to :-Correct Answer Top Management

Your Answer Supervisors & workmen Page 21





Correct Answer Simplest tool Your 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

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

or weakness of the activity.Correct Answer RelativeYour Answer Relative

Multiple Choice Single Answer Question Pareto's analysis underlines & operates philosophy of :-Correct Answer Vital few = trivial manyYour Answer Vital few = trivial many




Correct Answer Improved reliability mean time between failures ,mproved maintainability mean time to repair , Improvement in breakdownYour Answer Improved reliability mean time between failures ,m roved maintainabilit mean time to re air

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 , HumanYour Answer Equipment , Method , Human

Page 22




Question Some quantity in stock of item, is desirable if :-Correct Answer Manufacturing lead time is more


Multiple Choice Single Answer Question Sorting of usable items should beCorrect Answer Planned storage based on frequency of useYour Answer Within visual reach method

Multiple Choice Multiple Answer Question 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

Page 23




Skip Questions.








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

level.Correct Answer False

Your Answer False





Question Participants of the groups for quality circles should be decided by :-

Correct Answer Employees coming together by their own enthusiasm





Multiple Choice Single Answer Question SMED means :-



Match The Following








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






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 Answer Question 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

Match The Following




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

Multiple Choice Multiple Answer Question Few steps in construction in Radar chart are :-

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 draw

vertical line & calibrate it equal to the number of levels required , Draw concentric circles fromeach gradiation using 'o' point as centre



Your Answer Monthly

True/False

Question Fishbone analysis is used both in analysis & planning.




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 Answer Question 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 Answer Question 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 Answer Question One Master Black Belt may head a team of :-



Multiple Choice Single Answer 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 Answer Question 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







True/False

Question Kanban signals are required when assembly work, subassembly work and manufacturing atparts 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








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

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

True/False

Question In bar graph each bar is of same height.


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

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

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


Correct Answer Voluntary participants of everyone

Your Answer Voluntary participants of everyone

2nd Copy


Multiple Choice Multiple AnswerQuestion Training related to Quality includes:-


Your 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 little

Your Answer Very high





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 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

, A bird's eye view of the variation

True/False

Question In bar graph each bar is of same height.


Select The Blank

Question Basic objective of control chart is to ________ t he variation due to chance & assignable cause.




Question 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 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 the influencing factors , Finding out different

reasons


Question 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


Question 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 Blank

Question JIT helps to ________ the waste in the purchasing process.

Correct Answer Eliminates



Question 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/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


Question Causes of Muda of transport are :-

Correct Answer Faulty layout , Over production

Your Answer Faulty layout , Over production , Proper material handling equipment , Low rejection /

rework





Question Types of meetings held in DWM are :-

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

Your Answer Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA meeting


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


Question 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 d ust , 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 Blank

Question Benchmarking shows how an organization is ________ in comparison to its competitors.


True/False



Question Benefits of TQM are :-

Correct Answer Greater customer satisfaction , Lower manufacturing cost


Select The Blank

Question ________ ensures that communication is simple & effective.

Correct Answer Visual Management


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

Correct Answer True

Your Answer True

Multiple Choice Multiple AnswerQuestion Key principles of TQM :-

Correct Answer Continuous improvement , People involvement , Cost of quality

Your 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 o f

________ within the process.

Correct Answer Variation

Your Answer Variation

Select The Blank

Question To assess effectiveness of training ________ is essential.

Correct Answer EvaluationYour Answer Evaluation



Your Answer TPM

True/False


Your Answer True


Question Setting & maintaining optimal process condition to get quality product is the aim of : -


Match The Following







Question 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

Match The Following


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 of

variables 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 pair

of variables






Question 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

Question Flow chart helps to stop an old process.






Question Allowing worker's to stop machine / assembly line if they believe that product quality is belowstandard' is an example of :-

Correct Answer Empowerment

Your Answer Empowerment


Question Kanban Signals are required when :-Correct Answer Set up time on t he feeding operation is higher then the receiving operation.

Your Answer Set up time on the feeding operation is higher then the receiving operation.


Question Kanban system is

Correct Answer 1. Pull SystemYour Answer 1. Pull System


Question Quality problem solving tool is used to :-Correct Answer Improve qualityYour Answer Improve quality


Question To avoid short receipt of items to customers, provide the dispatch clerk with :

Correct Answer The check list for verification


True/False

Question Control chart is also called as 'Mean -Range or X-chart'.

Correct Answer True

Your 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 presentation

Your 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 Blank

Question ________ is the critical element of TQM.

Correct Answer Focus on customer






Question Management skill includes :-

Correct Answer Leadership , Motivation , Performance appraisals



Question 5-S technique is useful to:

Correct Answer To all places including homesYour Answer To all places including homes


Correct Answer True

Your Answer True

Select The Blank

Question Inspection activity for semi finished & finished component should be ________ to reduce mudaof transport .

Correct Answer Decentralized


True/False

Question Flow chart is pictorial representation of the steps in production control.Correct Answer False

Your Answer True

Select The Blank

Question Good ________ is the asset to acquire the success of quality circle.

Correct Answer TeamworkYour Answer Teamwork

3rd Copy





Multiple Choice Multiple Answer Question Benefits from the standardized containers are

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


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





Multiple Choice Single Answer Question 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

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

Correct Answer Men , Machine , Material


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

Correct Answer Managing points


Multiple Choice Multiple Answer Question Steps in setup time reduction are :-

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


Question POM essentially consists of :-

Correct Answer Time management , Team participation and performance , Moral boosting

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

Multiple Choice Single Answer Question Activity under quality management is :-

Correct Answer 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.


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

Match The Following





Sales of the months Cash saving per department


Customer complaints per period Customer complaints per period


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

Correct Answer Breakdown of machine


Multiple Choice Single Answer Question Kaizen emphasizes :-

Correct Answer Implementation of ideas









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

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




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





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

Correct Answer True

Your Answer True

Multiple Choice Single Answer Question TQM applicable to :-

Correct Answer Marketing, design & manufacturing


Select The Blank




Question Bar graph is display of data that facilitates ________ of quality.




Correct Answer P-kanban








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 True




Your Answer True

Multiple Choice Multiple Answer Question According to Seiketsu Standardization means :-

Correct Answer To develop easy to follow standards , Evolve standard operating procedure , Better visual 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.


Your Answer True




Multiple Choice Single Answer Question Total area under the normal curve is


Your Answer Six

Multiple Choice Multiple Answer Question Cpk =

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


Match The Following



To eliminate MUDA of processing To eliminate MUDA of over production

SMED To eliminate MUDA of over

production






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 Blank

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



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 steps

in 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.












Question Muda of defect is very serious in case of:-




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

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

clamping device




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

Correct Answer Hyderabad unit of BHEL


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

Correct Answer Product development , Technology transfer , Environmental Management


Multiple Choice Single Answer Question Responsibility for Quality should rest on:-

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


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

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


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

Correct Answer 3.4

Your Answer 6210

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

Correct Answer Multiskilled operators






Correct Answer Control chart


Match The Following


Ideally the histogram will have abell shape



Histogram is a graphical displayof distribution of measurementsand



Histogram is a diagrammaticpresentation of



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

Provide a clue about the quality of 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

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

Correct Answer Output , Quality , Cost



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






Correct Answer Continual Improvement


5th Copy


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




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 Answer Question In problem solving the best alternative is that :-






Multiple Choice Single Answer Question 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

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

quality characteristics.Correct Answer True

Your Answer True


Correct Answer True

Your Answer True


Question 5-S technique is useful to:



Match The Following


Reduce time of external setup Improve work aids positioningmethod

Improve work aids positioningmethod

Convert internal setup intoexternal setup Preparation of tools / dies as off line activity Preparation of tools / dies as off line activity








Question The facilitator should be normally :-



Match The Following




Philosophy of "vital few:trivialmany"

Philosophy of "vital few:trivialmany"


Arranging data according to thedescending order of their frequency of occurrence

Arranging data according to thedescending order of their frequency of occurrence

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 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 :-Correct Answer Cloud

Your Answer Cloud




Multiple Choice Multiple Answer Question Product benchmarking requires, comparison of product :-




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 of relationship

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 of relationship




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






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







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 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


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

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


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









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 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 Sorting of usable items should be



Multiple Choice Multiple Answer Question Benefits of Quality maintenance are :-



5th

Copy



Question Advantages of JIT :-








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 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

Match The Following


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 per

period



Question TPM helps to reduce down time due to:-Correct Answer Breakdown of machine



Question Kaizen emphasizes :-

Correct Answer Implementation of ideasYour Answer Collection of ideas

Select The Blank

Question Create as many ________ system as possible for better Seiketsu.Correct Answer Visual controlYour Answer Visual control

True/False

Question Inadequate maintenance of machine leads to muda of defects

Correct Answer True

Your Answer False

Select The Blank

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

Correct Answer Quality


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


Your Answer Defect

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



True/False

Question Inspection is poor method of assuring 100% quality.




Correct Answer True

Your Answer False

True/False

Question A radar chart is combination of a circle & line graphCorrect Answer True

Your Answer True


Question 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

True/False

Question Customer wise outstanding is discussed in daily work management meeting by operations

head.


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


Your Answer True

True/False

Question Automation can correct the basic faults of a improper setup process.


Your Answer True

Select The Blank

Question Cp for six sigma process is ________

Correct Answer 2

Your Answer 1.66

Select The Blank

Question Range ( R ) is obtained as the difference between the highest and ________ measurement of

a sample.

Correct Answer Lowest





True/False

Question U-Line layout is better than straight lime layout.Correct Answer True

Your Answer True


Question TQM applicable to :-Correct Answer Marketing, design & manufacturing


Select The Blank

Question Bar graph is display of data that facilitates ________ of quality.







Question Production kanban is presented by :-

Correct Answer P-kanbanYour Answer R- kanban

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



Select The Blank

Question Japanese believe that when they are ________ they are cleaning there minds too.



Select The Blank

Question Poka-Yoke devices under category use ________ to distinguish between similar parts which

may be assembled in wrong position.Correct Answer Color coding


Select The Blank

Question Shitsuke means ________ all the previous 4-S throughout the month/year.



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




Correct Answer True

Your Answer True


Question According to Seiketsu Standardization means :-

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 , Reduction

of wastage

True/False

Question Flow chart helps to stop an old process.Correct Answer False

Your Answer True


Question Training related to Quality includes:-Correct Answer Quality measures , Quality failure



Question Total area under the normal curve is





Your Answer Six


Question Cpk =

Correct Answer (x - USL)/3 sigma , (x - LSL)/3 sigmaYour Answer (x - USL)/6 sigma

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

Match The Following


Value analysis / value engineering To eliminate MUDA of processing To eliminate MUDA of overproduction



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

Select The Blank


Correct Answer RelativeYour Answer Comparative

------------------------------------------------------------


True/False

Question Performance benchmarking does not involves comparison of financial ratios at the aggregate

level.



Question 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 Blank

Question In PDCA cycle for benchmarking 'Identification of performance gap' is done in ________.

Correct Answer Checking


Select The Blank







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

value of 'x' increases.






Question Poka-yoke for employee not performing work as per established method is :-Correct Answer Implement work standard



Question Typical examples of process benchmark are :-

Correct Answer Procurement procedures , Budgeting , RecruitmentYour Answer Procurement procedures , Budgeting , Recruitment


Question 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


Question Errors by armatures is :-Correct Answer Lack of experienceYour Answer Absent mindedness

True/False

Question Control chart is also called as run-chart.

Correct Answer True

Your Answer True

Match The Following


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 of

tools / dies as off line activity



Question Muda of defect is very serious in case of:-







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


Question An erratic patterns falling above & below the control limits indicates :-

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



Question 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 operators



Question To maintain smoothness in production :-Correct Answer Elimination of buffer stock is recommended


Select The BlankQuestion ________ should be used to exercise control on the process.Correct Answer Control chart


Match The Following


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 variation

within 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 of

the lot

True/False

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


Your Answer False




True/False

Question 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

Select The Blank

Question Cpk for six sigma process is ________Correct Answer 1.5

Your Answer 1.5

True/False

Question Seiso prevents the potential problems by discovering abnormalities while cleaning your own

area.

Correct Answer True

Your Answer True


Question 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

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/False

Question Processing cost of a product is mainly decided by conversion process.



Question Work standards enable management to minimize variation in :-Correct Answer Output , Quality , CostYour Answer Output , Quality , Cost


Question Process can be made capable by :-

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


Question 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 the

percentage of each category into pie chart

Your 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 the

circle & segment the circle into angles calculated in step one , Colour different segments & enter thepercentage of each category into pie chart



Correct Answer Everyone, clerk to officer does cleaning his area , No sweeper or cleaner employees ,





Your Answer Everyone, clerk to officer does cleaning his area , No sweeper or cleaner employees ,


Select The Blank

Question Poka Yoke designed to help operators to know immediately ________ of the defeat calleddetection type Poka-Yoke.

Correct Answer On occurrence


Select The Blank

Question Flow chart helps to dissect a process for better understanding & ________ of process.Correct Answer Analysis



Question Small groups forming a circle should consist of :-

Correct Answer Employees of different department related to the problemYour Answer Employees of same department





Question Number of Kaizen projects suggested and implemented is checking point for :-

Correct Answer Continual Improvement


--------------------------------------------------------------------







Question Histograms are useful to :-Correct Answer Measure the current pattern & extent of variation , Assess current conformance to


Your Answer Measure the current pattern & extent of variation , Assess current conformance to


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



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







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



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


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/FalseQuestion 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


Question 5-S technique is useful to:Correct Answer To all places including homes



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


Reduce clamping & declamping time Use U-shaped washer Use U-shaped washer





Question The facilitator should be normally :-



Match The Following


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 byArranging 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 AnswerQuestion Quality problem solving tool is used to :-



True/False

Question 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



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 :-Correct Answer Cloud

Your Answer Cloud


Correct Answer Performance , Features , CostYour Answer Performance , Features , Cost


Question Steps in construction of scatter diagram :-

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 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





Question Implication of Quality problem is:-



Select The Blank

Question Each quality characteristic has permitted variation & is equal to ________.

Correct Answer USL - LSLYour A nswer USL - LSL




True/False

Question The flow charts are prepared to enhance the employees understanding of the process byindicating 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

Select The Blank

Question 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 BlankQuestion ________ is most difficult 'S' to implement & achieve.Correct Answer Shitsuke


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


Correct Answer Effectively & clearlyYour Answer Effectively & clearly


Question Errors by armatures is :-




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.


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



Question Number of kaizen in Group kaizen categories are :-



True/False

Question Flow chart is pictorial representation of the steps in production control.


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




Question Check sheet is easy to use because it is :-Correct Answer Simplest tool


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

muda of ________.

Correct Answer Processing


Select The Blank


Correct Answer RelativeYour Answer Relative


Question Pareto's analysis underlines & operates philosophy of :-Correct Answer Vital few = trivial many


True/False

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


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


Question Gap analysis & problem identification is done during converting internal setups into externalsetups in the areas like :-

Correct Answer Equipment , Method , Human



Question Some quantity in stock of item, is desirable if :-Correct Answer Manufacturing lead time is more



Question Sorting of usable items should be

Correct Answer Planned storage based on frequency of useYour Answer Within visual reach method

Multiple Choice Multiple AnswerQuestion Benefits of Quality maintenance are :-



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 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 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 problem

sets the boundaries for that follows. Decision maker, like a doctor, must take into accountall symptoms before prescribing the medicines (i.e. recommending the decision). Peter

Drucker 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 time

wasting 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

s the problemesolved?

nd

No



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 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 to

inquiries 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 supported

by 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. Most

common sources of collecting and listing of alternatives include experience, superiors, juniors, consultants, research, creativity, brain storming, critical examination, literature

etc.

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 unearththese alternatives. Usually, a brain storming or interaction session with those, concerned

with the problem can highlight several alternatives. For example, the company wasconsidering 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 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 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 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 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 areexamined 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 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 while

entailing 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 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 isrecycling 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 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 counter

measure

Measure /analyseachievement

Satisfactory

performance?

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 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 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 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.

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 the

horizontal 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

Cause D

Problem

Man Machine

MaterialsMethod



A cross function team constituted to study problem of employees’ poor morale have

conducted on following probable causes. Draw a “cause and effect” diagram fromthe given data…Ans:

oor Management selection

ack of communication

Improper management tra ning

EMPLOYEE

HIRINGREWARD/RECOGNITION

MANAGEMENTWORKING CONDITIONS

oor selection

Incom lete ob descri tion

ecruitin errors

Poor Management selection

Low pay level

Wage differentials

oor benefits

avoritism

ack of discipline methods

ublic reprimands

nclear company goals

aulty working assignment

Bad Lighting

oise

Temperature

Long working hours

xcessive 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 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 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

Girls

42%

Females

18%

Males

20%Boys

20%

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 analysisunderlines 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 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 moredangerous than others)

80% of the shopping that takes place is done in 20% of the time of the store areopen.(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 onmaterials.

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 inmany 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 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 “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 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 help

identified 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 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 7Wrong delivery of mail lllll lllll lllll 20Late delivery of outgoing mail to P.O lllll lllll ll 12

Rude 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 44.44

Late delivery… 12 26.67 72.1Behind schedule mail 7 15.55 86.65

Incorrect charges 5 11.11 97.76Rude clerks 1 2.22 100.00

PARETO's DIAGRAM

2012

7 5 1

44.44

26.67

15.55 11.112.22

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 improveeffectiveness 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 maymake 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 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 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 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 a

series 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 have

endangered 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. 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 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 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 likeProduction, 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 growthof 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-togetherso 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 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 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

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’s

o 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 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 progresswith 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 of the 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 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 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 quality

circles. The responsibility of the coordinating department includes:o Rendering assistance as request by circles

o Disseminating literature relating to circle activities elsewhereo Organizing training programmes

o Publishing newsletter to communicate circle activitieso Providing circles with necessary facilities for the meeting

o 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 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 addedactivities, 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.



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, 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 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’ cleaningresponsibility.

Seiketsu Standardize Standardization Maintain cleanliness through Seiri, Seiton andSeiso 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 aresupposed to be done (i.e. developing habit of

following rules/ practices) including 5-S practices.

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 low

volume 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 and

decrease 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 can

be 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 automats

iii. Lathes, turret lathesiv. Milling machines

v. Drilling machinesvi. Broaching machines.vii. Forging machines

viii. Paint manufacturing equipmentix. 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 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 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 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, burns

removal, 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 the

job 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. 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 timeso Drop in inventory levelso Reduction in set-up scrap

o 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 of

double 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, still

later 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 any

activity) 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 though perspiring, 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 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 torecent advances in manufacturing technologies), we also need to look at various other hidden wastages, besides human waste, to improve productivity.

Elimination of sampleruns, inspection,

ad ustments

Comp.

A run

Study

blue

rint

Remove

existing

Replace

oo at the

rib store

Install tools

for the new

job

Sample

runAdjust

Run for

componentA

SETUP Run for

component

Component

B

Component

A

Setup

Sample

run



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 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 sequenceo 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’tadd any value. Typical examples are –

o Walking to reach objects/ parts. Toolso Lifting or carrying objects

o Picking up and putting down a work pieceo 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 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 causes

physical 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 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?



List down different kinds of human errors. How can they be eliminated? How is

PokaYoke technique useful to eliminate human errors?



Ans:

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 tolower the crossing gate

Misunderstanding

Jumping to thewrong conclusion

due to poor

familiarity with thesituation

1. Putting foot on clutch

thinking it is brake1. Training2. Checking in advance

3. Standardizing work

procedures.

Mistakenidentity

Misjudging asituation

1. Mistaking Rs.500 note asRs.100 note

1. Improving attentiveness.

Errors byamateurs

Lack of experience 1. Improper welding

2. Wrong measurements1. On-the-job training2. Work Standardisation

Willful errors Ignoring rules/

deliberate wrongactions

1. gnoring safety rules

2. Crossing a street againsta red light just because

there are no vehicles insight at the moment.

3. Not replacing blunt toolon time

1. Attitude change.

2. Education

Inadvertenterrors

Absent mindednessi.e. not knowing how

the problem / error has occurred

1. emoving job beforecompleting drilling of allholes

2. Crossing street without

noticing that the light is red

1. Improving attentiveness2. Work standardization

Judgmental

errors

Errors due to absence

of instructions of work standards

1. ifference in method of

measurement used byvendor and by buyer’sinspection

2. Operator deciding his own

1. Works instructions

2. Work standardization.

Errors due toabsence of

standards

Lack of instructionsor absence of work

instructions

Measurements left to the

discretion of the workman

1. Works instructions

2. Work standardization.

Type of

Error

Forgetfulness 1. tering operator in advance

2. Checking at regular intervals

3. Verification by another

employee



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

together 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 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 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 is

about 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 lights

3. Limit switches4. Counters

5. 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 a

management 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 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

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 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 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 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 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.

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 be

used 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 which

allows 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 for failsafin

Model machinexercises in TPM

Exercises to identify MURA,UDA and MURI

Spotting abnormalities atGemba

Internal customer’scom laints

External customer’s

com laints

Cost of ualit

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 to

Kaizen teams

Conduct PDCA-SDCA

improvement cycles



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

The “PLAN” elementPlanning counter

measures

Preparing action plan to fix the

problem

The “DO” elementImplementing counter

measuresVerifying 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 + theSTANDARDIZE

element of SDCA




Select The BlankQuestion Due to SMED, ________ time cuts down.

Correct Answer Waiting

Your Answer Operation

Multiple Choice Multiple Answer Question 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 Answer Question A control chart is also called as :-

Correct Answer Run chart

Your Answer Flow chart

Select The Blank

Question Ideally the histogram will have a symmetrical ( i.e. also called asbell) 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 quantityYour 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



Correct Answer True

Your Answer False

True/FalseQuestion Review is important step in problem solving.

Correct Answer True

Your Answer True


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 Answer Question The area enclosed under normal distribution curve between

mean +3standard deviation is :-Correct Answer 0.9973

Your Answer 0.9545



Multiple Choice Single Answer Question In autonomus modules or cells, rate of production increases :-

Correct Answer Number of operators increases

Your Answer Number of operators increases


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 , Assess

current 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 Answer Question DOE stands for

Correct Answer Design of Experiments

Your Answer Degree of Evaluation

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


Your Answer True

Multiple Choice Multiple Answer Question Limitation of quality circles are :-

Correct Answer Problems headed by worker group must be simple & within their limit , Unions in India are reluctant , Management is also not

open for unionYour Answer Problems headed by worker group must be simple & within their limit , 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 Answer Question 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 Answer Question 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 Answer Question 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 Answer Question 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 Answer Question Causes of Muda of transport are :-


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 ariation

Your Answer Duplicating

Multiple Choice Single Answer Question 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 Answer Question Kaizen process is built on PDCA cycle, where P represents :-

Correct Answer PLAN

Your Answer PLAN

Multiple Choice Single Answer Question For normal distribution curve, skewness & kurtosis are : -

Correct Answer Zero



Your Answer One






Your Answer Japanese unit of scientist & engineers(JVSE)



Your Answer True

Match The Following


Kanban Pull system Statistical process control

Work standards Best way of doing job Best way of doing job

TPM Reducing breakdown of machines

Reducing breakdown of machines

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

Multiple Choice Multiple Answer Question 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 Answer Question Theoretically, the normal curve can extend :-

Correct Answer From - Infinity to + Infinity

Your Answer From 0 to+ infinity

Match The Following


Control chart can be used As process monitoringtool

Stability of the process

Control chart is agraphical method of checking

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 assignable

causes

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 Answer Question 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 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' , Circulateflowchart




Select The BlankQuestion _______ is management skill.

Correct Answer Delegation

Your Answer Delegation



range , Scale selected should be right to avoid wrongconclusions , Data should be free from bias or undue importanceYour Answer Data should be properly stratified & should be collected for full

range

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 Answer Question 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 Answer Question 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 danger zones/out of controls

Your Answer Create as many visual control systems as possible , Use colour code system for easy control , Display warning notices

Multiple Choice Single Answer Question 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 pointYour Answer Reducing process variability , Bringing target & average to fall at

the same point , Examine possibility of relaxing specification


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

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

projects



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 Answer Question 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


Question 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 wrong

position.Correct Answer Color coding

Your Answer Color coding




Match The Following


Any thing misplacedshould be visualimmediately

Seiketsu Display Colour codesmeanings

Unrepairable tool or equipments

To be scrapped under Seiri

To be scrapped under Seiri

Colour coding essentialthroughout but

Display Colour codesmeanings

Colour codes as per departments



Surprise Audit any timeshould shout consistentgood housekeeping

Shitsuke for maintenanceof 4-S

Seiketsu

Multiple Choice Single Answer Question 5-S technique is useful to:



Multiple Choice Single Answer Question 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 Answer Question 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 Answer Question Causes of Muda of transport are :-


Your Answer Faulty layout , Over production


Question For the presentation of the quality circle project what is requiredis :-

Correct Answer Presentation skills , Graphical data , Progressive efforts of theteam work

Your 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

Match The Following


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 Answer Question Benefits of TQM are :-

Correct Answer Greater customer satisfaction , Lower manufacturing cost




Multiple Choice Single Answer Question ilfredo 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 Answer Question 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 if further 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 if further stratification is required?

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





Your Answer Process

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

process.Correct Answer False

Your Answer True




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