1.

State the need of inspection

Here's a refined version for better clarity:
To ensure that a part, material, or component conforms to the
established standard.
To achieve interchangeability in manufacturing.
To maintain customer relations by ensuring that no faulty product
reaches the customer.

2. State objectives of quality control

1. Improved Income
2. Cost Reduction
3. Interchangeability
4. Customer’s Satisfaction
5. Optimum Quality
6. Integration of Quality Effects
7. Quality Mildness

3. State the application of p chart and c chart

Applications of P Chart & C Chart

P Chart (Proportion Defective Chart) Applications:

1. Determine average defect rate over time.

2. Used in sampling inspection of large lots.
3. Alerts management to changes in quality levels.
4. Helps identify & fix defects in processes.
5. Maintains a record of quality trends for analysis.

C Chart (Count of Defects Chart) Applications:

1. Detect surface defects in aircraft wings.

2. Identify defects like blowholes & cracks in castings.
3. Track imperfections in textiles per unit area.
4. Check surface defects in galvanized sheets.
5. Monitor small holes in glass bottles.

7. List advantages of S.Q.C

Advantages S.Q.C
 (a) Efficiency and cost red" (Reduction)
(0) Hou effective pressure
(2) Reduction snap
(d) Improvement in inspection std
(e) Improves productivity

8. Define T.Q.M and state four pillar/ principles of

T.Q.M.
TQM (Total Quality Management) is a business philosophy that focuses
on:
• Managing the entire organization to ensure excellence in
products and services.
• Customer satisfaction as the ultimate goal, beginning and ending
with the customer.
• Continuous improvement in processes, employee involvement,
and quality control.

Pillars of T.Q.M
1. Customer satisfaction

2. Do work right the first time

3. Continuous Improvement

4. Commitment of Top Management

5. Employee Involvement and Empowerment

6. Process centred

7. Integrated system

Define inspection. List stages/types of inspection.

It is defined as the act of checking of materials, products
and components of products at various stages of
manufacturing
1. Incoming inspection

2. In-process inspection

1.first piece 2. Floor 3. Operator 4. Last piece inspection

3. Final inspection

state the factors affecting the quality of

product(any-2)
Factors affecting the quality
• Machines
• Materials used
• Men
• Manufacturing process
• Dimensional variation in the product
• Inspection stages

9. State disadvantages of 100% inspection. (any-2)

1. High cost of inspection
2. Inspection fatigue

3. Time required is more

4. Equipment investment is high

Define cost of quality and value of quality

Cost of Quality
The cost of quality is categorized into cost of control
(conformance) and cost of failure (non-conformance).
 Cost of Control (Conformance):

1. Prevention Cost – Actions taken to prevent defects:

o Process control

o Training quality personnel

o Design review

2. Appraisal Cost – Cost to check quality during production:

o Inspection of raw materials

o In-process inspection

o Quality audits

Cost of Failure (Non-Conformance):

1. Internal Failure Cost – Before product delivery:

o Scrap

o Rework and repair

o Wastage of time

2. External Failure Cost – After customer receives the product:

o Replacement of defective products

o Customer complaints

Minimizing failure costs through effective prevention and

appraisal reduces overall quality-related expenses.

Value of Quality
Quality control provides both direct and indirect benefits to a
company, enhancing overall efficiency and customer satisfaction.

Direct Benefits:

• Increased sales volume due to better product quality.

 • Higher production efficiency, leading to cost savings.

• Reduced scrap and rework costs, minimizing material wastage.

Indirect Benefits:

• Improved brand reputation and customer goodwill.

• Psychological stability among workers due to job security.

• Long-term business growth and customer trust.

Maintaining high-quality standards ensures profitability,

efficiency, and a strong market presence.

State responsibilities of master black belt employee

of six sigma team

Responsibilities of a Master Black Belt in Six Sigma

A Master Black Belt (MBB) is responsible for leading and mentoring
Six Sigma projects across the organization. Their key responsibilities
include:
1. Training & Mentoring – Guides and supports Black Belts &
Green Belts in Six Sigma methodologies.
2. Strategic Implementation – Aligns Six Sigma projects with
business objectives.

Define quality of design and quality of conformance

Quality of Design:
• It refers to how precisely the product specifications are defined for
manufacturing.
• It includes factors such as geometry, tolerances, material selection, and
performance requirements.
• The quality of design is determined based on customer needs and
expectations.
Quality of Conformance:
 • It refers to how well the manufactured product meets the design
specifications.
• It ensures that the final product aligns with the intended quality standards.
• Both quality of design and quality of conformance play a crucial role
when the product is put to use.

4 marks question

1. List objectives of Quality control (any -4)

Objectives of quality control

• Improved income
• Cost reduction
• Interchangeability
• Customer satisfaction
• Optimum quality
• Integration of quality effects

2. With the help of graph explain optimum quality

of design.
Optimum quality of design is called as the balance between cost of
quality and value of quality'.
Data collected during market surveys, such as expected sales of
product, profit, competition in the
market etc. is used to design the component or product, which will
meet the needs of consumers.
But it is not necessary that a company produce 100% quality products
(l.e. products being extremely
high quality) because the more the quality is expected, the more the
production cost will be.
 Therefore, the aim of the company should be to produce products
which will meet the requirements of consumers at lower cost.

3.Apply 5S principle to an automobile service station

Sr. 5S English
Application in Service Station
No. Principle Meaning
Remove unnecessary items like scrap parts
1 SEIRI Sort
and waste oil.
Organize tools and equipment for easy
2 SEITON Set in Order
access based on usage frequency.
Clean the workplace regularly to maintain
3 SEISO Shine
hygiene and efficiency.
Set rules for cleanliness and assign
4 SEIKETSU Standardize
responsibilities for maintaining 5S.
 Sr. 5S English
Application in Service Station
No. Principle Meaning
Make 5S a habit through regular checks and
5 SHITSUKE Sustain
continuous improvement.

State any-4 tools of quality control. Explain fish

bone diagram.
Tools for Quality
Control
Check Sheets
Pareto Charts
Why-Why
Diagrams
Cause & Effect
Diagrams
Flowcharts
Histograms
Scatter Diagram
Control Charts

State any two similarities and differences between six

sigma and T.Q.M
Here’s a simple comparison of Six Sigma vs. TQM:
Comparison: Six Sigma vs. TQM
TQM (Total Quality
Aspect Six Sigma
Management)
Based on worker Led by business leaders
Approach
improvement & teamwork (Champions)
 TQM (Total Quality
Aspect Six Sigma
Management)
Workplace & departmental
Focus Cross-functional projects
improvements
Tools Used Simple improvement tools Advanced statistical tools
Financial Little financial Requires measurable ROI
Accountability accountability (Return on Investment)

Similarities Between Six Sigma & TQM

1. Both aim to reduce defects and improve quality.
2. Both link to profitability by cutting costs from rejections, rework, and
customer complaints.

Explain P.D.C.A cycle.

PDCA Cycle (Plan-Do-Check-Act)

1. Plan
o Identify the problem.
o Analyze the issue using quality control tools.
o Generate possible solutions.
o Select the best solution and create a detailed action plan.
2. Do
o Implement the plan on a small scale.
o Provide necessary training to employees.
 oConduct brainstorming and education sessions.
3. Check
o Evaluate the results by analyzing collected data.
o If results are positive, move to the next step.
o If negative, refine the plan and repeat until the desired results are
achieved.
4. Act
o Standardize successful changes.
o Fully implement improvements across the organization.
o Monitor continuously for further enhancements.

If the results of measurement and analysis are found satisfactory

during the 'Check' stage, the next step is to adopt the changed
process through standardization and incorporate it into regular
procedures or work instructions.

Explain the methodology of six sigma

Six Sigma Methodology: -

DMAIC vs. DMADV in Six Sigma

1. DMAIC (Define, Measure, Analyze, Improve, Control)
Used for improving existing processes.
• Define: Identify and select projects, set goals, and form teams.
• Measure: Collect data, identify key customer needs, and process
characteristics.
• Analyse: Determine critical performance factors and validate causes.
• Improve: Develop solutions, test improvements, and optimize processes.
• Control: Implement controls, monitor progress, and evaluate financial
impact.
 2. DMADV (Define, Measure, Analyze, Design, Validate)
Used for designing new processes or products.
• Define: Set goals and project objectives.
• Measure: Collect key data on customer needs and process characteristics.
• Analyze: Evaluate options and validate the best approach.
• Design: Develop a new optimized process or product.
• Validate: Test with a pilot run and implement at full scale.

State various certifications used in six sigma

Six Sigma Certifications
1. Green Belt
o Project leaders trained in Six Sigma for two weeks.
o Use statistical tools and assist in Six Sigma projects.
o Spend 50% of their time on projects (4-6 months).
2. Black Belt
o Advanced project leaders trained for four weeks.
o Focus on Six Sigma strategies and statistical methodologies.
o Spend 75% of their time on projects (4-6 months).
3. Master Black Belt
o Technical expert and mentor for Black Belts & Green Belts.
o Provides guidance and training in Six Sigma methodologies.
4. Champions
o Executive-level leaders responsible for Six Sigma implementation.
o Facilitate leadership and deployment of Six Sigma strategies.

Explain The Concept Of Quality Circle.

Quality Circle
A Quality Circle is a small group of employees (usually 6-12) from
the same work area who voluntarily meet to identify, analyze, and
solve workplace problems.
Concept:
• Encourages employee participation in decision-making.
• Focuses on continuous improvement in quality and productivity.
• Uses problem-solving techniques like brainstorming and cause-
effect analysis.
 • Enhances teamwork, motivation, and communication.

explain poka-yoke system

Poka-Yoke System
Poka-Yoke is a Japanese term meaning "mistake-proofing" or
"error prevention." It is a technique used in manufacturing and
service industries to prevent defects by detecting and correcting errors
before they cause problems.
Concept:
• Ensures zero defects by eliminating human errors.
• Uses simple mechanisms, sensors, or procedures to prevent
mistakes.
• Reduces rework, waste, and customer complaints.

Examples:
1. USB ports – Can only be inserted one way to avoid incorrect
connections.
2. ATM card insertion – Prevents incorrect card orientation.
3. Car seatbelt alarm – Alerts the driver if the seatbelt is not
fastened.
Poka-Yoke improves product quality, safety, and efficiency by
making errors impossible or easy to detect.

With the help of O.C Curve explain consumer risk

and
 producer risk.

Key Terms in Sampling Inspection

1. AQL (Acceptable Quality Level)
o Maximum proportion of defectives that is considered acceptable.
o Ensures quality meets consumer expectations.
2. LTPD (Lot Tolerance Percent Defective) / RQL (Rejectable Quality
Level)
o Maximum defect rate beyond which the lot is rejected.
o Represents unsatisfactory quality (low probability of acceptance).
o Also called Consumer’s Risk, as it protects the customer from bad
products.
3. OC Curve (Operating Characteristic Curve)
o A graph showing the probability of accepting a lot based on its
defect rate.
o Helps in evaluating sampling plans.
4. Sampling Plan Parameters
o N = Lot size (total items in a batch).
o n = Sample size (number of items inspected).
o c = Acceptance number (maximum defects allowed in the sample).
o Changing these parameters alters the OC curve.
5. AGL (Acceptable Quality Limit)
o Maximum defect rate considered satisfactory for process control.
6. IQL (Indifference Quality Level)
o A quality level between AQL and RQL.
 o Has a 50% probability of acceptance, meaning it’s neither clearly
acceptable nor rejectable.

Compare single and double sampling plan

Single Double Multiple
Comparison Point
Sampling Sampling Sampling
Average No. of In between
Pieces Inspected Largest Single & Lowest
per Lot Multiple
Cost of Highest (due to
Lowest Moderate
Administration multiple stages)
Least
Largest (one-
Information on (inspection
time Moderate
Quality Level spread over
inspection)
multiple stages)
Less Most acceptable
Acceptability to More
acceptable (flexible
Producers acceptable
(strict) process)
Longest
Inspection
Shortest Moderate (continues for a
Duration
long time)

Determine the control limits for X and

R charts, if ∑ X = 357.50 and ∑ R =
9.90. Number of subgroups = 20. It is
given that A2= 0.18, D3 = 0.41, D4=
1.59 and d2 = 3.735. Also find the
process capability.
The following X and R values of 10
samples of 5 each. The specification
limits for the component are 59+/-3.5.
Establish the control limits for X and
R chart will the product be able to
meet its specification given A2=.577,
D3=0, D4=2.111.
Sr.no X R
 1 57.8 1.50
2 58.8 1.75
3 58.8 2.00
4 59.8 2.25
5 59.8 2.2
6 60 2.00
7 60.3 1.00
8 60.4 1.50
9 60.9 2.00
10 61.8 1.75
The following table gives the
number of missing rivets noted at
aircraft final inspection find C
compute trial control limits and
plot control charts for C. What
values of C would you suggest for
the subsequent period.
Air No of Air No of Air No of
plane missing plane missing plane missing
no rivets no rivets no rivets
1 8 11 23 21 10
2 16 12 16 22 22
3 14 13 9 23 7
4 19 14 25 24 28
5 11 15 15 25 9
6 15 16 9
7 8 17 9
8 11 18 14
9 21 19 11
10 12 20 9