GE8077- Total Quality Management UNIT I- INTRODUCTION Introduction - Need for quality - Evolution of quality - Definitions of quality - Dimensions of product and service quality - Basic concepts of TQM - TQM Framework - Contributions of Deming, Juran and Crosby - Barriers to TQM - Customer focus - Customer orientation, Customer satisfaction, Customer complaints, Customer retention. PART A (15 x 1 = 15 marks) 1 Define Quality (Q) = __________. Where, P – Performance & E - Expectations b c d 2 a b c d P/E P*E P+E P–E Total Quality Management (TQM) focuses on ___________. Employees Customers Employees & Customers Management 3 Choose the responsibility for quality objective, ___________ Management a b c d Quality Frontline Middle level Top level 4 “Quality is Fitness free” is the term Coined by _________ a b c d 5 a b c d 6 a b c d 7 a b c d Joseph Juran Crossby Deming Shewart According to Deming, Quality problems are due to ________. Machine Materials Supply Management _______ helps organization reduce employee turnover and absenteeism Training and Development Job Design Salary revision Incentive Quality Trilogy includes______________ Quality planning Quality Definition Quality enhancement Quality Cost a GE8077- Total Quality Management 8 Quality Planning __________ a b c Identifies the customer Choose units of measurement Take action on the difference Provide Remedies d 9 a b c d 10 a b c d 11 a b c d 12 a b c d 13 a b c d 14 a b c d 15 "Quality is defined by the customer" is An unrealistic definition of quality A user-based definition of quality A manufacturing-based definition of quality A product-based definition of quality After E.deming, who is considered to have the greatest impact in quality management? Kauro Ishikawa Joseph M. Juran W.E. Deming Genichi Tagucchi Quality practices must be carried out ______________ At the start of the project Throughout the life of the project At the end of the project No need to carry out quality practices Based on his 14 Points, Deming is a strong proponent of ______________. Inspection at the end of the production process An increase in numerical quotas to boost productivity Looking for the cheapest supplier Training and knowledge ______________ is the set of activities that ensures the quality levels of products and services are properly maintained and that supplier and customer quality issues are properly resolved Quality Assurance Quality Planning Quality Control Quality Management Which of the following is not a target of Total Quality Management? Customer Satisfaction Reducing manpower Continuous Cost Reduction Continuous Operational Improvement __________ are the areas that will be covered by the organization's processes GE8077- Total Quality Management a Process areas b Product areas c Private areas d Preset areas PART B (10 x 2 = 20 marks) 1 “Total Quality Management approach of an organization, centered on quality, based on the participation of all its members and aiming at long-term success through customer satisfaction, and benefits to all members of the organization and to society” is a definition coined by a Indian Statistical Institute b c d Total Quality forum of USA E.Deming ISO Which of the following is correct option for given statements about TQM? Statement 1: Design of the formal system is a one time effort. Statement 2: TQM is a management philosophy. (T – TRUE, F – FALSE) 2 a b c d 3 a b c d 4 a b c d 5 F,F F,T T,T T, F Match the following A. Dr. Deming believes 1. Common causes B. Ishikawa development 2. To prevent defect C. Type of variation is due to 3. Cause & effect diagram D. Crosby’s objective of quality 4. Histogram A-3, B-2, C-1, D-4 A-2, B-3, C-4, D-1 A-2, B-3, C-1, D-4 A-4, B-3, C-1, D-2 Quality approach - Productivity quality - cost -Delivery Pillar of TQM - Continual improvement management Need for TQM is due - Employee TQM focuses on - Cut throat competition The correct order is A-2, B-1, C-4, D-3 A-1, B-2, C-4, D-3 A-2, B-1, C-3, D-4 A-2, B-4, C-1, D-3 Kano model is useful for GE8077- Total Quality Management User Conferences for the end users a Identifying Customer Needs b Government Laboratory Data c Simulate user experiments. d 6 Which of the following is NOT a common way to collect customer needs? Customer Surveys, focus groups , market research programs and studies a Compare performance with competitors b Routine communications, such as sales and service calls and reports c Tracking customer complaints,incident reports,letters and telephone contacts. d 7 a b c d 8 a b c d 9 a b c d 10 a b c d Which among the following a NOT a step involved inCROSBY s quality improvement? Build awareness of the need and opportunity Take actions to correct Problems identified through previous steps Hold a zero defects day to reaffirm management commitment Encourage individuals and groups to set improvement goals Evidence based decision making is a principle that includes Ensure that people’s ability are used Model Organization Values Meet Customer requirements Balance data analysis with practical experience Current Quality Concept is i. Increase in production ii. Continual improvement iii. Prevention of defect i&ii i&iii ii&iii i,ii&iii The fourth absolute of a quality defined by Crosby is The definition of quality is conformance to requirements ,not goodness The measurement of quality is the price of non-conformance ,not indexes The performance standard must be zero defect, not”that’s close enough” The system for causing quality is preventive, not appraisal. GE8077- Total Quality Management UNIT II- TQM PRINCIPLES Leadership - Quality Statements, Strategic quality planning, Quality Councils - Employee involvement - Motivation, Empowerment, Team and Teamwork, Recognition and Reward, Performance appraisal - Continuous process improvement PDCA cycle, 5S, Kaizen - Supplier partnership - Partnering, Supplier selection, Supplier Rating PART A (15 x 1 = 15 marks) 1 According to Maslow human motivation is a hierarchy of ____________ needs a Physiological, Esteem, Logical b c d Physiological, Societal, Personal Physiological, Social, Safety Physiological, Self-actualization, Biological Kaizen is a _________ process, the purpose of which goes beyond simple productivity improvement. Weekly Daily Monthly Annual 2 a b c d 3 Inspection is part of the ______________ a b c quality control Quality Planning Quality improvement Quality circle d 4 Which 5S phases focuses cleaning of work place? a b c SEIRI SEITON SESISO SEIKETSU d 5 a b c d 6 a b c d 7 What are the core principles of the TQM in a company-wide effort? Customer and process orientation only Continuous improvement only Process orientation and continuous improvement only Continuous improvement, process and customer orientation Vision states___________________. Where the workers want to go after work Whether we should use SPC Whether we should use inspection Where the company wants to be in the long run A Persons feeling of pleasure which results in products performance that match expectations is called ___________________. GE8077- Total Quality Management Customer Satisfaction a b c d Customer Retention Customer Focus Dissatisfaction 8 What does the Japanese word SEIRI refers to? a b c d 9 a b c d Self Discipline Systematic arrangement Sorting out Sweep QFD stands for ______________. Quantity for deployment Quality for deployment Quality function deployment Quality for decision _____________ is a Japanese word which means continuous improvement or improvement over improvement. Kaizen Kairyo Seiketsu Keirestu __________provides both customer and supplier the much needed environment to achieve the planned objective. 10 a b c d 11 a b c d 12 a b c d 13 a b c d i. 14 ii. iii. a b c d Trust Long-term Commitment Continuous Improvement Increased Efficiency ______________ is the use of only one supplier for the organization. uni sourcing Single sourcing Multiple Sourcing Sole Sourcing Which one of these is not part of the 5s ? System Sort Set in order Standardize While setting Goal, following things to be consider. i. Customer need ii. Marketability of product iii. Organization need i only i&ii ii&iii i,ii,iii GE8077- Total Quality Management 15 a b c d In which stage of supplier selection Performance of the supplier is evaluated mainly on the basis of quality and promptness in delivery is done ? Survey Stage Enquiry Stage Negotiation Stage Experience Stage PART B (10 x 2 = 20 marks) 1 a Two suppliers A and B deliver the same raw materials for production company Z. The price offered by supplier A is less compared to the price offered by supplier B. The quality of both the raw materials is the same. Which supplier should the company choose considering other factors remaining the same for both of them? Supplier A a b c d Supplier B Both of them None of them Continuing leadership between a buying firm and a supplying firm involving a commitment over an extended time period, an exchange of information, and acknowledgement of risks and rewards is termed as ______ Long –term Commitment Shared Vision Partnering Relationship development. 3 The requirements of Reliable supplier rating includes _______________ a b c d Survey Stage, Enquiry Stage, Negotiation Stage ,Experience stage Survey Stage, Enquiry Stage, Sourcing stage, Experience stage Partnering Stage Negotiation Stage ,Experience stage Rating stage Enquiry Stage, Negotiation Stage ,Sourcing stage Match the following group 1 items with group 2 items b c d 2 4 a b c d 5 a 1. Sort -------------------------------------------------- A. Seitan 2. Set in order ----------------------------------------- B. Seiketsu 3. Shine ------------------------------------------------ C. Seiri 4. Standardize ---------------------------------------- D. Seiso 1 – D, 2 – A, 3 – B, 4 – C 1 – C, 2 – A, 3 – D, 4 – B 1 – B, 2 – C, 3 – A, 4 – D 1 –A, 2 – C, 3 – D, 4 – B According to Maslow’s hierarchy of needs, which of the following does not belong to safety needs? Protection from fire and accident GE8077- Total Quality Management Lack of economic security involving health and insurance b The desire for an orderly and predictable environment c The desire to know the limits of acceptable behaviour d 6 a b c d 7 a b c d 8 a b c d 9 a b c d 10 a b c d Two suppliers A and B deliver the same raw materials for production company Z. The price offered by supplier A is less compared to the price offered by supplier B. Which supplier should the company choose? Supplier A Supplier B Both of the suppliers A & B Depends on other factors like quality Which of the following is an incorrect way of providing recognition in an organization? Create a ‘best ideas of the year’ booklet Feature the quality team of the month Develop a ‘behind the scenes’ award Feature the worst performer of the month Performance Appraisal is also known as _________ or __________ Performance review, Annual review Performance review, Loss review Loss review, Annual review Discount review, Loss review Kaizen works well in _________ and Kairyo works well in ___________ Slow-growth economy, fast-growth economy Fast-growth economy, slow-growth economy Fast-growth economy, fast-growth economy Slow-growth economy, slow-growth economy Which of the following is not an advantage of the performance appraisal system? Managers can assign the right job to the right employee based on his/her skills Employees can assess their performance Employees can compare their performance with fellow colleagues Employees feel demotivated after assessing their performance GE8077- Total Quality Management UNIT III- TQM TOOLS AND TECHNIQUES I The seven traditional tools of quality - New management tools - Six sigma: Concepts, Methodology, applications to manufacturing, service sector including IT - Bench marking - Reason to bench mark, Bench marking process - FMEA - Stages, Types. PART A (15 x 1 = 15 marks) 1 a Who among the following suggested seven quality tools for controlling quality? Juran 2 a b c d Kaoru Ishikawa Dr. W. Edward Deming Feigenbaum Which type of chart uses the rule of 20:80? Cause and effect chart Pareto chart fish bone diagram control chart 3 Benchmarking determines____________ a b c d Customer requirements How company is doing relative to others Getting ISO 9000 audit done Process capability 4 Cause-effect diagram is used in_________ a b c d 5 a b c d Problem identification Vendor surveys Problem analysis Negotiating with unions Fishbone diagrams are drawn_________ To find customer needs To find the cost of quality To brainstorm causes of an effect To screen workers’ suggestions Control chart is I Process monitoring tool II Process control tool III Process planning tool b c d i. ii. 6 iii. a b c d 7 iv. a b v. i only i & ii ii& iii i, ii & iii All the factors that might contribute to a production problem must be discovered. Which among the following problem-solving tools might be the best choice? Pareto diagrams Fishbone diagrams GE8077- Total Quality Management c vi. Histograms d vii. Control charts 8 a viii. b ix. c x. d xi. 9 a b c d 10 a b c d 11 a b c d 12 a b c d 13 a b c d 14 a b c d 15 Theysetvery clear scope for all Six Sigma projects. They are responsible for approving any changes to the scope of the project Six Sigma Deployment Leader Champion Black Belt Green Belt What is another name of fishbone diagram? Taugchis diagram Cause and effect Kaizen Poka yoke diagram ____________is a form for systematic data gathering and registering to get a clear view of the facts . Check sheet Delivery Sheet Cheat Code Invoice ____________ is a bar chart showing a distribution of variable quantities or characteristics Pareto chart FMEA Histogram Scatter Diagram ____________diagram which is a component of regression analysis uses a simple graphical device that depict the relationship between two variables. Scatter Diagram Cause and Effect Diagram Control Chart Pareto Chart Which tool is used to analyse the effects of a failure of individual components on the system? FTA FMEA Quality circles Fool proofing What is arrow diagram in TQM? A diagram used to plan the most appropriate schedule Diagram shows the relationship strength between the variables Used large amount of data and organise it on the basis of natural relationship between items Diagram showing the sequencing and inter relationships between factors Which of the following type of histogram represents two normal distributions with two peaks in the middle? GE8077- Total Quality Management Double-peaked a Bell-shaped b Plateau c Edged peak d PART B (10 x 2 = 20 marks) 1 The acronym DMAIC stands for a Develop ,Metrics, Analyse, implement, contain Define, measures, analyse, improve, control Define, measures, analyse, improve, control Develop ,Metrics, Analyse, implement, control Match the following b c d 2 a b c d 3 a b c d 4 a b c d 5 a b c d A. Dr. Deming believes 1. Histogram B. Ishikawa development 2. Common causes C. Type of variation is due to 3. Cause & effect diagram D. Crosby’s objective of quality 4. To prevent defect A-4, B-3, C-1, D-2 A-3, B-4, C-2, D-1 A-4, B-3, C-2, D-1 A-4, B-2, C-3, D-1 A welding shop receives a lot of complaints about poor quality solder joints. How could you analyze it using the Tools of Quality? ANOVA Cause and Effect Diagram Control Chart Bar Graph The seven basic quality tools focus on the __________ aspect and the new seven management tools focus on the ______ aspect. Quantitative, numerical Numerical, quantitative Quantitative, qualitative Qualitative, quantitative Which of the following is not a cause of poor marks of class 12 students in board exams after studying the cause and effect diagram? Improper teaching Lack of seriousness of students due to distractions Too much focus on competitive exams Extremely hot climate in the area GE8077- Total Quality Management 6 A scatter diagram represents the relationship between _________ and ________ Cause, effects a Cause, problem b Effects, output c Production, productivity d 7 a b c d 8 a b c d 9 a b c d 10 a b c d The horizontal lines above and below the centre line in control chart are known as _________ and ________ respectively. Upper control limit, lower control limit Lower control limit, upper control limit Upper control limit, medium control limit Lower control limit, medium control limit In a matrix data analysis diagram, two different brands are compared. Brand 1 is having the coordinates (40,6) and Brand 2 is having the coordinates (40,-6). Xaxis is the cost of the item and Y-axis is customer satisfaction. Which brand would you prefer? Brand 2 Brand 1 Both are equally preferred Can’t be determined Brand 1 and Brand 2 have the same x-component i.e. 40. So, the cost of the item is equal for both the brands. But, Brand 2 has a negative y-component i.e. -6 whereas Brand 1 has a positive y-component i.e. 6. So, Brand 1 has a positive customer satisfaction and Brand 2 has a negative customer satisfaction. Therefore, Brand 1 is preferred. In which form of benchmarking is comparison of a business process done with a similar process within the organization? Internal benchmarking Competitive benchmarking Functional benchmarking Generic benchmarking A particular product has been given the following rankings for calculating RPN while preparing FMEA chart, S=10, O=2, D=2. What is the value of RPN 20 10 40 2 The RPN is the product of Severity, Occurrence and Detection rankings. Therefore, RPN=S*O*D, or RPN=10*2*2=40. GE8077- Total Quality Management UNIT IV- TQM TOOLS AND TECHNIQUES II Quality Circles - Cost of Quality - Quality Function Deployment (QFD) - Taguchi quality loss function - TPM - Concepts, improvement needs - Performance measures. PART A (15 x 1 = 15 marks) 1 a Which technique is used to relate complex cause and effect relationships? Affinity diagram b c d 2 a b c d Pareto diagram Scatter diagram Interrelationship diagram 3 A __________ diagram Shows the location of defects in any unit. a b c d Affinity Relations Defect Concentration Scatter 4 _________ is used to identify what might go wrong in a plan under development. a b c d Pareto Chart PDPC Arrow Diagram Matrix Diagram Juran ‘s Quality Management Philosophy is based on three pillars namely planning, Control and ___________. Implementation Improvement Monitor Design 5 a b c d 6 a. a b c d xii. 7 a b c d xiii. 8 a b What is the formula for process capability index? (1-K)Cp (1+K)Cp (1-Cp)K (1+Cp)K For a point in the control chart to be out of the control , it must lie Above UCL or Below LCL Between Central Line and LCL Between Central Line and UCL None of the above The main aim of QFD is to Listen to the voice of customer Lower cost Reduce errors Reduce supplier defect When the number of defects is low, which among the following is true . We should use c or u chart Most samples will have non-zero defects GE8077- Total Quality Management Create a time between occurrence control chart c None of the above d 9 Arrow diagram in TQM is A diagram used to plan the most appropriate schedule a Diagram shows the relationship strength between the variables b Used large amount of data and organise it on the basis of natural relationship between items c Diagram showing the sequencing and inter relationships between factors d __________ is a powerful tool for breakthrough improvements ,starting all over again 10 from the scratch . a Reengineering b Benchmarking c Profiling d Best in Class ___________ is one where numerical data is used instead of symbols indicating the 11 existence and strength of a relationship. a Matrix Data Analysis Diagram b Tree Diagram c Affinity Diagram d Arrow Diagram ___________is a holistic approach to equipment maintenance that strives to achieve 12 perfect production. a Signal to Noise Ratio b Total Productive Maintenance c QLF d Performance Measures . 13 Performance indicator for the Customers are indicated by the ______ a Productivity b Throughput c Service Rating d Customer Satisfaction Index ____________ are prizes awarded for some aspect of quality performance which has 14 been demonstrated to an organization which normally has no responsibility for the recipient’s performance. a Performance Measures b Quality Awards c Process Capability Index d QLF 15 QFD is a method for a Controlling quality in restaurants b Finding out what customer wants c Translating customer needs to product specs d Quality circles GE8077- Total Quality Management PART B (10 x 2 = 20 marks) 1 a __________ is defined as keeping the running plant and equipment at its highest productive level with the co-operation of all areas of the organization. Predictive Maintenance a b c d Preventive Maintenance Total Inventive Maintenance Total Productive Maintenance Overall Equipment Effectiveness is an aspect with ______. Predictive Maintenance Preventive Maintenance Total Productive Maintenance Total Inventive Maintenance Quality Loss Occurs when a products deviates from target or nominal value. Deviation Grows, then Loss increases is _______ statement. Taguchi N shaped Loss Function Curve Taguchi U shaped Loss Function Curve Taguchi V shaped Loss Function Curve Taguchi L shaped Loss Function Curve 4 Taguchi Methods is a statistical methods developed largely by ______. a b c d Hamilton Taguchi Genichi Taguchi Albert Taguchi John V Taguchi Quality Function Deployment is a planning tool used to _____. Reduce Error Occurrence Customer Care Dealers Satisfaction Customer Fulfillment To Improve Customer satisfaction _________. Creates focus on customer requirements Decreases midstream design changes Limits post introduction problems Avoids future development redundancies Promotes Team Work To Reduce Implementation Time __________. Uses competitive information effectively Prioritizes resources Avoids future development redundancies Promotes Team Work Identifies items that can be acted upon b c d 2 a b c d 3 5 a b c d 6 a b c d 7 a b c d 8 a b c d 9 To implement Documentation __________. Limits post introduction problems Rational for design Creates communication Uses competitive information effectively The loss imparted by the product to society from the time the product is shipped GE8077- Total Quality Management a b c d 10 a b c d is defined by _______. Total Productive Maintenance House of Quality Taguchi Loss Function Quality Loss Concept Which one is not a Quality loss functions Average - the - better. Nominal - the - best Smaller - the - better. Larger - the - better. GE8077- Total Quality Management UNIT V- QUALITY MANAGEMENT SYSTEM Introduction—Benefits of ISO Registration—ISO 9000 Series of Standards—Sector-Specific Standards—AS 9100, TS16949 and TL 9000-- ISO 9001 Requirements—Implementation— Documentation—Internal Audits—Registration- ENVIRONMENTAL MANAGEMENT SYSTEM: Introduction—ISO 14000 Series Standards—Concepts of ISO 14001—Requirements of ISO 14001— Benefits of EMS. PART A (15 x 1 = 15 marks) 1 Which among the Following is not a national award? a The Deming Prize The UK Quality Award The Golden Peacock National Quality Award The Rajiv Gandhi National Quality Award. The process of Performance Evaluation where an organization should identify the ‘what’,’how’, and when is _____________ Monitoring ,Measurement,Analysis and Evaluation Management Review Internal Audit Documentation b c d 2 a b c d 3 a b c d 4 a b c d 5 a b c d 6 a b c d 7 a b c ___________ gives details of how individual work processes( like machining, welding ,casting, etc.), are carried out within a company Quality System Procedures Work Instructions Quality Policy Manual Record ___________standard applies to all telecom manufacturers and suppliers engaged in the design ,development, production, delivery, installation and maintenance of telecommunication products and services. AS9100 TS16949 TL9000 IATF16949 Which among the following don’t belong to Audit Performance Stage ? Open/entry meetings Audit schedules Audit Process Audit Deficiencies _______ helps organization reduce employee turnover and absenteeism. Job design Training & development Wage revision All of the above The objective of ISO-9000 family of Quality management is Customer satisfaction Employee satisfaction Skill enhancement GE8077- Total Quality Management Environmental issues d Match the Following 8 a b c d 9 a b c d 10 a b c d 11 a b c d 12 a b c d 13 a b c d 14 a b c d 15 A. ISO emphasis on 1. ISO – 9000 -2000 B. ISO 2. Qualified personnel C. Lead assessor 3. International organization for standard D. ISO currently in use 4. Prevention A-4, B-2, C-3, D-1 A-4, B-3, C-1, D-2 A-4, B-3, C-2, D-1 A-3, B-4, C-2, D-1 A problem definition should include Names of members of the team What the problem is and what it is not Who was operating the machine that day Ideas to solve the problem ISO 14000 quality standard is related with Environmental management systems Automotive quality standards Eliminating poor quality Customer satisfaction TQM & ISO both focuses on Customer Employee Supplier All of the above Which award is presented to different organizations for quality and excellent performances by president of USA? Malcolm Balbridge National Award Dr. W. Edward Deming National Award US Excellence Award None of the above The standards (ISO 9000, 9001, and 9004) were intended to be advisory and developed for use in _______. Fault Finding Law clearance Maintenance Auditing The fourth edition of ISO 9001 was released in the year ________. 2006 2007 2008 2009 Demonstrating conformity of the QMS to customers, regulatory and organizations own requirements. GE8077- Total Quality Management a ISO 9000: 2005 b ISO 9001 : 2008 c ISO 9004 : 2000 d ISO 9004 : 2005 PART B (10 x 2 = 20 marks) 1 Guidelines for Performance Improvement provided by __________. a b c d 2 a b c d ISO 9000: 2005 ISO 9001 : 2008 ISO 9004 : 2000 ISO 9004 : 2005 Design, Development, Production, Installation & Servicing is _______. ISO 9001 ISO 9002 ISO 9003 ISO 9004 3 Production, Installation & Servicing is ______. a b c d ISO 9001 ISO 9002 ISO 9003 ISO 9004 4 Inspection & Testing is _________. a b c d ISO 9001 ISO 9002 ISO 9003 ISO 9004 Provides guidelines on the technical, administrative and human factors affecting the product or services ________. ISO 9001 ISO 9002 ISO 9003 ISO 9004 Choose Which one is NOT a benefit of ISO 9000 __________. Achievement of international standard of quality Value for money Customer satisfaction Need for trained personnel Pitfalls of Successful Implementation of ISO 9000 ______. Developing a system that does not represent what actually occurs Write the Documents Install the New System 5 a b c d 6 a b c d 7 a b c GE8077- Total Quality Management Management Review d 8 a b c d 9 a b c d 10 a b c d Mention which is NOT a type of Audit ________. Process Audit Procurement Audit Product Audit System Audit Choose Which one is NOT an Objective of Internal Audit ________. To verify conformance to applicable standards To verify effectiveness of the processes in the system To identify opportunities to improve the system Determine weak points Environmental Performance Evaluation _________. 14011 Guidelines 14010 Guidelines 14031 Guidelines 14030 Guidelines