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1) What are the basics steps in the problem solving process? Explain them briefly.
Ans:
INTRODUCTION: Systematic problem solving provides a structured approach to
problem solving. Depending upon the nature of problem (i.e. maintenance or
improvement problem), some steps may be different.
SOLVING A MAINTENANCE PROBLEM: Maintenance problems as mentioned
earlier, surface when the status quo is distributed and decision make needs to
recommend/take measures to restore and maintain the status quo.
Fig: Steps to solve a maintenance problem.
Identify a maintenance problem
Collect data on “causes”
Perform Pareto Analysis
Identify root causes
Evolve alternatives & select
(Brain storming)
Implement best alternative
Monitor effect
Is the problem
resolved?
No
End
(a) Diagnose (define) the problem:
Sound diagnosis is the crucial step in the problem solving process. Defining the
problem sets the boundaries for that follows. Decision maker, like a doctor, must take
into account all symptoms before prescribing the medicines (i.e. recommending the
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decision). Peter Drucker rightly states, “The books and articles on leadership are full
of advice on how to make fast, forceful and useful decisions, but there is no more
foolish and no more time wasting advice than to decide quickly what a problem really
is. Defining the problem in most instances is a time-consuming task, but it is time
well spent.”
Sound diagnosis requires
(i)
Measurement of the gap between the desired performance and the actual
performance.
(ii)
Identification of the root cause for the gap.
(iii)
Identification of the restraints in the decision making process.
(b) Secure and analyse pertinent facts:
Once the problem has been diagnosed (defined), the next step is to collect data. Data
collection implies collecting background material, pertinent facts, decision taken in
the past and their outcome, previous solutions to similar problems etc.
General rules are:
(i)
The information should be collected from the most reliable source.
(ii)
All relevant facts, regardless of how disorganized or unrelated they seem
at the time of data gathering, should be recorded.
(iii)
The information should be subjected to checks and cross checks. The
conflicting data must be resolved. The temptation to accept first response
to inquiries should be avoided.
(iv)
The facts wherever possible should be supported by tangible evidence in
the form of copies of the appropriate documents. Facts when cannot be
supported by documentary evidence (i.e. facts which are bases on opinion
of the individuals) should carry the names of the contributors so that they
(individuals) can be contacted later if required.
Facts are next analysed to establish:
(i)
(ii)
(iii)
The length of time to which the decision should apply.
Effect of the decision on other functional areas.
Qualitative considerations to take overall view of the business.
(c) Develop alternative solutions:
This step concerns looking for the possible solutions and listing them down. Most
common sources of collecting and listing of alternatives include experience, superiors,
juniors, consultants, research, creativity, brain storming, critical examination,
literature etc.
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It is also the most important step and therefore good amount of time, effort and money
should be spent /invested to get good alternative solutions.
Generally, for every problem, alternative solutions exist and efforts need to put to
unearth these alternatives. Usually, a brain storming or interaction session with those,
concerned with the problem can highlight several alternatives. For example, the
company was considering purchase of a CNC machine. The general manager held a
series of brain storming session of his engineers and following alternatives got
identified:
(a) continue to make the part by present method, or
(b) buy the proposed CNC machine, or
(c) buy a machine other than the proposed one, or
(d) improvise the current method of making part (e.g retrofitting the
existing machine improves tooling and gauging method etc.), or
(e) subcontract CNC – compatible operations to a good quality vendor, or
(f) discontinue manufacturing the part at company’s own plant and buy
the part from an outside source.
After evaluating all the alternatives for their merits and demerits, the general manager
opted for alternatives ‘d’, ‘e’ and ‘f’ and got the best results.
(d) Evaluate alternatives:
Once all the alternative solutions have been enumerated, they are next evaluated. This
is usually done by testing each alternative against a set of objectives or specified
criteria which the solution must meet. The steps involved are:
(i)
Each alternative is analysed to see whether or not it meets the “must”
objectives. An alternative which does not meet the “must” objective is
immediately removed from further study.
(ii)
Alternatives which meet the “must” objectives are next checked for “want”
objectives and those which are good in terms of “want” objectives are
examined for adverse consequences. Since each alternative usually entails
some risk, the decision maker next assesses the risk, the probability of risk,
the probability or risk, and /or seriousness of the risk.
(iii)
Every attempt is made to eliminate or minimize risk (or disadvantages). T
chart analysis is usually helpful.
(iv)
Alternatives are next weighed for their effectiveness by identifying their
long term and short term consequences. The advantages of the alternatives
are quantified in terms of common denominator, usually the money.
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(e) Select the best alternative:
The alternative cleared at the evaluation stage are ranked according to their worth.
Final selection is then made of the alternative which provides the maximum
advantages while entailing acceptance risk (i.e. the alternative that best meets the
solution criteria is selected)
(f) Implement the selected decision:
Once the final choice has been made the next step is to implement the decision and
follow up for verification of the consequences (or effect of the decision)
Though the steps mentioned above are sequential and separate but usually there is
recycling among the steps. For example, while trying to evaluate alternatives, the
decision maker may have to ho back to data collection step if he finds that he does not
have all the information.
STEPS FOR SOLVING AN IMPROVEMENT PROBLEM:
The Japanese have provided a structured methodology for solving “improvement”
problem. The methodology is also known as QC story and it comprises of the
following six steps based on famous Deming Plan-Do-Check-Act (PDCA) cycle.
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Fig: Steps to solve an improvement problem
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Define improvement problem
Measure current status
Decide on desired level
Find gap in performance
Set Target
Prepare action plan
(counter measure)
Plan (P)
Implement counter
measure
Do (D)
Measure /analyse
achievement
No
Check (C)
Satisfactory
performance?
Yes
Stabilize/standardize (SDCA)
Yes
New target
No
Maintain status quo
End
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2. (a) What is “Cause and effect” diagram? How is it useful in analyzing a
problem? How is it constructed?
Ans: INTRODUCTION: Every organization has contributory causes. The causes
need to be identified to eliminate problems or minimize the effect of the problems. All
causes including probable causes (i.e. which have not occurred earlier) should be
identified so that preventive action can be taken (After all, prevention is better than
cure)
After the causes have been identified, they should be put into a systematic form that
facilitates presentation and analysis.
Cause and effect diagram is also called as “Ishikawa Diagram” or a fishbone diagram
(due to its shape) – an effective tool for diagnosis to a problem – was developed by
Dr. Kaoru Ishikawa, a professor of Tokyo University.
The diagram lists out in a classified and systematic manner all causes which are
responsible for the problem (called effect). The diagram consists of a main line to
represent the actual problem and few lines to represent the major causes – materials,
men, methods and machines – and horizontal or slanting arrows to represent subcauses 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 the
horizontal line and connect them to horizontal line by vertical or standing
arrows. Think of these as branches of the main truck of the tree.
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Man
Machine
Problem
Method
Materials
(c) Enter the detailed cause data for each category / theme by arrows meeting the
horizontal or slanting lines (i.e. lines representing the main theme). Look upon
these as limbs or twigs of the branches.
Man
Machine
Cause A
Cause B
Cause A
Cause B
Cause D
Cause C
Cause C
Problem
Cause B
Cause A
Cause A
Cause C
Cause C
Cause B
Cause D
Method
Materials
(d) Review diagram drawn above to ensure that no cause has been missed.
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A cross function team constituted to study problem of employees’ poor morale
have conducted on following probable causes. Draw a “cause and effect”
diagram from the given data…
Ans:
REWARD/RECOGNITION
HIRING
Poor selection
Poor Management selection
Poor Management selection
Low pay level
Incomplete job description
Wage differentials
Recruiting errors
Poor benefits
Favoritism
EMPLOYEE
Lack of discipline methods
Faulty working assignment
Bad Lighting
Improper management training
Noise
Lack of communication
Temperature
Unclear company goals
Long working hours
Public reprimands
Excessive Criticism
MANAGEMENT
WORKING CONDITIONS
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3. a) What is Pie-Chart? How is it constructed?
Ans: INTRODUCTION: Pie chart is also called an angular diagram. It is the graph of
percentage breakdown of data.
Steps in Construction of a PIE CHART:
i.
ii.
Express value of each category of component group as a percentage of
total of all categories or components or groups.
Calculate degree of the angle formed by each category/component/group
as under
Degree of particular category
iii.
iv.
=
Value of the group X 360
Total Value
Draw a circle of a suitable diameter (say diameter of 3”)
Segment the circle into angles calculated in step 2 with the help of a
protractor
v.
Shade or color different segments suitable to make distinction between
different categories.
vi.
Enter the percentage of each category in to the pie chart.
b) Draw a Pie Chart to represent the following population in a village.
Males
2000
Females
1800
Girls
4200
Boys
2000
Total
10000
Sol:
S.No
1.
2.
3.
4.
Gender
Males
Females
Girls
Boys
Population
2000
1800
4200
2000
Population %
20%
18%
42%
20%
Total
10000
100%
10
Degree
72o
64.8o
151.2o
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POPULATION
Boys
20%
Males
20%
Girls
42%
Males
Females
Females
18%
Girls
Boys
4. a) What is Pareto’s analysis? How is it used for problem solving?
Ans: Introduction: Every problem is the result of few causes and all causes are not
equally important. Some causes are more significant than others. Pareto’s analysis
underlines and operates his philosophy of “vital few: trivial many”. It is a technique
of identifying vital causes by arranging the data according to the descending order of
their frequency of occurrence.
Pareto’s diagram is the outcome of the study conducted by Vilfredo Pareto to study
the phenomenon of wealth in his country. Pareto observed that in his native country
80% of the wealth was held by 20% of the population. He eventually realized that he
had discovered a universal law – around 20% of the activity causes 80% of the effect.
For Example:
• 80% to 90% of the Italy’s wealth lay in the hands of 10% to 20% of the
population.
• 80% of the accidents occur on 20% of the roads (i.e. some roads are more
dangerous than others)
• 80% of the shopping that takes place is done in 20% of the time of the store
are open.(i.e. people try to shop at the same time).
• 80% of the absenteeism in a company is generally on account of 20% of the
work force.
• 20% of the machines are responsible for 80% of the total down time.
• 20% of the end products generate 80% of sales revenue.
• 20% of the clerks make 80% of the clerical errors.
• 20% of the employees create 80% of the troubles.
• 20% of the customers are responsible for 80% of the bad debts.
• 20% of the total items in the stock account for 80% of the annual expenditure
on materials.
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U.S Economist M.C. Lorenz presented this lop sided distribution in the form of
theoretical curve, called Lorenz’s curve. Dr. J. M. Juran observed similar
phenomenon in many other fields including quality. He names this phenomenon as
Pareto Analysis in honor of the originator of the concept.
We need to follow few steps in order to solve the problems using Pareto’s Chart. They
are listed as follows:
1) Select the problem and identify causes into a handful of categories. For
example, for a problem of “late coming to works”, possible categories of
causes may be heavy traffic oversleeping, sickness, vehicle problem, family
problem etc.
2) Select the standard unit for measurement (e.g. frequency, cost, sales etc.)
3) Select the time period over which data will be collected (e.g. 8 hours, 5 days, 2
weeks, etc.)
4) Collect necessary data on each category and summarize results.
It is generally convenient to create a three-column-table having heading as
“error category”. “frequency (or cost)”, and “percentage of total”. This
information can be directly taken from the check sheet.
5) Rearrange the data in the descending order of the frequency or cost.
6) Organize the Pareto’s chart
(a) Draw two vertical axis, one on either side of a horizontal side axis
(leaving enough space on the horizontal axis to list the problem
categories). Mark the frequency of occurrence of the problem along left
vertical axis and percentage along right vertical axis.
(b) Divide the horizontal axis into intervals equal to the number of
categories.
(c) List down the categories from left to right in their order of decreasing
frequency or cost.
(d) Construct a bar or rectangle above each category with height equal to
frequency or cost.
7) Draw the cumulative line /curve (Pareto’s curve) by plotting each point at the
right hand corner of each bar and them connecting these points.
8) Write all necessary information concerning the diagram.
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b) Shrivastive, an administrative officer, working with Dattatreya Chemicals
Ltd. has been receiving frequent complaints from internal customers regarding
late and wrong receipt of mail delivered by his department. In order to correct
the problem, he called a meeting of a small group of his internal customers and
with their help identified five error categories, namely mail behind schedule,
wrong deliveries, and late delivery of outgoing mail to post office, rude clerks
and incorrect charges.
The administrative officer then started tracking complaints. The data collected
by him in a 30-day span in the form of a check-sheet reproduced below.
Error Category
Behind schedule mail
Wrong delivery of mail
Late delivery of outgoing mail to P.O
Rude clerks
Incorrect charges
Tally Mark
lllll
ll
lllll
lllll
lllll
lllll
l
lllll
Total
lllll
ll
Frequency
7
20
12
1
5
45
Draw a Pareto’s Chart.
Sol:
1. Collect the data concerning the problem under study.
2. Rearrange the data in the descending order.
Error Category
Cumulative%
Wrong delivery of mail
44.44
Late delivery…
72.1
Behind schedule mail
86.65
Incorrect charges
97.76
Rude clerks
100.00
Frequency
%of
Error
20
44.44
12
26.67
7
15.55
5
11.11
1
2.22
13
to
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PARETO's DIAGRAM
120
100
97.76 100
86.65
80
Frequency
72.1
%of Error to total
60
Cumulative%
44.44
40
20
20
12
0
0
Log. (Cumulative%)
26.67
2
15.55 11.11
7
5
2.22
1
4
6
5. What are the quality circles? How are they formed? Explain briefly the
organization of quality circles.
Ans:
Introduction: Quality circle is basically a small group of employees – who volunteer
to meet regularly to undertake work related projects – quality, productivity, safety,
efficiency, cost, working conditions, etc., - and evolve recommendations to improve
effectiveness in the selected functional area.
The size of quality circle is important. Too big a size 9 (too many members) may not
provide enough time to each member to effectively participate and too small a size
may make a circle dormant. An ideal size of the circle is eight to ten members but in
any case it should not exceed fifteen members.
More than one circle may be formed if too many employees in a particular work area
are willing to participate in the quality circle activities. For example, if there are 25
clerks in the organization doing identical jobs, 2 to 3 circles may be formed.
Participation in the circle activities is absolutely voluntary. Members are not selected
/nominated. They are not elected or rotated either. Employees, however, are
encouraged to form circles.
Ideally, members of a particular circle should be from the same area or who do similar
work so that problems that they select /analyse / discuss will be familiar to all of
them.
Brief History: Japanese Union of Scientists and Engineers (JUSE) was established in
1946 after the World War II in which Japanese industries were completely destroyed.
JUSE worked for growth and development of quality and in 1950 it invited Dr.
Edward Deming, a renowned American expert on quality to visit Japan. Dr. Deming
delivered a series of lectures on various aspects of quality control to the top
management of several companies of Japan.
These circles have lifted war-ravaged Japan to its present dominant position and have
endangered even the very existence of American industry. A quality circle in Japan on
the average saves $56, 000. All this is achieved without any monetary incentives.
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Around 25% of the profitability of the Japanese industries is attributed to the quality
circles. Nissan motor, for example works with 57,000 employees, has 4,200 quality
circles which have helped the company to double its productivity in ten years.
Quality circles in India were first launched in the Hyderabad unit of BHEL in 1980
which has now around 100 quality circles in its various branches throughout India.
Quality circles forum of India was formed in 1982 to propagate concept. The concept
of quality circles is gaining momentum and quite a few firms in the private and public
sector – Kirloskars, Alwayns, Tata’s, H.A., Bharat Forge, Balaji Auto, Vulcan Laval,
Rourkela Steel plant etc., have instituted quality circles.
Organization for quality circles: The Organization of circles consists of:
i.
Steering Committee: Steering committee is the apex body at the highest
level of the plant which is made up of heads of the major departments like
Production, Finance, Materials, Marketing, Engineering, Quality
Assurance, etc, and is headed by the Chief Executive of the plant. The
committee meet periodically and ito Evolves policies and guidelines for the formation, functioning and
growth of quality circles.
o Appoints facilitators and a co-coordinator.
o Identifies overall quality and productivity problems in the
organization.
o Authorizes budget for quality circle activities
o Takes part in top management presentation and annual get-togethers
o Demonstrates, in visible manner, management commitment and
support
o Reviews performance of the quality circles regularly on the basis of
reports from the coordinator and facilitators.
o Evolves guidelines for recognizing the good performance of quality
circles.
The head of the Quality Assurance department takes the responsibility of convening
the meeting of the committee.
ii.
Facilitators: The facilitators are selected by the steering committee to
supervise the activities of two, three or more circles. Facilitator is usually a
senior officer nominated by the management who is incharge of shop or
department. The facilitator acts as a teacher, a promoter, a catalyst, and a
guide to the quality circles. The responsibilities of the facilitators include:
o To co-ordinate the activities of quality circles under their supervision
and guidance
o To train QC leaders and lend help in training QC members.
o To interface between circles
o To render support and assistance to the circles under his control.
o To encourage employees to form more QC’s
o To demonstrate support of the management.
iii.
Leaders: A leader acts as an integral part of the quality circle. The leaders
should have good knowledge of statistical methods and approaches to be
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used to identify and analysis problems. The leaders also, like other regular
members, participate in the discussions. The leader should preferably be
the first line supervisor but it not essential. Supervisors taking over the
task of leaders ensure some leadership quality inputs are already available.
Responsibilities of the leader are:
o To conduct training of members of the circle with the help of facilitator
and other agencies.
o To prepare agenda for the meetings.
o To organize and conduct meeting
o To evolve action plans and milestone charts to compare actual progress
with targets by periodic reviews and take mid-course correction.
o To assign roles to members and to guide them for effective
contribution towards the achievement of goals.
o To ensure participation and involvement of all members in the
activities of the circle.
o To ensure records and liaison with other agencies to obtain help in
solving the problem
o To catalyse attitudinal changes in his own and other related areas.
o To make management presentations
o To take sincere interest individually by active involvement in the
progress of quality circle movement.
o To endeavour to promote quality circles as a way of life in the
organization.
iv.
Members: Members form hard core of the quality circles; Members are
selected on “purely voluntarily basis” and are from the same or similar
functional areas. The group should basically be small, between 8 to 10
members. The members should have adequate education and experience in
the concerned field and should have the ability to express clearly and
freely.
v.
Co-ordinator: In a large manufacturing organization, some agency –
usually Quality Assurance – is required to co-ordinate the activities of the
quality circles. The responsibility of the coordinating department includes:
o Rendering assistance as request by circles
o Disseminating literature relating to circle activities elsewhere
o Organizing training programmes
o Publishing newsletter to communicate circle activities
o Providing circles with necessary facilities for the meeting
o Organizing social get-together for circle members and senior
executives
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6. “5-S is an excellent technique to achieve good house-keeping”. Discuss.
Ans: Introduction: Good housekeeping is the foundation for and first step towards
quality achievement in a manufacturing organization. It boosts employee morale and
inspires customer confidence.
Good quality of work place is essential as –
1. Good environment has a strong influence on the people and the quality of
product they produce.
2. A customer visiting the plant sees in a quality work place a guarantee for the
product quality.
3. Good housekeeping helps to eliminate waste by identifying non-value added
activities, such as searching for tools, time lost in reaching out to retrieve
items, over production, etc.
4. Housekeeping reflects management’s general attitude towards work in the
organization.
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Housekeeping is measured the way
- Factory floor are swept and machines are cleaned
- Tools are stored
- Scarp and chips from machines are handled
- Work tables are organized
- Personal items are stored
- Records are maintained
- Targets and achievements are displayed or communicated to
employees.
Good housekeeping is simply the basic to a better workplace and to –
-
Reduce cost of products and service
Achieve discipline in manufacturing
Bring improvement in quality and productivity
5-S (Seiri, Seiton, Seiso, Seiketsu and Shitsuke) are considered in Japan the basics of
any job. 5-S principles have been practiced in Japan the basics of any job. 5-S
principles have been practiced in Japan to establish and maintain quality environment
in the organization. Japanese managements are of the view that if the housekeeping in
a plant is weak, no further diagnosis is needed to know as to why that plant produces
poor quality products. 5-S technique has been defined as –
“A systematic and rational approach to work place organization and methodical
housekeeping with a sense of purpose”
Japanese
English
Meaning
How to apply it to the work place?
Seiri
Structurise
Sorting
Classify items into necessary and unnecessary,
retain only those which are required and
dispose off others. (i.e. those not needed)
Seiton
Systematise
Re-organise
Store things systematically to ensure safety,
quality and efficiency. Storage methods must
permit efficient use of space-accident free
stage, long shelf and easy retrievability of
items within pre-fixed target retrieval time.
Seiso
Sanitise
Cleanup
Maintain work place free of dirt/ dust and
garbage by fixing individuals’ cleaning
responsibility.
Seiketsu
Standardize
Shitsuke
Self-discipline
Standardization
Sustain
18
Maintain cleanliness through Seiri, Seiton and
Seiso by ensuring transparency and uniformly
of everything that is done in the organization.
Make a habit of doing things the way they are
supposed to be done (i.e. developing habit of
following rules/ practices) including 5-S
practices.
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Relationship between 5-S’s:
SEIRI
(Organisation
SEIKETSU
(Standardisation)
SHITSUKE
(Discipline)
SEISO
(Clean Up)
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SEITON
(Maintenance)
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7. What is SMED? How is it used to reduce setup time of an operation?
Ans: Introduction: Every organization must increase line of its products, accept low
volume orders, shorten delivery lead time, and keep its cost low to maintain its market
share in a competitive market. The organization must cut production lead time and
decrease production batch sizes. It should also reduce inventory levels in the
production and inventory systems. Since small batches require frequent changeovers,
production capacity is expected to shrink unless setup times are reduced. Set up time
reduction, therefore, is the key to developing or monitoring a company’s
competitiveness in today’s market where more diversified products are desired at
short production lead time.
Quick Die/ set up change is not restricted to set-up reduction of press shop alone, it
can be extended to all areas of manufacturing wherever there is requirement of tool
change/ set up on a machine prior to manufacturing.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
Presses
Multi-spindle automats
Lathes, turret lathes
Milling machines
Drilling machines
Broaching machines.
Forging machines
Paint manufacturing equipment
Powder coating machines
Oil extracting mill
Meaning:
Set up time is the time required to prepare a machine or a group of machines to
changeover from one job to another. Time of a conventional set up consists of
following tasks.
(a) The time to study blue print , including time spent on receiving instructions
from supervisor or foreman.
(b) The time to go to tool crib to get necessary tools and gauges, etc and to return
the tools used to previous job.
(c) The time to select fixture (Vice, mandrel, suitable sized collets, face plate, etc)
and secure it to the bed of the machines.
(d) The time to install/ mount necessary tools on to the machine, make
adjustments, set longitudinal or traverse feed stoppers wherever necessary to
ensure that each tool cuts properly and to dimensions.
(e) The time to call the inspector and get inspection done (pilot piece inspection).
Alternatively it is the time necessary to deliver the part to the inspection booth
for inspection. Inspection time, however, does not include time to manufacture
the part.
(f) The time spent by the operative, over and above the unit standard time, to
produce first few pieces.
(g) The time to physically count the jobs produced, including time to sign the
completed work-order.
(h) The time to remove tools from their tool-holders after required quantity has
been manufactured, clean each tool and put it away in proper place.
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(i) The time to clean measuring instruments and put them away in proper places.
(j) The time to release and remove fixture blow or brush it clean and keep it
aside.
(k) The time to remove borings, turning, drilling etc, from the bed of the machine.
Normally, turnings/ drillings/ borings should be removed by a helper (even
when the production is in progress) when these gather in large quantity.
However, burns removal, would have to be considered part of set up operation
if different material is required on the next job (e.g. Steel for the job just
completed and brass for the job to be loaded).
Traditional set up operations involve several kinds of waste and SMED technique was
developed to eliminate waste and to reduce set up time from hours to minutes. SMED
also has interesting history of development.
Reduction in set up time results in the following benefits:
o Reduction in batch sizes
o Lowering of manufacturing lead times
o Drop in inventory levels
o Reduction in set-up scrap
o Increase in machine efficiency
o Increased flexibility to respond to changes.
The firm desiring to reduce change-over time may not achieve its target figure in one
attempt, but after a series of improvements. From its current level of set up time of
double digit on a particular machine, it may be able to reduce to single digit hours.
And subsequently on the same machine from single digit hours to double digit
minutes, still later from double digit minutes to single-digit ones and finally in to few
extreme situations one touch change over.
Comp.
A run
Study
blue
print
Remove Replace Install tools Sample
existing too at the for the new run
crib store job
Run for
component
A
SETUP
Component
A
Sample
run
Elimination of sample
runs, inspection,
adjustments
Run for
component
B
Component
B
Setup
Step-by-step reduction of set-up time
21
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Techniques for Operation Efficiency
8 a) What is meaning of MUDA? What are the various types of MUDAS?
Ans:
Introduction: MUDA is a Japanese word for waste and waste means anything (or any
activity) which does not add value to the product.
o A worker looking, even though affectionately, at an automatic machine does
not add any value while machine does (MUDA of Waiting)
o A maintenance engineer who walks over a long distance with tool in his hand,
does not add any value (value is added when he uses the tool to fix the
machine) ( MUDA of Transport)
o Piles of material lying in racks in the stores don’t add any value but add to cost
(MUDA of Stock)
o A material handler while pushing a heavy trolley full of parts, even though
perspiring, adds no value (MUDA of Transport)
o An assembly operator, overstretching his hand to pick up parts for assembly,
adds no value but causes fatigue to himself (MUDA of Motion)
o A welding operation, performed to join metal parts of assembly constituent,
does add value but the welding operation performed to repair weld a blowhole
in job is a non-value added activity (MUDA of Processing)
Waste (MUDA) is the major element of company’s product cost and must be
continually identified and eliminated from its processes to stay competitive.
Since labour cost is hardly 8-10% of total cost (which also is on the decline due to
recent advances in manufacturing technologies), we also need to look at various
other hidden wastages, besides human waste, to improve productivity.
Types of MUDA:
There are seven types of MUDA in manufacturing:
1. MUDA of Over Production.
2. MUDA of Stock (inventory)
3. MUDA of Waiting
4. MUDA of Transport
5. MUDA of Defects
6. MUDA of Motion
7. MUDA of Processing
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Techniques for Operation Efficiency
b) What Causes MUDA of “Motions”? How can it be eliminated?
Ans: Introduction: A workman while performing a task makes use of a number of
motions. The scrutiny of these motions may reveal that some of these motions –
o Are unnecessary and can be eliminated
o Can be combined / modified by changing their sequence
o Can be simplified by effecting changes in work bench layout
o Can be performed efficiently by other members of the body.
In the absence of the above mentioned actions, the workman makes motions which
don’t add any value. Typical examples are –
o
o
o
o
o
Walking to reach objects/ parts. Tools
Lifting or carrying objects
Picking up and putting down a work piece
Transferring objects from one hand to another
Searching to find the required object
While dealing with MUDA of motion it is recommended to get rid of operations that
are difficult dirty and / or dangerous (3D’s). such actions include –
o
o
o
o
Work that makes and employee move over long distances
Work that causes physical strain (i.e. use of undue physical effort)
Work that causes mental strain (e.g. work that needs memorizing lot of details)
Work that involves search or unnecessary sorting.
Tools and techniques to eliminate MUDA of Motion:
i)
ii)
iii)
Improvement in layout: Lifting or carrying a heavy object is undesirable
on two counts, firstly because it represents MUDA and secondly it causes
physical exertion. The need for the operator to carry a heavy object can be
eliminated by rearranging the work place.
Motion economy principles: Motions of the hands/ legs can be shortened
and some of them can be eliminated by rearranging the parts on work table
and development of tools and jigs.
Effective supervision: Finding workmen busy with their jobs may give
supervisor satisfaction but it may do no good to the company. A supervisor
must watch closely his people to find as to –
- What are they doing?
- How are they doing?
- Do they need to do what they are doing?
- Are they doing the right way?
- Are they doing work which adds value?
- Are they using motions of the lowest classification?
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Techniques for Operation Efficiency
List down different kinds of human errors. How can they be eliminated? How is
PokaYoke technique useful to eliminate human errors?
Ans:
Type of
Error
Forgetfulness
Description of the
error
Forgetting to do a
thing
Typical examples
3. Operator skipping an
operation.
4. Operator forgetting to
tighten bolts
5. station master forgetting to
lower the crossing gate
1. Putting foot on clutch
thinking it is brake
Remedial action
1. Altering operator in advance
2. Checking at regular intervals
3. Verification by another
employee
Misunderstan
ding
Jumping to the
wrong conclusion
due to poor
familiarity with the
situation
1. Training
2. Checking in advance
3. Standardizing work
procedures.
Mistaken
identity
Misjudging a
situation
1. Mistaking Rs.500 note as
Errors by
amateurs
Lack of experience
1. Improper welding
2. Wrong measurements
1. On-the-job training
2. Work Standardisation
Willful errors
Ignoring rules/
deliberate wrong
actions
1. Ignoring safety rules
2. Crossing a street against
1. Attitude change.
2. Education
Inadvertent
errors
Absent mindedness
i.e. not knowing how
the problem / error
has occurred
1. Removing job before
1. Improving attentiveness
completing drilling of all
2. Work standardization
holes
2. Crossing street without
noticing that the light is red
Judgmental
errors
Errors due to absence 1. Difference in method of
measurement used by
of instructions of
vendor and by buyer’s
work standards
1. Improving attentiveness.
Rs.100 note
a red light just because
there are no vehicles in
sight at the moment.
3. Not replacing blunt tool
on time
1. Works instructions
2. Work standardization.
inspection
2. Operator deciding his own
Errors due to
absence of
standards
Lack of instructions
or absence of work
instructions
Measurements left to the
discretion of the workman
1. Works instructions
2. Work standardization.
“Poka-Yoke” is a combination of two Japanese words, “Poka” meaning “inadvertent
errors” and “Yoke” (derived from Japanese word Yokerie) meaning “to avoid” and
24
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Techniques for Operation Efficiency
together they translate as “Error/ mistake proofing” or “Fool proofing” or “Failsafing”
a work process system to eliminate inadvertent errors.
Poka-Yoke is a powerful and comprehensive tool for identification, measurement and
analysis of mistakes/ defects at the Gemba (real piece of work) and implementation of
measure that prevent the activity from being incorrectly performed, thereby ensuring
production of quality goods and services.
Errors are inevitable but can be eliminated, using Poka-Yoke technique. This is
the technique that can help to analyse the kinds of mistakes employees make and to
eliminate these mistakes by implementing / installing simple Poka-Yoke devices.
Poka-Yoke Devices:
Poka-Yoke may be designed either to help the operator to recognize the defect before
it is about to occur called “Prevention type Poka-Yoke” or to help the operator to
know immediately on occurrence of the defect called “Detection type Poka-Yoke”.
Some of the Poka-Yoke devices which can help to avoid defects are –
1.
2.
3.
4.
5.
6.
Guide Pins / locators
Error detection buzzers/ alarms and blinking lights
Limit switches
Counters
Color coding
Checklist
9.a) What is Kaizen? What are different types of Kaizen?
Ans: Introduction: Kaizen is a combination of two Japanese words, “Kai” and “Zen”,
Kai means “to change or modify” and Zen means “to improve or make better” and
together they translate as “improvement”. Kaizen when used in the context of a
management process, has come to mean as continual and slow improvement in every
aspect of management (i.e. improvement in whatever company does and the way it
does things) through the active involvement of all company’s employees. Kaizen does
not just merely mean doing things better but it is an unending process to eliminate
muda, improve quality, cost and delivery, thereby creating more and more customers.
Few Definitions:
Kaizen is a management supported, employee driven process, where employees seek
development of their own capabilities by challenging existing system and finding
improvement in them
R.R. Asawa & Dr. D. R. Baheti
Kaizen is a program, a philosophy and a strategy to improve quality of goods and
services or an organization Samuel KHO
Kaizen means making a great number of continuous lasting improvements by
discovering small problems and eliminating them permanently (attacking root causes
of the problems) thereby helping the organization in setting and reaching higher
standards of performance.
Surindra Narang
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Techniques for Operation Efficiency
The Spirit of kaizen is that whatever you are doing, you can do better. Kaizen thus
helps in setting and reaching higher standards of performance.
The word “Kaizen” was used for the first time by Maasaki Imai, who wrote a look of
same name. although a registered name of Kaizen Institute, the work is now widely
used and understood all over the world to mean “continuous improvement”. The word
“Kaizen” also now appears in the English dictionary. Recently, Imai has elaborated on
Kaizen in his book titled “Gemba Kaizen”
Types of Kaizen:
Kaizen depending upon the complexity and level, can be placed into one of three
categories
1) Management Kaizen
2) Group Kaizen
3) Individual Kaizen
1) Management oriented Kaizen: Concentrates on strategic issues and often
involves people from different departments working together on crossfunctional problems as project teams. Typical examples of management
oriented Kaizen are:
♦
♦
♦
♦
♦
Identification and elimination of waste in workers motions
Charges in plant layout for better efficienvy
Reduction in buffer stocks
Just-in-time production
System improvement
2) Group oriented Kaizen: Concentrates on improvement within the same
workplace or department brought about by employees working in small
groups, called quality circles. Typical areas of group Kaizen generally include
–
♦
♦
♦
♦
Productivity improvement
Defect prevention
Accident prevention
Absenteeism
3) Individual oriented Kaizen: Concentrates on issues concerning worker’s own
work area and improvements are brought about through worker’s own
suggestions. Problems solved through individual Kaizen generally include –
♦
♦
♦
♦
♦
Improvement in machines and processes
Improvement in jigs and fixtures
Reduction in defect level
Customer service and customer complaints
Improvements in working environment.
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Vikas Choudhary
200323811
Techniques for Operation Efficiency
b) Discuss in brief the Kaizen process and its steps.
Ans: Introduction:
Kaizen process provides a disciplined and analytical approach, sometimes called the
kaizen story to problems solving. It consists of a series of sequential steps that can be
used to guide a group (say an improvement team) for the process of identifying and
fixing problems. The Kaizen story (or Kaizen process) is built on PDCA mnemonic –
Plan, Do, Check and Act. The Kaizen process is a seven step basic procedure which
allows any individual or team to solve problems scientifically, rationally, effectively
and efficiently. These seven steps are –
1. Defining the problem
2. Understanding/ assessing the current status
3. Finding the root cause.
4. Planning counter measures
5. Implementing counter measure
6. Verifying results
7. Standardising and establishing control.
A brief of each of the steps in the Kaizen process is given.
Fig: Problem definition phase
27
Vikas Choudhary
200323811
Techniques for Operation Efficiency
Poka-yoke for
failsafing
Model machine
exercises in TPM
Spotting abnormalities at
Gemba
Cost of Quality
SMED/ JIT
Targets
Exercises to identify MURA,
MUDA and MURI
Problems
Internal customer’s
complaints
5-S Audits
External customer’s
complaints
ISO-9000, QS-9000
and ISO-14000 nonconformities
Define Problems
Enlist problems
Prioritize problems
Select topics for Kaizen
Assign themes to
Kaizen teams
Conduct PDCA-SDCA
improvement cycles
When Deming cycle is used as a tool for systematic problem solving (improvement),
the PDCA activities take the form as shown below…
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Vikas Choudhary
200323811
Techniques for Operation Efficiency
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 The “PLAN” element
you are trying to improve
Finding the root cause
Identifying underlying causes of
the problem
The “PLAN” element
Planning counter
measures
Preparing action plan to fix the
problem
The “PLAN” element
Implementing counter
measures
Implementing the action plan
The “DO” element
Verifying results
Confirming the effect of
implementation
The “CHECK” element
Standardizing and
establishing control
Consolidating the change
The “ACT” element of
PDCA and / or + the
STANDARDIZE
element of SDCA
29
Staff attitude
measurement
Employee satisfaction
index
Employee satisfaction
index
Select The Blank
Question
________ is an effect due to the muda of defect.
Correct Answer Wear & tear of parts while disassembling
Your Answer
Poor production planning & control
Select The Blank
Question
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
Question
Parato diagram always
indicates
Correct Answer
Your Answer
Magnitude of defects
Philosophy of 20% of the
activity causes 80% of the
effect
Parato analysis underlines Philosophy of "vital
& operates on
few:trivial many"
Philosophy of "vital
few:trivial many"
Parato analysis is
technique of identifying
vital causes by
Arranging data according
to the descending order of
their frequency of
occurrence
Arranging data according
to the descending order of
their frequency of
occurrence
Parato diagram is a Bar
Arranging data in
graph with height or value descending order
drawn by
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 & divide it 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
Sem – 3rd
Techniques for Operations Efficiency
2
Your Answer
levels required , Draw concentric circles from each gradiation
using 'o' point as centre
Brainstorming to enlist characteristics which require to be
evaluated & draw the circle & divide it 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 from each gradiation
using 'o' point as centre
Select The Blank
Question
5 S audit result is discussed in ________ meeting.
Correct Answer Monthly
Your Answer
Monthly
True/False
Question
Fishbone analysis is used both in analysis & planning.
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
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
Monitor progress of six sigma projects , Approve six sigma
projects , Remove road block in the 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 batch
Your 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
Sem – 3rd
Techniques for Operations Efficiency
3
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 , Collect information of short listed
partners
Your Answer
Decide level of benchmarking , List down a few prospective
candidates of partnership , Collect information 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
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 Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Gap in performance
Select The Blank
Question
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/False
Question
Non-availability of files /document in time is a problem to be
addressed by office TPM.
Correct Answer True
Sem – 3rd
Techniques for Operations Efficiency
4
Your Answer
True
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
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
True/False
Question
Flow chart is pictorial representation of the steps in production
control.
Correct Answer False
Your Answer
True
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)
Select The Blank
Question
A control chart to exhibit counted data on number of defect is
called ________.
Correct Answer c-chart
Your Answer
c-chart
Select The Blank
Question
Procedure for implementation of TPM consists of ________
numbers of steps.
Correct Answer 12
Your Answer
8
Select The Blank
Question
Capability index Cp = ________
Correct Answer Specification width/process width
Sem – 3rd
Techniques for Operations Efficiency
5
Your Answer
Specification width/process width
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer Vital few = trivial many
Your Answer
Vital few = trivial many
True/False
Question
Kanban signals are required when assembly work, subassembly
work and manufacturing at parts is carried out at different
locations.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
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
Select The Blank
Question
Benchmarking allows exchange of ________ between the
benchmarking partners.
Correct Answer Information
Your 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
True/False
Question
In bar graph each bar is of same height.
Correct Answer False
Your Answer
False
Multiple Choice Multiple Answer
Question
During SMED implementation, primary study consists of :-
Sem – 3rd
Techniques for Operations Efficiency
6
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/False
Question
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 :Correct Answer Improve quality
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 Blank
Question
JIT advocates the philosophy at elimination of waste from
system which occurs due to ________.
Correct Answer Over Production
Your Answer
Over Production
True/False
Question
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 :Sem – 3rd
Techniques for Operations Efficiency
7
Correct Answer Defect in materials , Frequent adjustment of machines , Poorly
trained operators
Your Answer
Defect in materials , Frequent adjustment of machines , Poorly
trained operators
True/False
Question
Sample size for the construction of p-chart are larger than X barR 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 & within
specific limits
Your Answer
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
Multiple Choice Single Answer
Question
Productivity improves by :Correct Answer Voluntary participants of everyone
Your Answer
Sem – 3rd
Voluntary participants of everyone
Techniques for Operations Efficiency
8
Techniques
For
Operations
Efficiency
ASSIGNMENTS
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Select The Blank
Question
Cp for six sigma process is ________
Correct Answer 2
Your Answer
2
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
Select The Blank
Question
________ 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 progress
by presentation to steering committee , Convince committee for
financial help for running the project
Select The Blank
Question
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 from Seiso
top to bottom
Cleaning yourself your
equipments
Evolve standard operating Seiketsu
procedure & implement.
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/False
Question
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 Blank
Question
________ 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 Blank
Question
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 are
Correct Answer 100 % inspection is required , Reduce variability , Possibility of
squeezing tolerances
Your 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 , To
develop abilities to discover analyze malfunction
Your Answer
To develop abilities to respond quickly to abnormalities , To
develop abilities to discover analyze malfunction , To have
multiskilled employees in all departments
Multiple Choice Multiple Answer
Question
Typical examples of process benchmark are :Correct Answer Procurement procedures , Budgeting , Recruitment
Your Answer
Procurement procedures , Budgeting , Recruitment
True/False
Question
Along with problem solving tools experience and judgment is
also used.
Correct Answer True
Your Answer
True
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength or
weakness of the activity.
Correct Answer Relative
Your Answer
Relative
True/False
Question
Exercise to identify MURA, MUDA & MURI is not helpful to
identify problems.
Correct Answer False
Your Answer
False
Select The Blank
Question
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 Voluntary participants of everyone
Your Answer
Voluntary 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 Blank
Question
World class benchmarking candidate in 'Quality' is ________.
Correct Answer Motorola
Your Answer
Motorola
True/False
Question
Seiso prevents the potential problems by discovering
abnormalities while cleaning your own area.
Correct Answer True
Your Answer
True
Select The Blank
Question
________ 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 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
Your Answer
Strong negative
Multiple Choice Single Answer
Question
POP is :-
Correct Answer Process Oriented Management
Your Answer
Process Oriented Management
True/False
Question
TQM improves the quality by improving processes.
Correct Answer True
Your Answer
True
True/False
Question
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 Blank
Question
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 & all
possibilities
Your Answer
Efforts to avoid the problem permanently , Ultimate aim of the
customers satisfaction , Attacking the real root causes & all
possibilities
True/False
Question
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 & 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
True/False
Question
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 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
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
Question
Correct Answer
Your Answer
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 ) / p + 3 ( sq.root( p ( 1 - p ) /
n ))
n ))
LCLp
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
p - 3 ( sq.root( p ( 1- p ) /
n))
)))
)))
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
service
Your Answer
Increase the amount of time, the customer spend till he receive
service
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 , Converting
internal setup into external setup
True/False
Question
Everyone in the team of quality should target his own benefits
i.e. promotion, etc.
Correct Answer False
Your Answer
False
Techniques for Operations Efficiency assgn :01: Naresh
Multiple Choice Multiple Answer
Question
Advantages of JIT :Correct
Answer
Your Answer
Reduce incoming inspection , Reduce inventory , Lower per unit cost
Reduce incoming inspection , Reduce inventory , Lower per unit cost
Multiple Choice Multiple Answer
Question
Benefits from the standardized containers are
Correct
Answer
Your Answer
Minimization of transit damages , Ease in verification of quantity of parts , Automatic
signal to supplier to replenish stock
Minimization of transit damages , Ease in verification of quantity of parts , Automatic
signal to supplier to replenish stock
Multiple Choice Multiple Answer
Question
Benefits from SMED are :Correct
Answer
Your Answer
Reduce work in process , Better average daily production , Increase capacity
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
Main competitor
Answer
Your Answer
Main competitor
Multiple Choice Multiple Answer
Question
Benefits of stratification are :Correct
Answer
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
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 following production inputs :Correct
Answer
Your Answer
Men , Machine , Material
Men , Machine , Management
Multiple Choice Single Answer
Question
The success indicators in quality, cost, delivery & product development are :Correct
Answer
Your Answer
Managing points
Accountability
Multiple Choice Multiple Answer
Question
Steps in setup time reduction are :-
1
Correct
Answer
Your Answer
Team formation , Training , Recoding of activities on multiple activity charts
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
Your Answer
Time management , Team participation and performance , Moral boosting
Time management , Team participation and performance , Cost Management
Multiple Choice Single Answer
Question
Activity under quality management is :Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
Use team approach to track down root causes of the problem
Maintenance of equipment condition by eliminating lubricant leakage.
Every department should make their own rules of standardization.
False
True
Multiple Choice Multiple Answer
Question
Histogram is an important diagnostic tool. Analysis of the histogram gives :Correct
Answer
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
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
Question
Correct Answer
Your Answer
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
Staff attitude measurement
Employee satisfaction index
Employee satisfaction index
Multiple Choice Single Answer
Question
TPM helps to reduce down time due to:Correct
Answer
Your Answer
Breakdown of machine
Breakdown of machine
2
Multiple Choice Single Answer
Question
Kaizen emphasizes :Correct
Answer
Your Answer
Implementation of ideas
Collection of ideas
Select The Blank
Question
Create as many ________ system as possible for better Seiketsu.
Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
Visual control
Visual control
Inadequate maintenance of machine leads to muda of defects
True
False
Select The Blank
Question
The shape of histogram can provide a clue about the ________ of the lot.
Correct
Answer
Your Answer
Quality
Distribution
Multiple Choice Single Answer
Question
Customer's return is an indicators of the MUDA of :Correct
Answer
Your Answer
Defect
Defect
Multiple Choice Single Answer
Question
In bar graph the interval (gap) between the bars is :Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Equal
Symmetrical
Inspection is poor method of assuring 100% quality.
True
False
A radar chart is combination of a circle & line graph
True
3
Your Answer
True
Multiple Choice Single Answer
Question
A workshop is to be treated as :Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
Place where one's creativity can be applied
Place where one's creativity can be applied
Customer wise outstanding is discussed in daily work management meeting by
operations head.
False
True
Number of operation can change according to production requirement in U-Line
arrangement.
False
True
Automation can correct the basic faults of a improper setup process.
False
True
Select The Blank
Question
Cp for six sigma process is ________
Correct
Answer
Your Answer
2
1.66
Select The Blank
Question
Range ( R ) is obtained as the difference between the highest and ________
measurement of a sample.
Correct
Lowest
Answer
Your Answer
Second highest
Select The Blank
Question
________is an important step toward successful JIT purchasing.
Correct
Answer
Your Answer
JIT Contract
JIT Contract
True/False
4
Question
Correct
Answer
Your Answer
U-Line layout is better than straight lime layout.
True
True
Multiple Choice Single Answer
Question
TQM applicable to :Correct
Answer
Your Answer
Marketing, design & manufacturing
Quality Control department
Select The Blank
Question
Bar graph is display of data that facilitates ________ of quality.
Correct
Answer
Your Answer
Comparison
Performance
Multiple Choice Single Answer
Question
Production kanban is presented by :Correct
Answer
Your Answer
P-kanban
R-kanban
Multiple Choice Single Answer
Question
Check sheet are also used as :Correct
Answer
Your Answer
Data gathering & interpretation tool
Cause finding & effect finding tool
Select The Blank
Question
Japanese believe that when they are ________ they are cleaning there minds too.
Correct
Answer
Your Answer
Cleaning
Repairing machines
Select The Blank
Question
Poka-Yoke devices under category use ________ to distinguish between similar parts
which may be assembled in wrong position.
Correct
Color coding
Answer
Your Answer
Counting device
Select The Blank
Question
Shitsuke means ________ all the previous 4-S throughout the month/year.
Correct
Answer
Sustaining
5
Your Answer
Implementing
Multiple Choice Multiple Answer
Question
Types of meetings held in DWM are :Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
Daily PDCA meeting , Weekly PDCA meeting , Monthly PDCA meeting
Weekly PDCA meeting , Monthly PDCA meeting , Yearly PDCA meeting
By TPM, consumption of electrical energy can be reduced.
True
True
Multiple Choice Multiple Answer
Question
According to Seiketsu Standardization means :Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
To develop easy to follow standards , Evolve standard operating procedure , Better
visual management
To develop easy to follow standards , Evolve standard operating procedure , Reduction
of wastage
Flow chart helps to stop an old process.
False
True
Multiple Choice Multiple Answer
Question
Training related to Quality includes:Correct
Answer
Your Answer
Quality measures , Quality failure
Quality measures , Quality failure , Goal of business
Multiple Choice Single Answer
Question
Total area under the normal curve is
Correct
Answer
Your Answer
Unity
Six
Multiple Choice Multiple Answer
Question
Cpk =
Correct
Answer
Your Answer
(x - USL)/3 sigma , (x - LSL)/3 sigma
(x - USL)/6 sigma
Select The Blank
6
Question
Correct
Answer
Your Answer
A histogram is a graphical display of distribution of measurements & reveals the
amounts of ________ within the process.
Variation
Percentage defects
Match The Following
Question
Correct Answer
Your Answer
Value analysis / value
engineering
To eliminate MUDA of processing To 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 eliminate MUDA of processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength or weakness of the activity.
Correct
Answer
Your Answer
Relative
Comparative
2nd assignment
Techniques for Operations Efficiency assgn :02: Naresh
True/False
Question
Correct
Answer
Your Answer
Performance benchmarking does not involves comparison of financial ratios at the
aggregate level.
False
False
Multiple Choice Multiple Answer
Question
Few steps to construct a flow chart are :Correct
Answer
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'
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
Checking
Answer
Your Answer
Checking
Select The Blank
Question
5 S audit result is discussed in ________ meeting.
7
Correct
Answer
Your Answer
Monthly
Shift beginning
Select The Blank
Question
In scatter diagram "________" relationship is said to exist when value of 'y' decreases
as the value of 'x' increases.
Correct
Strong negative
Answer
Your Answer
Strong negative
Select The Blank
Question
Kaizen projects are managed by ________
Correct
Answer
Your Answer
Cross functional team
Management
Multiple Choice Single Answer
Question
Poka-yoke for employee not performing work as per established method is :Correct
Answer
Your Answer
Implement work standard
Implement work standard
Multiple Choice Multiple Answer
Question
Typical examples of process benchmark are :Correct
Answer
Your Answer
Procurement procedures , Budgeting , Recruitment
Procurement procedures , Budgeting , Recruitment
Multiple Choice Multiple Answer
Question
What are the steps in deciding the benchmarking partner?
Correct
Answer
Your Answer
Decide level of benchmarking , List down a few prospective candidates of partnership ,
Collect information of short listed partners
Decide level of benchmarking , Collect information of short listed partners
Multiple Choice Single Answer
Question
Errors by armatures is :Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
Lack of experience
Absent mindedness
Control chart is also called as run-chart.
True
True
8
Match The Following
Question
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
Improve work aids positioning
method
Convert internal setup into
external setup
Preparation of tools / dies as off
line activity
Preparation of tools / dies as off
line activity
Eliminate adjustment
Pre setting of tool
Pre setting of tool
Multiple Choice Single Answer
Question
Muda of defect is very serious in case of:Correct
Answer
Your Answer
High speed automatic machines
High speed automatic machines
Multiple Choice Multiple Answer
Question
To reduce clamping & declamping time, following actions are desirable :Correct
Answer
Your Answer
Standardize clamping bolts / screws , Cut off unnecessary threads , Use quick
clamping device
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
Your Answer
Muda of overproduction
Muda of waiting
Multiple Choice Single Answer
Question
In India quality circle was first launched by :Correct
Answer
Your Answer
Hyderabad unit of BHEL
Hyderabad unit of BHEL
Multiple Choice Multiple Answer
Question
3M' is world class benchmarking ' candidates in the field of :Correct
Answer
Your Answer
Product development , Technology transfer , Environmental Management
Product development , Technology transfer , Environmental Management
Multiple Choice Single Answer
Question
Responsibility for Quality should rest on:Correct
Answer
Your Answer
Who produce the product
Quality control department
9
True/False
Question
Correct
Answer
Your Answer
Increase in defect rate is an example of 'Deviation from an established norms'
True
True
Select The Blank
Question
________ are implemented for defect detection & prevention.
Correct
Answer
Your Answer
Poka-Yokes
Poka-Yokes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct
Answer
Your Answer
Improve quality
Improve quality
Multiple Choice Single Answer
Question
Implication of Quality problem is:Correct
Answer
Your Answer
True/False
Question
Co rrect
Answer
Your Answer
Gap in performance
Lower efficiency
Presentation of graphs in pictorial form of data collection are for easy understanding.
True
True
Select The Blank
Question
________ waste is probably the biggest waste in most of the organizations.
Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
True/False
Question
Time
Labor
Globalization of trade and industrial operations have forced Indian companies to
become more & more competitive and customer driven.
True
True
TQM improves the quality by improving processes.
10
Co rrect
Answer
Your Answer
True
True
Multiple Choice Multiple Answer
Question
An erratic patterns falling above & below the control limits indicates :Correct
Answer
Your Answer
Poorly trained operators , Defect in materials , Frequent adjustment of machines
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
Your Answer
3.4
6210
Multiple Choice Single Answer
Question
To provide flexibility to supervisors in allocation of task, JIT emphasizes :Correct
Answer
Your Answer
Multiskilled operators
Multiskilled operators
Multiple Choice Single Answer
Question
To maintain smoothness in production :Correct
Answer
Your Answer
Elimination of buffer stock is recommended
Maintenance of buffer stock is recommended.
Select The Blank
Question
________ should be used to exercise control on the process.
Correct
Answer
Your Answer
Control chart
Latest checking instruments
Match The Following
Question
Correct Answer
Your Answer
Ideally the histogram will have a Tapering away on the both sides Tapering away on the both sides
bell shape
from average value
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
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/False
11
Question
Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
In single card kanban system production greater than quantity withdrawn is
permitted.
False
False
Flow chart are drawn to document a process charting the tasks performed & the
sequence in which tasks are performed.
True
True
Select The Blank
Question
Cpk for six sigma process is ________
Correct
Answer
Your Answer
True/False
Question
Correct
Answer
Your Answer
1.5
1.5
Seiso prevents the potential problems by discovering abnormalities while cleaning
your own area.
True
True
Multiple Choice Multiple Answer
Question
Some steps for stratification are :Correct
Answer
Your Answer
True/False
Question
Correct
Answer
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?
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?
Processing cost of a product is mainly decided by conversion process.
True
True
Multiple Choice Multiple Answer
Question
Work standards enable management to minimize variation in :Correct
Answer
Your Answer
Output , Quality , Cost
Output , Quality , Cost
Multiple Choice Multiple Answer
Question
Process can be made capable by :-
12
Correct
Answer
Your Answer
Reducing process variability , Bringing target & average to fall at the same point ,
Examine possibility of relaxing specification
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
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 the percentage of each category into pie chart
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 the percentage of each category into pie chart
Multiple Choice Multiple Answer
Question
As benchmark in Japan seiso activities means :Correct
Answer
Your Answer
Everyone, clerk to officer does cleaning his area , No sweeper or cleaner employees ,
Every family does cleaning of pavement of their residence
Everyone, clerk to officer does cleaning his area , No sweeper or cleaner employees ,
Every family does cleaning of pavement of their residence
Select The Blank
Question
Poka Yoke designed to help operators to know immediately ________ of the defeat
called detection type Poka-Yoke.
Correct
On occurrence
Answer
Your Answer
Before Occurrence
Select The Blank
Question
Flow chart helps to dissect a process for better understanding & ________ of process.
Correct
Answer
Your Answer
Analysis
Analysis
Multiple Choice Single Answer
Question
Small groups forming a circle should consist of :Correct
Answer
Your Answer
Employees of different department related to the problem
Employees of same department
Select The Blank
Question
Graphs convey a situation more ________ than summary of data or figures.
Correct
Answer
Your Answer
Effectively & clearly
Effectively & clearly
Multiple Choice Single Answer
Question
Number of Kaizen projects suggested and implemented is checking point for :-
13
Correct
Answer
Your Answer
Continual Improvement
Continual Improvement
3rd assignment
Techniques for Operations Efficiency assgn :03: Senthil N
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following production inputs :Correct Answer
Material , Men , Machine
Your Answer
Material , Men , Machine
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer
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
Measure the current pattern & extent of variation , Assess current conformance
to specification & scope of improvement , Determine whether or not the process
is in the state of control
Multiple Choice Single Answer
Question
In problem solving the best alternative is that :Correct Answer
Which best meets the criteria
Your Answer
Which best meets the criteria
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer
DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
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
Your Answer
Select The Blank
Question
Internal benchmarking
Correct Answer
JIT advocates the philosophy at elimination of waste from system which occurs
due to ________.
Over Production
Your Answer
Over Production
Select The Blank
Question
In scatter diagram "________" relationship is said to exist when there is
positive relationship upto certain level & negative thereafter or negative
relationship upto certain level & positive thereafter.
14
Correct Answer
Curvilinear
Your Answer
Curvilinear
True/False
Question
Correct Answer
Kanban signals are required when assembly work, subassembly work and
manufacturing at parts is carried out at different locations.
True
Your Answer
True
Multiple Choice Multiple Answer
Question
Customers complaints may be segregated by :Correct Answer
Your Answer
True/False
Question
Nature of compliant i.e. defective product , Delayed delivery , Short/excess
quantity
Nature of compliant i.e. defective product , Delayed delivery , Short/excess
quantity
Correct Answer
In case of more than one quality characteristics, separate chart is made for
each quality characteristics.
True
Your Answer
True
True/False
Question
Safety, hygiene and environment control is one of the pillar of TPM.
Correct Answer
True
Your Answer
True
Multiple Choice Single Answer
Question
5-S technique is useful to:
Correct Answer
To all places including homes
Your Answer
To all places including homes
Match The Following
Question
Correct Answer
Your Answer
Reduce time of external setup
Improve work aids positioning
method
Improve work aids positioning
method
Convert internal setup into
external setup
Preparation of tools / dies as off
line activity
Preparation of tools / dies as off
line activity
Eliminate adjustment
Pre setting of tool
Pre setting of tool
Reduce clamping & declamping
time
Use U-shaped washer
Use U-shaped washer
Multiple Choice Single Answer
Question
The facilitator should be normally :-
15
Correct Answer
Senior officer /Shop incharge
Your Answer
Senior officer /Shop incharge
Match The Following
Question
Correct Answer
Your Answer
Parato diagram always indicates Magnitude of defects
Philosophy of 20% of the activity
causes 80% of the effect
Parato analysis underlines &
operates on
Philosophy of "vital few:trivial
many"
Philosophy of "vital few:trivial
many"
Parato analysis is technique of
identifying vital causes by
Arranging data according to the
descending order of their
frequency of occurrence
Arranging data according to the
descending order of their
frequency of occurrence
Parato diagram is a Bar graph
with height or value drawn by
Arranging data in descending
order
Magnitude of defects
Multiple Choice Single Answer
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 Blank
Question
Correct Answer
In scatter diagram "________" relationship is said to exist when value of 'y'
somewhat decreases as the value of 'x' increases.
Weak negative
Your 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
Performance , Features , Cost
Your Answer
Performance , Features , Cost
Multiple Choice Multiple Answer
16
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
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
Multiple Choice Single Answer
Question
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 Blank
Question
Kaizen is ________ supported process.
Correct Answer
Management
Your Answer
Management
True/False
Question
Correct Answer
The flow charts are prepared to enhance the employees understanding of the
process by indicating interrelationship within the process.
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
Correct Answer
In scatter diagram "________" relationship is said to exist when value of 'y'
decreases as the value of 'x' increases.
Strong negative
Your Answer
Strong negative
Select The Blank
17
Question
________ is most difficult 'S' to implement & achieve.
Correct Answer
Shitsuke
Your Answer
Shitsuke
True/False
Question
Correct Answer
Presentation of graphs in pictorial form of data collection are for easy
understanding.
True
Your Answer
True
Select The Blank
Question
Graphs convey a situation more ________ than summary of data or figures.
Correct Answer
Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer
Lack of experience
Your Answer
Lack of experience
Multiple Choice Multiple Answer
Question
While preparing scatter diagram following precautions are to be taken :Correct Answer
Your Answer
True/False
Question
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
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
Correct Answer
Globalization of trade and industrial operations have forced Indian companies to
become more & more competitive and customer driven.
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
Your 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
18
Your Answer
True/False
Question
Two to three per year
Flow chart is pictorial representation of the steps in production control.
Correct Answer
False
Your Answer
False
Multiple Choice Single Answer
Question
It is essential to convey customer's expectations to :Correct Answer
Top Management
Your Answer
Supervisors & workmen
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer
Simplest tool
Your Answer
Simplest tool
Select The Blank
Question
Correct Answer
Identification of non-value added operations & their elimination is the first step
to eliminate muda of ________.
Processing
Your Answer
Processing
Select The Blank
Question
Correct Answer
A 'Radar chart' is used to portray ________ strength or weakness of the
activity.
Relative
Your Answer
Relative
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer
Vital few = trivial many
Your Answer
Vital few = trivial many
True/False
Question
Correct Answer
In single card kanban system production greater than quantity withdrawn is
permitted.
False
Your Answer
False
Multiple Choice Multiple Answer
Question
Benefits of planned maintenance are :-
19
Correct Answer
Your Answer
Improved reliability mean time between failures , Improved maintainability
mean time to repair , Improvement in breakdown
Improved reliability mean time between failures , Improved maintainability
mean time to repair
Multiple Choice Multiple Answer
Question
Gap analysis & problem identification is done during converting internal setups
into external setups in the areas like :Correct Answer
Equipment , Method , Human
Your Answer
Equipment , Method , Human
Multiple Choice Single Answer
Question
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 Answer
Question
Sorting of usable items should be
Correct Answer
Planned storage based on frequency of use
Your 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 time
Your Answer
Reduction in customer quality complaints , Reduction in inspection time
th
4 assignment
Techniques for Operations Efficiency assgn :04: Sameer
Multiple Choice Multiple Answer
Question Training related to Quality includes:Correct Answer Quality measures , Quality failure
Your 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 little
Your Answer Very high
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 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.
20
Correct Answer False
Your Answer False
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 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
Multiple Choice Single Answer
Question 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 Answer
Question Organizing the place is not enough , what is required is :
Correct Answer Planning storage based on Frequency of use
Your Answer Planning storage based on Frequency of use
Select The Blank
Question JIT helps to ________ the waste in the purchasing process.
Correct Answer Eliminates
Your Answer Eliminates
Multiple Choice Single Answer
Question In cellular manufacturing system, the cells are designed so that the material flow within
the cell and between the cells are :Correct Answer Minimized
Your 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
Multiple Choice Multiple Answer
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
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 Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA meeting
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 ,
Payment problem
21
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 while cleaning you may find
a fault , Saving of further failure due to dust
Your Answer You know your self how to avoid dust , When you touch while cleaning you may find a
fault , Saving of further failure due to dust , Utilization of spare time
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 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 ________ i n comparison to its competitors.
Correct Answer Performing
Your Answer Performing
True/False
Question Inspection is poor method of assuring 100% quality.
Correct Answer True
Your Answer False
Multiple Choice Multiple Answer
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
Your Answer Visual Management
True/False
Question 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 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
of ________ within the process.
Correct Answer Variation
Your Answer Variation
Select The Blank
Question To assess effectiveness of training ________ is essential.
Correct Answer Evaluation
Your Answer Evaluation
Select The Blank
Question ________ are implemented for defect detection & prevention.
Correct Answer Poka-Yokes
Your Answer TPM
22
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 qualit y product is the aim of :Correct Answer Quality maintenance
Your Answer Quality maintenance
Match The Following
Question 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
Staff attitude measurement Employee satisfaction index Employee satisfaction index
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
Your Answer Video recording
Match The Following
Question Correct Answer Your Answer
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
The scatter is also known as Correlation diagram Correlation diagram
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 Flow chart helps to stop an old process.
Correct Answer False
Your 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 :-
23
Correct Answer Empowerment
Your Answer Empowerment
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.
Multiple Choice Single Answer
Question Kanban system is
Correct Answer 1. Pull System
Your Answer 1. Pull System
Multiple Choice Single Answer
Question Quality problem solving tool is used to :Correct Answer Improve quality
Your 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
Your 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 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 finding of the products
Select The Blank
Question ________ is the critical element of TQM.
Correct Answer Focus on customer
Your 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
Your Answer To all places including homes
True/False
Question Safety, hygiene and environment control is one of the pillar of TPM.
Correct Answer True
Your Answer True
Select The Blank
Question Inspection activity for semi finished & finished component should be ________ to reduce
muda of transport .
Correct Answer Decentralized
Your Answer Decentralized
24
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 Teamwork
Your Answer Teamwork
5th assignment
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
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
Multiple Choice Single Answer
Question
SMED means :Correct Answer Single minute exchange of dies
Your Answer
Single minute exchange of dies
Match The Following
Question
Correct Answer
Your Answer
Productivity performance
measurement
Turnover employee
Cost of quality
Financial performance
measurement
Sales of the months
Sales of the months
25
Customer satisfaction measurement Customer complaints per period
Customer complaints per period
Staff attitude measurement
Employee satisfaction index
Employee satisfaction index
Select The Blank
Question
________ is an effect due to the muda of defect.
Correct Answer Wear & tear of parts while disassembling
Your Answer
Poor production planning & control
Select The Blank
Question
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
Question
Correct Answer
Your Answer
Parato diagram always indicates
Magnitude of defects
Philosophy of 20% of the activity
causes 80% of the effect
Parato analysis underlines &
operates on
Philosophy of "vital few:trivial many" Philosophy of "vital few:trivial many"
Parato analysis is technique of
identifying vital causes by
Arranging data according to the
Arranging data according to the
descending order of their frequency descending order of their frequency
of occurrence
of occurrence
Parato diagram is a Bar graph with Arranging data in descending order Magnitude of defects
height or value drawn by
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 & divide
it 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 from
each gradiation using 'o' point as centre
Your Answer
Brainstorming to enlist characteristics which require to be evaluated & draw the circle & divide
it 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 from
each gradiation using 'o' point as centre
Select The Blank
Question
5 S audit result is discussed in ________ meeting.
Correct Answer Monthly
26
Your Answer
Monthly
True/False
Question
Fishbone analysis is used both in analysis & planning.
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
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
Monitor progress of six sigma projects , Approve six sigma projects , Remove road block in the
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 batch
Your 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 , Collect
information of short listed partners
Your Answer
Decide level of benchmarking , List down a few prospective candidates of partnership , Collect
information 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
Multiple Choice Single Answer
27
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 Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Gap in performance
Select The Blank
Question
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/False
Question
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 :Correct Answer Simplest tool
Your Answer
Simplest tool
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
True/False
Question
Flow chart is pictorial representation of the steps in production control.
Correct Answer False
Your Answer
True
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)
28
Select The Blank
Question
A control chart to exhibit counted data on number of defect is called ________.
Correct Answer c-chart
Your Answer
c-chart
Select The Blank
Question
Procedure for implementation of TPM consists of ________ numbers of steps.
Correct Answer 12
Your Answer
8
Select The Blank
Question
Capability index Cp = ________
Correct Answer Specification width/process width
Your Answer
Specification width/process width
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer Vital few = trivial many
Your Answer
Vital few = trivial many
True/False
Question
Kanban signals are required when assembly work, subassembly work and manufacturing at
parts is carried out at different locations.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
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
Select The Blank
Question
Benchmarking allows exchange of ________ between the benchmarking partners.
Correct Answer Information
Your 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
29
Your Answer
True/False
Question
Worried about losing jobs , Afraid of being reprimanded if there are mistakes , Scared of their
bosses
In bar graph each bar is of same height.
Correct Answer False
Your Answer
False
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 , Preparation items (storage place , method)
analysis
True/False
Question
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 :Correct Answer Improve quality
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 Blank
Question
JIT advocates the philosophy at elimination of waste from system which occurs due to
________.
Correct Answer Over Production
Your Answer
Over Production
True/False
Question
Without measuring initial performance, target can't be set.
30
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
Your Answer
Defect in materials , Frequent adjustment of machines , Poorly trained operators
True/False
Question
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 & within
specific limits
Your Answer
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
Multiple Choice Single Answer
Question
Productivity improves by :Correct Answer Voluntary participants of everyone
Your Answer
Voluntary participants of everyone
th
6 assignments
Multiple Choice Multiple Answer
Question
Steps to six sigma process consists of :Correct
Identify the work you do , Identify your customers , Map the process
Answer
True/False
Question
Member giving suggestion in his quality circle may not concern for the work
related problem.
Correct
False
Answer
Match The Following
Question
Correct Answer
Your Answer
Review your efforts & success Check
achieved
Check
Act about the causes found out Do
Act
Collect the initial data for the
Control
Plan
31
problem
Actions further after reviewing Act
Repeat
the progress
True/False
Question
Seiso means cleaning the workplace, is the responsibility of sweeper or cleaning
person.
Correct
False
Answer
Multiple Choice Multiple Answer
Question
The purpose of Shitsuke is especially for :Correct
Maintaining the 4-S consistently , Develop discipline attitude in everyone , Any
Answer
day throughout the year sustain the discipline
Multiple Choice Single Answer
Question
Chronic problems of poor quality, bad quality delivery, absentism etc, all gets
hide if inventory is
Correct
High
Answer
Multiple Choice Single Answer
Question
Quality is the responsibility of :Correct
Everyone in the organization
Answer
Multiple Choice Single Answer
Question
"DOW chemical' is world class benchmarking candidate in :Correct
Answer
True/False
Question
Environmental Management
Benefits of DWN is faster response to customer needs.
Correct
True
Answer
Multiple Choice Single Answer
Question
Control chart is a graphical method of ascertaining / checking :Correct
Stability of the process
Answer
Select The Blank
Question
Poka-Yoke devices under category 'locating pins' to eliminate cause of ________
Correct
Incorrect positioning
Answer
Match The Following
Question
Correct Answer
Your Answer
In scatter diagram, the strength By "correlation coefficient"
of relationship can be
determined
By "correlation coefficient"
The scatter diagram provides
The possible dependency
The possible relationship
32
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 of
points
The pair of data as a cloud of
points
The scatter is also known as
Correlation diagram
By "correlation ratio"
Multiple Choice Single Answer
Question
Time required to prepare machine to change over from one job to another is
called :Correct
Setup time
Answer
Select The Blank
Question
________ % of quality problems are due to individual errors.
Correct
15
Answer
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 factors
Multiple Choice Multiple Answer
Question
Product benchmarking requires, comparison of product :-
Correct
Performance , Features , Cost
Answer
Multiple Choice Single Answer
Question
To help operators to recognize the defect before it occurs :Correct
Build up low cost automated detection method for each process
Answer
Multiple Choice Multiple Answer
Question
Interrupted flow of work from the preceeding operation which may be due to :Correct
Answer
True/False
Question
Lack of parts , Machine breakdown , Operator temporarily absent from place of
work
Daily work management develops problem finding & solving attitude.
Correct
True
Answer
Multiple Choice Multiple Answer
Question
Typical examples of process benchmark are :Correct
Procurement procedures , Budgeting , Recruitment
Answer
Select The Blank
Question
Suppliers may________ their prices to cover for cost of delivery, small production
run etc.
33
Correct
Raise
Answer
Multiple Choice Single Answer
Question
Benefits of Seiton means
Correct
Answer
True/False
Question
Easy irretrievability of material
New benchmarking projects are initiated after reviewing competitive position
periodically.
True
Correct
Answer
Select The Blank
Question
Graphs convey a situation more ________ than summary of data or figures.
Correct
Answer
True/False
Question
Effectively & clearly
TQM improves the quality by improving processes.
Correct
True
Answer
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 confirm anticipated relationship between
two variables / associated sets of data
Select The Blank
Question
Basic objective of control chart is to ________ the variation due to chance &
assignable cause.
Correct
Separate out
Answer
True/False
Question
TQM improves manufacturing as well as clerical activities.
Correct
True
Answer
Select The Blank
Question
Poka Yoke designed to help operators to know immediately ________ of the
defeat called detection type Poka-Yoke.
Correct
On occurrence
Answer
True/False
Question
A control chart is a chart with UCL & LCL placed at 6 Sigma distance on either
side of the process average.
Correct
False
Answer
Multiple Choice Multiple Answer
34
Question
Cleaning your own area/equipments gives benefits of :-
Correct
You know your self how to avoid dust , When you touch while cleaning you may
Answer
find a fault , Saving of further failure due to dust
Multiple Choice Single Answer
Question
For 'Analysis of non conformance' checking point will be :Correct
Find out root cause and take corrective & preventive action
Answer
Multiple Choice Single Answer
Question
Assignable causes :Correct
Can be eliminated
Answer
Select The Blank
Question
________ used to detect drop in air pressure.
Correct
Buzzers / alarms
Answer
Multiple Choice Single Answer
Question
Statistical process control is application of statistical technique to control :Correct
Process
Answer
Multiple Choice Multiple Answer
Question
Benefits from SMED are :Correct
Reduce work in process , Better average daily production , Increase capacity
Answer
Multiple Choice Multiple Answer
Question
According to Seiketsu Standardization means :Correct
To develop easy to follow standards , Evolve standard operating procedure ,
Answer
Better visual management
Select The Blank
Question
________ PDCA cycle is the systematic approach towards meeting the target.
Correct
Kaoishikawa
Answer
Multiple Choice Multiple Answer
Question
To draw control charts, sample must be representative of homogeneous segment
of production for which :Correct
The items of the sample should be from the same machine setting , The items
Answer
should be of the same batch , Items should be made from the same raw material
batch
Multiple Choice Single Answer
Question
Withdrawal kanban is presented by :Correct
C- kanban
Answer
Multiple Choice Multiple Answer
Question
Steps in construction of scatter diagram :-
35
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
Multiple Choice Single Answer
Question
Small groups forming a circle should consist of :-
Correct
Employees of different department related to the problem
Answer
Select The Blank
Question
A ________ is an excellent device to condense & present large mass of data in an
elegant form.
Correct
Frequency distribution
Answer
Select The Blank
Question
In PDCA cycle for benchmarking 'Identification of performance gap' is done in
________.
Correct
Checking
Answer
True/False
Question
Low level of delegation is an example of muda in office.
Correct
True
Answer
True/False
Question
Change of job titles can help to raise employee's morale.
Correct
True
Answer
Select The Blank
Question
________ is benefit of TPM.
Correct
Low production cost
Answer
My assignment attempt 2nd
True/False
Question
The flow charts are prepared to enhance the employees understanding of the process by
indicating interrelationship within the process.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
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 Answer
Question
Setup time includes :-
36
Correct Answer Internal setup time & External setup time
Your Answer
Internal setup time & External setup time
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 causes
Your 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 , 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
Match The Following
Question
Correct Answer
Your Answer
World class benchmarking company Ford
in assembly automation
Ford
World class benchmarking company Microsoft
in marketing
Microsoft
World class benchmarking company Motorola
in quality
Motorola
World class benchmarking company General Electric
in training
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
Your Answer
Product development , Technology transfer , Environmental Management
True/False
Question
By TPM, consumption of electrical energy can be reduced.
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
Multiple Choice Single Answer
Question
The area enclosed under normal distribution curve between mean +1standard deviation is :-
37
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/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
True/False
Question
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
Question
Correct Answer
Your Answer
Ideally the histogram will have a bell Tapering away on the both sides
shape
from average value
Tapering 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
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
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
38
Question
Capability index Cp = ________
Correct Answer Specification width/process width
Your Answer
Specification width/process width
Select The Blank
Question
Pie chart is the graph of ________ data.
Correct Answer Percentage breakdown
Your Answer
Percentage breakdown
Select The Blank
Question
________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 on
rejection / 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 to
specification & scope of improvement , Determine whether or not the process is in the state of
control
Your Answer
Measure the current pattern & extent of variation , Assess current conformance to
specification & scope of improvement , Determine whether or not the process is in the state of
control
Multiple Choice Multiple Answer
Question
Training related to Quality includes:Correct Answer Quality measures , Quality failure
Your Answer
Quality measures , Quality failure
Select The Blank
Question
Benchmarking allows exchange of ________ between the benchmarking partners.
Correct Answer Information
39
Your Answer
Information
Select The Blank
Question
Good ________ is the asset to acquire the success of quality circle.
Correct Answer Teamwork
Your Answer
Teamwork
Select The Blank
Question
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
Select The Blank
Question
Japanese believe that when they are ________ they are cleaning there minds too.
Correct Answer Cleaning
Your Answer
Cleaning
True/False
Question
Key element of JIT is continuous improvement.
Correct Answer True
Your Answer
True
True/False
Question
Statistical limits are calculated from averages of samples, instead of a single sample of large
size.
Correct Answer True
Your Answer
True
Select The Blank
Question
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 Blank
Question
________ are implemented for defect detection & prevention.
40
Correct Answer Poka-Yokes
Your Answer
Poka-Yokes
Multiple Choice Single Answer
Question
Muda of defect is very serious in case of:Correct Answer High speed automatic machines
Your 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 should
be right to avoid wrong conclusions , Data should be free from bias or undue importance
Your Answer
Data should be properly stratified & should be collected for full range , Scale selected should
be right to avoid wrong conclusions , Data should be free from bias or undue importance
Multiple Choice Multiple Answer
Question
The purpose of Shitsuke is especially for :Correct Answer Maintaining the 4-S consistently , Develop discipline attitude in everyone , Any day throughout
the year sustain the discipline
Your Answer
Maintaining the 4-S consistently , Develop discipline attitude in everyone , Any day throughout
the year sustain the discipline
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)
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.
Correct Answer False
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
41
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
Select The Blank
Question
To assess effectiveness of training ________ is essential.
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/False
Question
In P-chart, the value of P can never be negative.
Correct Answer True
Your Answer
True
42
My skipped qustions
1. Control chart is a graphical
method of checking
1. As process monitoring tool
2. Control chart can be used to
determine
2. At 6 Sigma distance on either side of the process average
3. Control chart is a chart with
UCL & 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
contributing
Low er levels
who are not usually considered capable
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)
Regular meeting plan to follow
Discuss on the root cause by
brainstorming
d)
Mechanization &
29.
Discipline
Study individually for the problem
Follow the Deming PDCA circle
are the two constituents of streamlining
is serve as a stepping stone to TQM
Actions that can be thought for the process having process capability is approximately equal to
the specification tolerance are :-
a)
Greater
attention to
b) centering of
the process
c)
Keep
mean
&
d)
standard
deviation
under strict
control
Put
efforts to
reduce
variability
43
Use of
less
precision
machine
Technique involved in listing of setup task, establishing technological relationship between tasks, drawing
arrow diagram is called as
36.
.
True
False
44
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Advantages of JIT :Correct Answer Reduce incoming inspection , Reduce inventory , Lower per unit cost
Your 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
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 , 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 factors
Your Answer
It helps to separate data into groups so that you can draw connect &
meaningful inference , It helps to diagnose & localize problem ,
Finding out different reasons
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following production inputs
:Correct Answer Men , Machine , Material
Your Answer
Men , Machine , Management
Multiple Choice Single Answer
Question
The success indicators in quality, cost, delivery & product
development are :-
Correct Answer Managing points
Your Answer
Accountability
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 external setups in to internal setups
Multiple Choice Multiple Answer
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
True/False
Question
Maintenance of equipment condition by eliminating lubricant
leakage.
Every department should make their own rules of standardization.
Correct Answer False
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 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
Question
Correct Answer
Your Answer
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
Staff attitude measurement Employee satisfaction
index
Customer complaints per
period
Employee satisfaction index
Multiple Choice Single Answer
Question
TPM helps to reduce down time due to:Correct Answer Breakdown of machine
Your Answer
Breakdown of machine
Multiple Choice Single Answer
Question
Kaizen emphasizes :Correct Answer Implementation of ideas
Your Answer
Collection of ideas
Select The Blank
Question
Create as many ________ system as possible for better Seiketsu.
Correct Answer Visual control
Your 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
Your Answer
Distribution
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
Your Answer
Symmetrical
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 graph
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
Your 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.
Correct Answer False
Your Answer
True
True/False
Question
Number of operation can change according to production
requirement in U-Line arrangement.
Correct Answer False
Your Answer
True
True/False
Question
Automation can correct the basic faults of a improper setup process.
Correct Answer False
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
Your Answer
Second highest
Select The Blank
Question
________is an important step toward successful JIT purchasing.
Correct Answer JIT Contract
Your Answer
JIT Contract
True/False
Question
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
Your Answer
Quality Control department
Select The Blank
Question
Bar graph is display of data that facilitates ________ of quality.
Correct Answer Comparison
Your Answer
Performance
Multiple Choice Single Answer
Question
Production kanban is presented by :Correct Answer P-kanban
Your Answer
R-kanban
Multiple Choice Single Answer
Question
Check sheet are also used as :Correct Answer Data gathering & interpretation tool
Your Answer
Cause finding & effect finding tool
Select The Blank
Question
Japanese believe that when they are ________ they are cleaning
there minds too.
Correct Answer Cleaning
Your Answer
Repairing machines
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
Your Answer
Counting device
Select The Blank
Question
Shitsuke means ________ all the previous 4-S throughout the
month/year.
Correct Answer Sustaining
Your Answer
Implementing
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 PDCA
meeting
True/False
Question
By TPM, consumption of electrical energy can be reduced.
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 , Reduction of wastage
True/False
Question
Flow chart helps to stop an old process.
Correct Answer False
Your Answer
True
Multiple Choice Multiple Answer
Question
Training related to Quality includes:Correct Answer Quality measures , Quality failure
Your Answer
Quality measures , Quality failure , Goal of business
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
Your Answer
(x - USL)/6 sigma
Select The Blank
Question
A histogram is a graphical display of distribution of measurements &
reveals the amounts of ________ within the process.
Correct Answer Variation
Your Answer
Percentage defects
Match The Following
Question
Correct Answer
Your Answer
Value analysis / value
engineering
To eliminate MUDA of
processing
To eliminate MUDA of over
production
SMED
To eliminate MUDA of over To eliminate MUDA of
production
defect
VMI ( Vendor Management To eliminate MUDA of
Inventory) system
stock
To eliminate MUDA of stock
Flow / string diagram
To eliminate MUDA of
processing
To eliminate MUDA of
transport
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength or weakness of
the activity.
Correct Answer Relative
Your Answer
Comparative
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
2. Parato analysis is technique of
identifying vital causes by
3. Parato diagram is a Bar graph
with height or value drawn by
4. Parato diagram always
indicates
1. Arranging data according to the
descending order of their frequency of
occurrence
2. Philosophy of 20% of the activity causes
80% of the effect
3. Magnitude of defects
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)
Unity
b)
Zero
c)
Infinity
d)
Six
U shape arrangement of layout provides the operator
48.
Quality problems may be segregated by & regrouped by :-
a)
Machines
b)
Workers
c)
Materials
degree of mobility.
d)
Suggestion
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
TQM can never flourish if the staff are:Correct Answer Scared of their bosses , Worried about losing jobs , Afraid of
being reprimanded if there are mistakes
Your Answer
Scared of their bosses , Worried about losing jobs , Afraid of
being reprimanded if there are mistakes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer Improve quality
Your Answer
Improve quality
Multiple Choice Single Answer
Question
The concept of quality circle was mooted by :Correct Answer Prof. Kaoishikawa
Your Answer
Prof. Kaoishikawa
Match The Following
Question
Correct Answer
Your Answer
SMED
Setup time reduction
Setup time reduction
5 'S
Cleanliness
Total productive
maintenance
Muda elimination
Waste elimination
Waste elimination
Poka-Yoke
Error proofing
Error proofing
Multiple Choice Single Answer
Question
Allowing worker's to stop machine / assembly line if they believe
that product quality is below standard' is an example of :Correct Answer Empowerment
Your Answer
Involvement
Select The Blank
Question
Kaizen is ________ supported process.
Correct Answer Management
Your Answer
Workmen
Select The Blank
Question
Ratio of ________ to the number of pieces inspected is called
fraction defectives.
Correct Answer Number of item rejected
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 Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Gap in performance
Multiple Choice Multiple Answer
Question
Steps to six sigma process consists of :Correct Answer Identify the work you do , Identify your customers , Map the
process
Your Answer
Identify the work you do , Identify your customers , Map the
process
Multiple Choice Single Answer
Question
From scatter diagram the strength of relationship between two
variables or associated set of data can be inferred from the
examination of the shape of :-
Correct Answer Cloud
Your Answer
Cloud
True/False
Question
Non-availability of files /document in time is a problem to be
addressed by office TPM.
Correct Answer True
Your Answer
True
Select The Blank
Question
________ used to detect drop in air pressure.
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
Multiple Choice Multiple Answer
Question
The aim of education & training under TPM is :Correct Answer To develop abilities to respond quickly to abnormalities , To
develop abilities to discover analyze malfunction
Your Answer
To develop abilities to respond quickly to abnormalities , To
develop abilities to discover analyze malfunction , To have
multiskilled employees in all departments
Match The Following
Question
In scatter diagram, the
strength of relationship
can be determined
Correct Answer
Your Answer
By "correlation coefficient" By "correlation coefficient"
The scatter diagram
The possible relationship
provides the technique to between a pair of
establish
variables
The possible relationship
between a pair of variables
The scatter diagram
displays
The pair of data as a cloud
of points
The pair of data as a
cloud of points
The scatter is also known Correlation diagram
as
Correlation diagram
True/False
Question
Flow chart is pictorial representation of the steps in production
control.
Correct Answer False
Your Answer
True
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer Vital few = trivial many
Your Answer
Vital few = trivial many
Multiple Choice Single Answer
Question
Pareto diagram always indicate magnitude of :Correct Answer Defect
Your Answer
Influence of defect
True/False
Question
By cutting the cost of quality, profitability decreases.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
True/False
Question
The flow charts are prepared to enhance the employees
understanding of the process by indicating interrelationship
within the process.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
Abnormal variations can occur if :-
Correct Answer There are assignable causes
Your Answer
There are assignable causes
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
True/False
Question
Control limits of control charts should be revised from time to
time as additional data is accumulated.
Correct Answer True
Your Answer
True
Select The Blank
Question
Kaizen is an excellent method to involve ________ to unearth &
eliminate hidden waste.
Correct Answer Employees
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
Select The Blank
Question
Cp for six sigma process is ________
Correct Answer 2
Your Answer
2
Select The Blank
Question
________ participants in monthly meeting(MRM)
Correct Answer GM, operation heads, corporate functional heads
Your Answer
True/False
Department heads & supervisors
Question
Processing cost of a product is mainly decided by conversion
process.
Correct Answer True
Your Answer
True
Select The Blank
Question
Production in last shift & production plan for next shift is
discussed during ________.
Correct Answer Shift beginning & shift end/change meeting
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 reduce
inspection
Your Answer
To eliminate handling , To reduce transporting , To reduce
inspection
True/False
Question
Inadequate maintenance of machine leads to muda of defects
Correct Answer True
Your Answer
True
True/False
Question
Most of the external setups are treated as internal setup.
Correct Answer True
Your Answer
False
Multiple Choice Multiple Answer
Question
Benefits from SMED are :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 Multiple Answer
Question
Typical examples of process benchmark are :Correct Answer Procurement procedures , Budgeting , Recruitment
Your Answer
Procurement procedures , Budgeting , Recruitment
True/False
Question
Low level of delegation is an example of muda in office.
Correct Answer True
Your Answer
False
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Your Answer
Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Multiple Choice Multiple Answer
Question
While preparing scatter diagram following precautions are to be
taken :Correct Answer Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
Your Answer
Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
Multiple Choice Single Answer
Question
Through continuous improvement in the process & procedures,
kobetsu-kaizen is continuously improve utilization of :Correct Answer Worker, equipment & material
Your Answer
Workers & materials
True/False
Question
Every department should make their own rules of
standardization.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
Quality circle should consist adequate experienced members
between :Correct Answer 8 to 10
Your Answer
8 to 10
Multiple Choice Single Answer
Question
Number of kaizen in Group kaizen categories are :Correct Answer Two to three per year
Your Answer
As many as management decides
Select The Blank
Question
Flow chart helps to provide clarity of the ________ without
visiting actual spot.
Correct Answer Process
Your Answer
Process
Multiple Choice Single Answer
Question
Gap in performance = Ideal situation minus :Correct Answer Current situation
Your Answer
Current situation
Select The Blank
Question
Seminar talks and video show are organized to introduce TPM
concept to ________
Correct Answer General employees
Your Answer
General employees
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
True/False
Question
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 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
Your Answer
Checking
Select The Blank
Question
5 S audit result is discussed in ________ meeting.
Correct Answer Monthly
Your Answer
Shift beginning
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
Your Answer
Strong negative
Select The Blank
Question
Kaizen projects are managed by ________
Correct Answer Cross functional team
Your Answer
Management
Multiple Choice Single Answer
Question
Poka-yoke for employee not performing work as per established
method is :Correct Answer Implement work standard
Your Answer
Implement work standard
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 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 , Collect information of short listed
partners
Your Answer
Decide level of benchmarking , Collect information of short listed
partners
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer Lack of experience
Your Answer
Absent mindedness
True/False
Question
Control chart is also called as run-chart.
Correct Answer True
Your Answer
True
Match The Following
Question
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
Improve work aids
positioning method
Convert internal setup into Preparation of tools / dies
external setup
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 Answer
Question
Muda of defect is very serious in case of:-
Correct Answer High speed automatic machines
Your 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 overproduction
Your Answer
Muda of waiting
Multiple Choice Single Answer
Question
In India quality circle was first launched by :Correct Answer Hyderabad unit of BHEL
Your 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
Your 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/False
Question
Increase in defect rate is an example of 'Deviation from an
established norms'
Correct Answer True
Your Answer
True
Select The Blank
Question
________ are implemented for defect detection & prevention.
Correct Answer Poka-Yokes
Your Answer
Poka-Yokes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer Improve quality
Your Answer
Improve quality
Multiple Choice Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Lower efficiency
True/False
Question
Presentation of graphs in pictorial form of data collection are for
easy understanding.
Correct Answer True
Your Answer
True
Select The Blank
Question
________ waste is probably the biggest waste in most of the
organizations.
Correct Answer Time
Your Answer
Labor
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
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 adjustment
of machines
Your 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 3.4
Your Answer
6210
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 Single Answer
Question
To maintain smoothness in production :Correct Answer Elimination of buffer stock is recommended
Your Answer
Maintenance of buffer stock is recommended.
Select The Blank
Question
________ should be used to exercise control on the process.
Correct Answer Control chart
Your Answer
Latest checking instruments
Match The Following
Question
Correct Answer
Ideally the histogram will
have a bell shape
Tapering away on the both Tapering away on the both
sides from average value sides from average value
Histogram is a graphical
display of distribution of
measurements and
Reveals the amount of
Reveals the amount of
variation within the process variation within the process
Your Answer
Histogram is a
The frequency distribution
diagrammatic presentation of a characteristics
of
The frequency distribution of
a characteristics
The shape of histogram
can
Provide a clue about the
quality of the lot
True/False
Question
Provide a clue about the
quality of the lot
In single card kanban system production greater than quantity
withdrawn is permitted.
Correct Answer False
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
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/False
Question
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
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 specification
Your 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 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 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 the percentage of each category
into 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 Blank
Question
Poka Yoke designed to help operators to know immediately
________ of the defeat called detection type Poka-Yoke.
Correct Answer On occurrence
Your Answer
Before Occurrence
Select The Blank
Question
Flow chart helps to dissect a process for better understanding &
________ of process.
Correct Answer Analysis
Your 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
Question
Graphs convey a situation more ________ than summary of data or
figures.
Correct Answer Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Number of Kaizen projects suggested and implemented is checking
point for :Correct Answer Continual Improvement
Your Answer
Continual Improvement
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following production
inputs :Correct Answer Material , Men , Machine
Your Answer
Material , Men , Machine
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Your Answer
Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Multiple Choice Single Answer
Question
In problem solving the best alternative is that :Correct Answer Which best meets the criteria
Your Answer
Which best meets the criteria
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
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
Your Answer
Internal benchmarking
Select The Blank
Question
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 is positive relationship upto certain level & negative
thereafter or negative relationship upto certain level & positive
thereafter.
Correct Answer Curvilinear
Your Answer
Curvilinear
True/False
Question
Kanban signals are required when assembly work, subassembly
work and manufacturing at parts is carried out at different
locations.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
Customers complaints may be segregated by :Correct Answer Nature of compliant i.e. defective product , Delayed delivery ,
Short/excess quantity
Your Answer
Nature of compliant i.e. defective product , Delayed delivery ,
Short/excess quantity
True/False
Question
In case of more than one quality characteristics, separate chart
is made for each quality characteristics.
Correct Answer True
Your Answer
True
True/False
Question
Safety, hygiene and environment control is one of the pillar of
TPM.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
5-S technique is useful to:
Correct Answer To all places including homes
Your Answer
To all places including homes
Match The Following
Question
Correct Answer
Your Answer
Reduce time of external
setup
Improve work aids
positioning method
Improve work aids
positioning method
Convert internal setup into Preparation of tools / dies Preparation of tools / dies
external setup
as off line activity
as off line activity
Eliminate adjustment
Pre setting of tool
Pre setting of tool
Reduce clamping &
declamping time
Use U-shaped washer
Use U-shaped washer
Multiple Choice Single Answer
Question
The facilitator should be normally :Correct Answer Senior officer /Shop incharge
Your Answer
Senior officer /Shop incharge
Match The Following
Question
Parato diagram always
indicates
Correct Answer
Your Answer
Magnitude of defects
Philosophy of 20% of the
activity causes 80% of the
effect
Parato analysis
Philosophy of "vital
underlines & operates on few:trivial many"
Philosophy of "vital
few:trivial many"
Parato analysis is
technique of identifying
vital causes by
Arranging data according
to the descending order of
their frequency of
occurrence
Arranging data according
to the descending order of
their frequency of
occurrence
Parato diagram is a Bar Arranging data in
graph with height or value descending order
drawn by
Magnitude of defects
Multiple Choice Single Answer
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 Blank
Question
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 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 Performance , Features , Cost
Your Answer
Performance , Features , Cost
Multiple Choice Multiple Answer
Question
Steps in construction of scatter diagram :Correct Answer Collect paired data (X,Y) from two variables who's relationship is
to be studied , Find out max & min values for both X & Y and
these values to scale X & Y axis & plot the paired data ,
Examine the shape of the cloud of points & discover type &
strength of relationship
Your Answer
Collect paired data (X,Y) from two variables who's relationship is
to be studied , Find out max & min values for both X & Y and
these values to scale X & Y axis & plot the paired data ,
Examine the shape of the cloud of points & discover type &
strength of relationship
Multiple Choice Single Answer
Question
Implication of Quality problem is: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 Blank
Question
Kaizen is ________ supported process.
Correct Answer Management
Your Answer
Management
True/False
Question
The flow charts are prepared to enhance the employees
understanding of the process by indicating interrelationship
within the process.
Correct Answer True
Your Answer
False
True/False
Question
Gap analysis for production & dispatches is discussed in
monthly meeting.
Correct Answer False
Your Answer
False
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
Your Answer
Strong negative
Select The Blank
Question
________ is most difficult 'S' to implement & achieve.
Correct Answer Shitsuke
Your 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
Question
Graphs convey a situation more ________ than summary of
data or figures.
Correct Answer Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer Lack of experience
Your 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 for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue
importance
Your Answer
Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue
importance
True/False
Question
Globalization of trade and industrial operations have forced
Indian companies to become more & more competitive and
customer driven.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
If 'Annual saving in procurement expenses is managing point',
then checking points will be :Correct Answer Price revision , Credit period , Transport expenses
Your 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
True/False
Two to three per year
Question
Flow chart is pictorial representation of the steps in production
control.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
It is essential to convey customer's expectations to :Correct Answer Top Management
Your Answer
Supervisors & workmen
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
Select The Blank
Question
Identification of non-value added operations & their elimination
is the first step to eliminate muda of ________.
Correct Answer Processing
Your Answer
Processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength or
weakness of the activity.
Correct Answer Relative
Your Answer
Relative
Multiple Choice Single Answer
Question
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 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 , Improved
maintainability mean time to repair , Improvement in breakdown
Your Answer
Improved reliability mean time between failures , Improved
maintainability mean time to repair
Multiple Choice Multiple Answer
Question
Gap analysis & problem identification is done during converting
internal setups into external setups in the areas like : Correct Answer Equipment , Method , Human
Your Answer
Equipment , Method , Human
Multiple Choice Single Answer
Question
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 Answer
Question
Sorting of usable items should be
Correct Answer Planned storage based on frequency of use
Your 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 time
Your Answer
Reduction in customer quality complaints , Reduction in
inspection time
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
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
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
Multiple Choice Single Answer
Question
SMED means :Correct Answer Single minute exchange of dies
Your Answer
Single minute exchange of dies
Match The Following
Question
Correct Answer
Your Answer
Productivity performance Turnover employee
measurement
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
Sem – 3rd
Techniques for Operations Efficiency
1
Staff attitude
measurement
Employee satisfaction
index
Employee satisfaction
index
Select The Blank
Question
________ is an effect due to the muda of defect.
Correct Answer Wear & tear of parts while disassembling
Your Answer
Poor production planning & control
Select The Blank
Question
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
Question
Parato diagram always
indicates
Correct Answer
Your Answer
Magnitude of defects
Philosophy of 20% of the
activity causes 80% of the
effect
Parato analysis underlines Philosophy of "vital
& operates on
few:trivial many"
Philosophy of "vital
few:trivial many"
Parato analysis is
technique of identifying
vital causes by
Arranging data according
to the descending order of
their frequency of
occurrence
Arranging data according
to the descending order of
their frequency of
occurrence
Parato diagram is a Bar
Arranging data in
graph with height or value descending order
drawn by
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 & divide it 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
Sem – 3rd
Techniques for Operations Efficiency
2
Your Answer
levels required , Draw concentric circles from each gradiation
using 'o' point as centre
Brainstorming to enlist characteristics which require to be
evaluated & draw the circle & divide it 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 from each gradiation
using 'o' point as centre
Select The Blank
Question
5 S audit result is discussed in ________ meeting.
Correct Answer Monthly
Your Answer
Monthly
True/False
Question
Fishbone analysis is used both in analysis & planning.
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
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
Monitor progress of six sigma projects , Approve six sigma
projects , Remove road block in the 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 batch
Your 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
Sem – 3rd
Techniques for Operations Efficiency
3
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 , Collect information of short listed
partners
Your Answer
Decide level of benchmarking , List down a few prospective
candidates of partnership , Collect information 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
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 Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Gap in performance
Select The Blank
Question
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/False
Question
Non-availability of files /document in time is a problem to be
addressed by office TPM.
Correct Answer True
Sem – 3rd
Techniques for Operations Efficiency
4
Your Answer
True
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
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
True/False
Question
Flow chart is pictorial representation of the steps in production
control.
Correct Answer False
Your Answer
True
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)
Select The Blank
Question
A control chart to exhibit counted data on number of defect is
called ________.
Correct Answer c-chart
Your Answer
c-chart
Select The Blank
Question
Procedure for implementation of TPM consists of ________
numbers of steps.
Correct Answer 12
Your Answer
8
Select The Blank
Question
Capability index Cp = ________
Correct Answer Specification width/process width
Sem – 3rd
Techniques for Operations Efficiency
5
Your Answer
Specification width/process width
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer Vital few = trivial many
Your Answer
Vital few = trivial many
True/False
Question
Kanban signals are required when assembly work, subassembly
work and manufacturing at parts is carried out at different
locations.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
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
Select The Blank
Question
Benchmarking allows exchange of ________ between the
benchmarking partners.
Correct Answer Information
Your 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
True/False
Question
In bar graph each bar is of same height.
Correct Answer False
Your Answer
False
Multiple Choice Multiple Answer
Question
During SMED implementation, primary study consists of :-
Sem – 3rd
Techniques for Operations Efficiency
6
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/False
Question
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 :Correct Answer Improve quality
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 Blank
Question
JIT advocates the philosophy at elimination of waste from
system which occurs due to ________.
Correct Answer Over Production
Your Answer
Over Production
True/False
Question
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 :Sem – 3rd
Techniques for Operations Efficiency
7
Correct Answer Defect in materials , Frequent adjustment of machines , Poorly
trained operators
Your Answer
Defect in materials , Frequent adjustment of machines , Poorly
trained operators
True/False
Question
Sample size for the construction of p-chart are larger than X barR 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 & within
specific limits
Your Answer
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
Multiple Choice Single Answer
Question
Productivity improves by :Correct Answer Voluntary participants of everyone
Your Answer
Sem – 3rd
Voluntary participants of everyone
Techniques for Operations Efficiency
8
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question Training related to Quality includes:Correct Answer Quality measures , Quality failure
Your 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 little
Your Answer Very high
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 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.
Correct Answer False
Your Answer False
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 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
Multiple Choice Single Answer
Question 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 Answer
Question Organizing the place is not enough , what is required is :
Correct Answer Planning storage based on Frequency of use
Your Answer Planning storage based on Frequency of use
Select The Blank
Question JIT helps to ________ the waste in the purchasing process.
Correct Answer Eliminates
Your Answer Eliminates
Multiple Choice Single Answer
Question In cellular manufacturing system, the cells are designed so that the material
flow within the cell and between the cells are :Correct Answer Minimized
Your 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
Multiple Choice Multiple Answer
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
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 Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA
meeting
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 , 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 while
cleaning you may find a fault , Saving of further failure due to dust
Your Answer You know your self how to avoid dust , When you touch while cleaning
you may find a fault , Saving of further failure due to dust , Utilization of spare time
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 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.
Correct Answer Performing
Your Answer Performing
True/False
Question Inspection is poor method of assuring 100% quality.
Correct Answer True
Your Answer False
Multiple Choice Multiple Answer
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
Your Answer Visual Management
True/False
Question 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 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 of ________ within the process.
Correct Answer Variation
Your Answer Variation
Select The Blank
Question To assess effectiveness of training ________ is essential.
Correct Answer Evaluation
Your 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 maintenance
Your Answer Quality maintenance
Match The Following
Question 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
Staff attitude measurement Employee satisfaction index Employee satisfaction index
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
Your Answer Video recording
Match The Following
Question Correct Answer Your Answer
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
The scatter is also known as Correlation diagram Correlation diagram
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 Flow chart helps to stop an old process.
Correct Answer False
Your 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 :Correct Answer Empowerment
Your Answer Empowerment
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.
Multiple Choice Single Answer
Question Kanban system is
Correct Answer 1. Pull System
Your Answer 1. Pull System
Multiple Choice Single Answer
Question Quality problem solving tool is used to :Correct Answer Improve quality
Your 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
Your 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 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 finding
of the products
Select The Blank
Question ________ is the critical element of TQM.
Correct Answer Focus on customer
Your 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
Your Answer To all places including homes
True/False
Question Safety, hygiene and environment control is one of the pillar of TPM.
Correct Answer True
Your Answer True
Select The Blank
Question Inspection activity for semi finished & finished component should be
________ to reduce muda of transport .
Correct Answer Decentralized
Your 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 Teamwork
Your Answer Teamwork
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question Training related to Quality includes:Correct Answer Quality measures , Quality failure
Your 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 little
Your Answer Very high
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 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.
Correct Answer False
Your Answer False
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 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
Multiple Choice Single Answer
Question 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 Answer
Question Organizing the place is not enough , what is required is :
Correct Answer Planning storage based on Frequency of use
Your Answer Planning storage based on Frequency of use
Select The Blank
Question JIT helps to ________ the waste in the purchasing process.
Correct Answer Eliminates
Your Answer Eliminates
Multiple Choice Single Answer
Question In cellular manufacturing system, the cells are designed so that the material
flow within the cell and between the cells are :Correct Answer Minimized
Your 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
Multiple Choice Multiple Answer
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
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 Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA
meeting
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 , 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 while
cleaning you may find a fault , Saving of further failure due to dust
Your Answer You know your self how to avoid dust , When you touch while cleaning
you may find a fault , Saving of further failure due to dust , Utilization of spare time
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 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.
Correct Answer Performing
Your Answer Performing
True/False
Question Inspection is poor method of assuring 100% quality.
Correct Answer True
Your Answer False
Multiple Choice Multiple Answer
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
Your Answer Visual Management
True/False
Question 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 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 of ________ within the process.
Correct Answer Variation
Your Answer Variation
Select The Blank
Question To assess effectiveness of training ________ is essential.
Correct Answer Evaluation
Your 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 maintenance
Your Answer Quality maintenance
Match The Following
Question 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
Staff attitude measurement Employee satisfaction index Employee satisfaction index
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
Your Answer Video recording
Match The Following
Question Correct Answer Your Answer
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
The scatter is also known as Correlation diagram Correlation diagram
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 Flow chart helps to stop an old process.
Correct Answer False
Your 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 :Correct Answer Empowerment
Your Answer Empowerment
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.
Multiple Choice Single Answer
Question Kanban system is
Correct Answer 1. Pull System
Your Answer 1. Pull System
Multiple Choice Single Answer
Question Quality problem solving tool is used to :Correct Answer Improve quality
Your 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
Your 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 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 finding
of the products
Select The Blank
Question ________ is the critical element of TQM.
Correct Answer Focus on customer
Your 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
Your Answer To all places including homes
True/False
Question Safety, hygiene and environment control is one of the pillar of TPM.
Correct Answer True
Your Answer True
Select The Blank
Question Inspection activity for semi finished & finished component should be
________ to reduce muda of transport .
Correct Answer Decentralized
Your 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 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
2. Parato analysis is technique of
identifying vital causes by
3. Parato diagram is a Bar graph
with height or value drawn by
4. Parato diagram always
indicates
1. Arranging data according to the
descending order of their frequency of
occurrence
2. Philosophy of 20% of the activity causes
80% of the effect
3. Magnitude of defects
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)
Unity
b)
Zero
c)
Infinity
d)
Six
U shape arrangement of layout provides the operator
48.
Quality problems may be segregated by & regrouped by :-
a)
Machines
b)
Workers
c)
Materials
degree of mobility.
d)
Suggestion
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
TQM can never flourish if the staff are:Correct Answer Scared of their bosses , Worried about losing jobs , Afraid of
being reprimanded if there are mistakes
Your Answer
Scared of their bosses , Worried about losing jobs , Afraid of
being reprimanded if there are mistakes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer Improve quality
Your Answer
Improve quality
Multiple Choice Single Answer
Question
The concept of quality circle was mooted by :Correct Answer Prof. Kaoishikawa
Your Answer
Prof. Kaoishikawa
Match The Following
Question
Correct Answer
Your Answer
SMED
Setup time reduction
Setup time reduction
5 'S
Cleanliness
Total productive
maintenance
Muda elimination
Waste elimination
Waste elimination
Poka-Yoke
Error proofing
Error proofing
Multiple Choice Single Answer
Question
Allowing worker's to stop machine / assembly line if they believe
that product quality is below standard' is an example of :Correct Answer Empowerment
Your Answer
Involvement
Select The Blank
Question
Kaizen is ________ supported process.
Correct Answer Management
Your Answer
Workmen
Select The Blank
Question
Ratio of ________ to the number of pieces inspected is called
fraction defectives.
Correct Answer Number of item rejected
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 Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Gap in performance
Multiple Choice Multiple Answer
Question
Steps to six sigma process consists of :Correct Answer Identify the work you do , Identify your customers , Map the
process
Your Answer
Identify the work you do , Identify your customers , Map the
process
Multiple Choice Single Answer
Question
From scatter diagram the strength of relationship between two
variables or associated set of data can be inferred from the
examination of the shape of :-
Correct Answer Cloud
Your Answer
Cloud
True/False
Question
Non-availability of files /document in time is a problem to be
addressed by office TPM.
Correct Answer True
Your Answer
True
Select The Blank
Question
________ used to detect drop in air pressure.
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
Multiple Choice Multiple Answer
Question
The aim of education & training under TPM is :Correct Answer To develop abilities to respond quickly to abnormalities , To
develop abilities to discover analyze malfunction
Your Answer
To develop abilities to respond quickly to abnormalities , To
develop abilities to discover analyze malfunction , To have
multiskilled employees in all departments
Match The Following
Question
In scatter diagram, the
strength of relationship
can be determined
Correct Answer
Your Answer
By "correlation coefficient" By "correlation coefficient"
The scatter diagram
The possible relationship
provides the technique to between a pair of
establish
variables
The possible relationship
between a pair of variables
The scatter diagram
displays
The pair of data as a cloud
of points
The pair of data as a
cloud of points
The scatter is also known Correlation diagram
as
Correlation diagram
True/False
Question
Flow chart is pictorial representation of the steps in production
control.
Correct Answer False
Your Answer
True
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer Vital few = trivial many
Your Answer
Vital few = trivial many
Multiple Choice Single Answer
Question
Pareto diagram always indicate magnitude of :Correct Answer Defect
Your Answer
Influence of defect
True/False
Question
By cutting the cost of quality, profitability decreases.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
True/False
Question
The flow charts are prepared to enhance the employees
understanding of the process by indicating interrelationship
within the process.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
Abnormal variations can occur if :-
Correct Answer There are assignable causes
Your Answer
There are assignable causes
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
True/False
Question
Control limits of control charts should be revised from time to
time as additional data is accumulated.
Correct Answer True
Your Answer
True
Select The Blank
Question
Kaizen is an excellent method to involve ________ to unearth &
eliminate hidden waste.
Correct Answer Employees
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
Select The Blank
Question
Cp for six sigma process is ________
Correct Answer 2
Your Answer
2
Select The Blank
Question
________ participants in monthly meeting(MRM)
Correct Answer GM, operation heads, corporate functional heads
Your Answer
True/False
Department heads & supervisors
Question
Processing cost of a product is mainly decided by conversion
process.
Correct Answer True
Your Answer
True
Select The Blank
Question
Production in last shift & production plan for next shift is
discussed during ________.
Correct Answer Shift beginning & shift end/change meeting
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 reduce
inspection
Your Answer
To eliminate handling , To reduce transporting , To reduce
inspection
True/False
Question
Inadequate maintenance of machine leads to muda of defects
Correct Answer True
Your Answer
True
True/False
Question
Most of the external setups are treated as internal setup.
Correct Answer True
Your Answer
False
Multiple Choice Multiple Answer
Question
Benefits from SMED are :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 Multiple Answer
Question
Typical examples of process benchmark are :Correct Answer Procurement procedures , Budgeting , Recruitment
Your Answer
Procurement procedures , Budgeting , Recruitment
True/False
Question
Low level of delegation is an example of muda in office.
Correct Answer True
Your Answer
False
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Your Answer
Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Multiple Choice Multiple Answer
Question
While preparing scatter diagram following precautions are to be
taken :Correct Answer Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
Your Answer
Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
Multiple Choice Single Answer
Question
Through continuous improvement in the process & procedures,
kobetsu-kaizen is continuously improve utilization of :Correct Answer Worker, equipment & material
Your Answer
Workers & materials
True/False
Question
Every department should make their own rules of
standardization.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
Quality circle should consist adequate experienced members
between :Correct Answer 8 to 10
Your Answer
8 to 10
Multiple Choice Single Answer
Question
Number of kaizen in Group kaizen categories are :Correct Answer Two to three per year
Your Answer
As many as management decides
Select The Blank
Question
Flow chart helps to provide clarity of the ________ without
visiting actual spot.
Correct Answer Process
Your Answer
Process
Multiple Choice Single Answer
Question
Gap in performance = Ideal situation minus :Correct Answer Current situation
Your Answer
Current situation
Select The Blank
Question
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 Implementation
Your Answer Implementation
True/False
Question Benefits of DWN is faster response to customer needs.
Correct Answer True
Your 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 recording
Your 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) analysis
Your Answer Equipment analysis , Setup change analysis , Preparation
items (storage place , method) analysis
Select The Blank
Question 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
Select The Blank
Question ________ 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_8
six sigma implementation , Monitor progress of six sigma projects
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 on rejection / rework
Your Answer PPM level , Initiate corrective actions on rejection/rework ,
Initiate preventive action on rejection / rework
Multiple Choice Single Answer
Question POP is :Correct Answer Process Oriented Management
Your Answer Process Oriented Management
True/False
Question TQM improves the quality by improving processes.
Correct Answer True
Your Answer True
True/False
Question 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 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
progress by presentation to steering committee , Convince committee for
financial help for running the project
Match The Following
Question Correct Answer Your Answer
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 relationship between a
Page 2
TechniquesForOperationsEfficiency_8
pair of variables
The scatter diagram displays The pair of data as a cloud of points The pair of
data as a cloud of points
The scatter is also known as Correlation diagram Correlation diagram
True/False
Question In single card kanban system production greater than quantity
withdrawn is permitted.
Correct Answer False
Your Answer False
Select The Blank
Question ________ is the root cause of the problems.
Correct Answer Variation
Your 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
project. , Receive training
Your 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. Kaoishikawa
Your Answer Prof. Kaoishikawa
Select The Blank
Question ________ helps to generate creative ideas .
Correct Answer Brainstorming
Your Answer Brainstorming
Multiple Choice Single Answer
Page 3
TechniquesForOperationsEfficiency_8
Question For small batch quality production, number of setups :Correct Answer Increases
Your Answer Increases
True/False
Question 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
True/False
Question Kaizen looks at process as a part of quality & quantity as a part of
process
Correct Answer False
Your Answer True
Select The Blank
Question ________ participants in monthly meeting(MRM)
Correct Answer GM, operation heads, corporate functional heads
Your Answer Department heads & supervisors
Multiple Choice Multiple Answer
Question Examples of Muda of defects are :Correct Answer Customer complaints , Poor material yield , Rejection and
rework
Your 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 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
True/False
Question TQM organizations also harness the goodwill and interest of the
Page 4
TechniquesForOperationsEfficiency_8
family members of the employees.
Correct Answer True
Your Answer True
Select The Blank
Question Technique involved in listing of setup task, establishing
technological relationship between tasks, drawing arrow diagram is called as
________.
Correct Answer Network diagram
Your Answer Flow chart
Multiple Choice Multiple Answer
Question Kanban System may be :Correct Answer Single card kanban system , Double card kanban system
Your 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 production
Your Answer Machine utilization
Multiple Choice Single Answer
Question SWOT analysis is an important step in :Correct Answer Deciding what to benchmark
Your Answer Deciding what to benchmark
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
Select The Blank
Question ________ is a must in meeting of quality circles.
Correct Answer Brainstorming
Your 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 & operators
Your Answer Self inspection by suppliers & operators
Select The Blank
Question A histogram is a graphical display of distribution of
measurements & reveals the amounts of ________ within the process.
Correct Answer Variation
Your Answer Variation
Multiple Choice Single Answer
Question Statistical process control is application of statistical technique to
control :Correct Answer Process
Your Answer Process
Multiple Choice Single Answer
Question In India quality circle was first launched by :Correct Answer Hyderabad unit of BHEL
Your Answer Hyderabad unit of BHEL
True/False
Question A control chart is a chart with UCL & LCL placed at 6 Sigma
distance on either side of the process average.
Correct Answer False
Your Answer False
True/False
Question Control limits of control charts should be revised from time to time
as additional data is accumulated.
Correct Answer True
Your Answer True
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_8
Question Kanban signals are required when assembly work, subassembly
work and manufacturing at parts is carried out at different locations.
Correct Answer True
Your Answer True
Multiple Choice Multiple Answer
Question Six sigma organization consists of :Correct Answer Champions , Black Belts , Green Belts
Your Answer Champions , Black Belts , Green Belts
Match The Following
Question Correct Answer Your Answer
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 Blank
Question JIT helps to ________ the waste in the purchasing process.
Correct Answer Eliminates
Your Answer Eliminates
Select The Blank
Question Poka Yoke is ________.
Correct Answer Simple technique
Your Answer Simple technique
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Single Answer
Question 5-S technique is useful to:
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TechniquesForOperationsEfficiency_8
Correct Answer To all places including homes
Your Answer To all places including homes
Multiple Choice Single Answer
Question Empowerment means making best use of the firm's most valuable
resource, namely:Correct Answer Human
Your Answer Human
Select The Blank
Question 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 Continuously
Your 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 , 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
True/False
Question JIT is not possible for each and every item held as inventory
Correct Answer True
Your Answer False
True/False
Question Customer wise outstanding is discussed in daily work
management meeting by operations head.
Correct Answer False
Your Answer False
Select The Blank
Question Poka-Yoke devices under category 'locating pins' to eliminate
cause of ________
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TechniquesForOperationsEfficiency_8
Correct Answer Incorrect positioning
Your Answer Incorrect positioning
Multiple Choice Single Answer
Question Customer's return is an indicators of the MUDA of :Correct Answer Defect
Your Answer Defect
Match The Following
Question Correct Answer Your Answer
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
Multiple Choice Single Answer
Question Accountability means :Correct Answer Responsibility of Business Results
Your Answer Responsibility Execution or Action
Multiple Choice Single Answer
Question Quality problem solving tool is used to :Correct Answer Improve quality
Your Answer Improve quality
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 Competitive benchmarking is usually conducted :Correct Answer Through third party research
Your Answer Through third party research
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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/False
Question 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
Multiple Choice Multiple Answer
Question Histograms are useful to :Correct Answer Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement , Determine
whether or not the process is in the state of control
Your Answer Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement , Determine
whether or not the process is in the state of control
True/False
Question Non-availability of files /document in time is a problem to be
addressed by office TPM.
Correct Answer True
Your Answer True
Select The Blank
Question A control chart to exhibit counted data on number of defect is
called ________.
Correct Answer c-chart
Your Answer c-chart
True/False
Question Fishbone analysis is used both in analysis & planning.
Correct Answer True
Your Answer True
Select The Blank
Question Inspection activity for semi finished & finished component should
be ________ to reduce muda of transport .
Correct Answer Decentralized
Your Answer Decentralized
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TechniquesForOperationsEfficiency_8
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 confirm
anticipated 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 Blank
Question U shape arrangement of layout provides the operator ________
degree of mobility.
Correct Answer 360
Your Answer 360
True/False
Question Chance causes can not be identified.
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
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
Multiple Choice Multiple Answer
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
Multiple Choice Multiple Answer
Question Causes of Muda of transport are :Correct Answer Faulty layout , Over production
Your Answer Faulty layout , Over production
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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 diagram
Your 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 malfunction
Your Answer To develop abilities to respond quickly to abnormalities , To
develop abilities to discover analyze malfunction , To have multiskilled
employees in all departments
Multiple Choice Multiple Answer
Question Material Supply on DSL basis helps :Correct Answer To eliminate handling , To reduce transporting , To reduce
inspection
Your Answer To eliminate handling , To reduce transporting , To reduce
inspection
Select The Blank
Question Poka Yoke designed to help operators to know immediately
________ of the defeat called detection type Poka-Yoke.
Correct Answer On occurrence
Your 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
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TechniquesForOperationsEfficiency_8
True/False
Question Daily work management can also be extended to non
manufacturing areas like procurement, QA, HRD etc.
Correct Answer True
Your Answer True
Match The Following
Question Correct Answer Your Answer
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 Blank
Question ________ PDCA cycle is the systematic approach towards
meeting the target.
Correct Answer Kaoishikawa
Your Answer Deming
Select The Blank
Question ________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 Frequency
Your Answer Frequency
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 Worker, equipment & material
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TechniquesForOperationsEfficiency_8
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
Multiple Choice Multiple Answer
Question Muda of waiting is due to :Correct Answer Interrupted flow of work , Delay in movement of raw
material from stores
Your Answer Interrupted flow of work , Delay in movement of raw
material from stores
Select The Blank
Question CFT ( cross functional team ) consisting of ________
Correct Answer Operators, supervisors from different departments
Your Answer Operators, supervisors from different departments
Select The Blank
Question In PDCA cycle for benchmarking 'Identification of performance
gap' is done in ________.
Correct Answer Checking
Your Answer Checking
Multiple Choice Multiple Answer
Question Management skill includes :Correct Answer Leadership , Motivation , Performance appraisals
Your Answer Leadership , Motivation
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
True/False
Question Flow charts are drawn to identify deviations by observing actual
& comparing with running process.
Correct Answer False
Your Answer False
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
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TechniquesForOperationsEfficiency_8
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
Multiple Choice Single Answer
Question Toyota, Honda & Nissan are world class benchmarking
candidates in :Correct Answer Employee selection
Your Answer Employee selection
Multiple Choice Single Answer
Question The leader of the circle should be selected by :Correct Answer Circle members
Your 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 planning
Your Answer Poor planning
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 throughout the year sustain the discipline
Your 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
positive , Double peaked
Your Answer Symmetrical (or bell shaped) , Asymmetrical skewed positive ,
Double peaked
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TechniquesForOperationsEfficiency_8
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
True/False
Question Inspection is poor method of assuring 100% quality.
Correct Answer True
Your Answer True
Select The Blank
Question ________ used to detect drop in air pressure.
Correct Answer Buzzers / alarms
Your 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)
Your 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
inspection
Your Answer Reduce inventory , Lower per unit cost , Reduce incoming
inspection
Multiple Choice Single Answer
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
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TechniquesForOperationsEfficiency_8
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 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/False
Question To achieve quality, it has to be designed into the product.
Correct Answer True
Your Answer True
Match The Following
Question Correct Answer Your Answer
Review your efforts & success achieved Check Check
Act about the causes found out Do Act
Collect the initial data for the problem Plan Plan
Actions further after reviewing the progress Act Repeat
Select The Blank
Question 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 Process
Your 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
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TechniquesForOperationsEfficiency_8
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 the
percentage of each category into pie chart
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 Single Answer
Question Benefits of Seiton means
Correct 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 , Every
family does cleaning of pavement of their residence , Separate department for
cleaning supervision
True/False
Question Six sigma process requires 100 % inspection
Correct Answer False
Your Answer False
True/False
Question 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 What are the steps in deciding the benchmarking partner?
Correct Answer Decide level of benchmarking , List down a few prospective
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TechniquesForOperationsEfficiency_8
candidates of partnership , Collect information of short listed partners
Your Answer Decide level of benchmarking , List down a few prospective
candidates of partnership , Collect information of short listed partners
Select The Blank
Question ________feel that quality circle cause erosion of their control
over workmen.
Correct Answer Supervisors
Your Answer Supervisors
True/False
Question Errors are inevitable but can be eliminated.
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 , Better visual management
Select The Blank
Question Ford, general electric & Motorola are word class benchmarking
for ________
Correct Answer Training
Your Answer Training
Select The Blank
Question 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/False
Question Process capability index Cp is a measure of capability of the
process to meet the specification limits.
Correct Answer True
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TechniquesForOperationsEfficiency_8
Your 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 Blank
Question Flow chart helps to dissect a process for better understanding &
________ of process.
Correct Answer Analysis
Your Answer Analysis
Select The Blank
Question ________ 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 moving
bolster , 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
Question Correct Answer Your Answer
Monthly meeting Discussion for capital expenditure & customer outstanding.
Discussion for capital expenditure & customer outstanding.
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
Daily work management meeting Discussion on gap analysis for production
maintenance, dispatch Discussion on gap analysis for production
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TechniquesForOperationsEfficiency_8
maintenance, dispatch
Weekly meeting Discussion for customer complaints Discussion for customer
complaints
True/False
Question TQM improves manufacturing as well as clerical activities.
Correct Answer True
Your Answer True
Select The Blank
Question To find out root cause ________used
Correct Answer Why-why Technique
Your 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 manufacturing
company is:Correct Answer 20-30%
Your Answer 0.6
True/False
Question U-Line layout is better than straight lime layout.
Correct Answer True
Your Answer True
Select The Blank
Question In traditional purchasing ________ inventory is required.
Correct Answer Plenty of
Your Answer Plenty of
Select The Blank
Question The process capability of the process =________(where sigma is
the standard deviation of the population / lot.
Correct Answer 6 sigma
Your Answer 2 sigma
True/False
Question A radar chart is combination of a circle & line graph
Correct Answer True
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TechniquesForOperationsEfficiency_8
Your Answer True
Page 22
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Select The Blank
Question
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/False
Question
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 value
falls , Count the tally marks i.e. frequency in each class &
construct a histogram 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
sheet determining the cell or class into which each value
falls , Count the tally marks i.e. frequency in each class &
construct a histogram by plotting a bar graph for each
class , Analyze & conclude whether process is is meeting
the 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
Your 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 job
Your 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's
own division & branches comes under :Correct Answer Internal benchmarking
Your Answer
Functional benchmarking
True/False
Question
"Display of safety posture & slogans" is an essential step
of TPM.
Correct Answer False
Your Answer
True
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer Lack of experience
Your Answer
Lack of experience
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 throughout the year
sustain the discipline
Your Answer
Maintaining the 4-S consistently , Develop discipline
attitude in everyone , Any day throughout the year
sustain the discipline
True/False
Question
Change of job titles can help to raise employee's morale.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
Few steps to construct a flow chart are :Correct Answer 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' ,
Decide on the objective of flowchart & define boundaries
of the process
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 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
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/False
Question
Exercise to identify MURA, MUDA & MURI is not helpful
to identify problems.
Correct Answer False
Your Answer
False
Select The Blank
Question
Kaizen projects are managed by ________
Correct Answer Cross functional team
Your Answer
Management
Multiple Choice Single Answer
Question
Number of Kaizen projects suggested and implemented
is checking point for :Correct Answer Continual Improvement
Your Answer
Continual Improvement
Match The Following
Question
Correct Answer
Your Answer
Flow chart are drawn to Identifying non-value
effect improvement in added activities
the process by
Providing a documented
description of the tasks
involved
Flow chart are drawn to charting the tasks
document a process by performed & the
sequence in which
tasks are performed
Steps in a process by
pictorial representation
Flow chart are prepared Indicating
to enhance the
interrelationship within
employees
process
understanding of the
process by
charting the tasks
performed & the
sequence in which tasks
are performed
Flow charts are drawn Observing actual &
to identify deviations by comparing with
documented process
Indicating
interrelationship within
process
Multiple Choice Single Answer
Question
Quality is the responsibility of :Correct Answer Everyone in the organization
Your Answer
Everyone in the organization
Select The Blank
Question
________is serve as a stepping stone to TQM
Correct Answer ISO-9000 quality standard
Your Answer
ISO-9000 quality standard
True/False
Question
Generally time interval should be proportional to the
average frequency of out of control conditions.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
Advantages of JIT :Correct Answer Reduce inventory , Lower per unit cost , Reduce
incoming inspection
Your 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 activities
involved in the process , Identifying the root causes
Your Answer
Defining the problem , Trying to know the activities
involved 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
Question
Correct Answer
Your Answer
Productivity
performance
measurement
Turnover employee
Turnover employee
Financial performance
measurement
Sales of the months
Sales of the months
Customer satisfaction
measurement
Customer complaints
per period
Customer complaints
per period
Staff attitude
measurement
Employee satisfaction
index
Employee satisfaction
index
True/False
Question
Shitsuke is most difficult out of all 5-S because it means
to sustain all the first 4-S throughout the year.
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
Your Answer
Effectively & clearly
True/False
Question
Key element of JIT is continuous improvement.
Correct Answer True
Your Answer
False
Select The Blank
Question
Histogram is a diagrammatic presentation of the
________ distribution of characteristics such as strength,
diameter, etc.
Correct Answer Frequency
Your Answer
Frequency
Multiple Choice Single Answer
Question
Control chart indicates :Correct Answer Trend of process
Your Answer
Control on process
Select The Blank
Question
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 Blank
Question
JIT helps to ________ the waste in the purchasing
process.
Correct Answer Eliminates
Your Answer
Eliminates
Select The Blank
Question
To assess effectiveness of training ________ is
essential.
Correct Answer Evaluation
Your Answer
Evaluation
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
Daily PDCA meeting , Weekly PDCA meeting , Monthly
PDCA meeting
Select The Blank
Question
A 'Radar chart' is a combination of circle & ________
Graph.
Correct Answer Line
Your Answer
Line
True/False
Question
Kaizen looks at process as a part of quality & quantity as
a part of process
Correct Answer False
Your Answer
True
True/False
Question
TQM improves manufacturing as well as clerical
activities.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
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 Blank
Question
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 Management
Your 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
True/False
Guide pins , Limit switches , Checklist
Question
Gap analysis for production & dispatches is discussed in
monthly meeting.
Correct Answer False
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 employees
to improve their qualification
Your Answer
Job rotation exercise , Preference to be given to
employees during job vacancies , Encourage employees
to improve their qualification
1. SMED
2. VMI ( Vendor Management
Inventory) system
3. Flow / string diagram
4. Value analysis / value
engineering
1. To eliminate MUDA of
transport
2. To eliminate MUDA of
processing
3. To eliminate MUDA of
defect
4. 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
2. Control chart can be
used to determine
3. Control chart is a chart
with UCL & LCL placed
4. Control chart can be
used
1. How much variability in the process is due
to random causes & how much is due to
assignable causes
2. As process monitoring tool
3. For quality monitoring
4. At 6 Sigma distance on either side of the
process average
5. At 3 Sigma distance on either side of the
process 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
2. Histogram is a diagrammatic
presentation of
1. Tapering away on the both
sides from average value
2. The frequency distribution of
defects in the process
3. The shape of histogram can
3. The frequency distribution of
a characteristics
4. Provide a clue about the
quality of the lot
5. Reveals the amount of
variation within the process
4. Ideally the histogram will have a bell
shape
6. Provides the clue about the
process information
1. Shift begining & shift end /
change meeting
2. Daily work management
meeting
3. Weekly meeting
4. Monthly meeting
1. Discussion for customer complaints
2. Discussion on performance of sister
company.
3. Discussion for capital expenditure &
customer outstanding.
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 in
marketing
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 assembly
automation
4. British airways
5. Microsoft
6. American
Express
1. Early management
2. Quality management
1. To achieve zero defect by ensuring
defect free equipment
2. To achieve zero breakdown.
3. Safety, hygiene and
environment
3. To improve product features
4. Planned maintenance
4. To achieve zero accident &zero
contamination
5. To ensure easy to manufacture product
development
6. To manage breakdown
15.
The area enclosed under normal distribution curve between mean +3standard
deviation is :-
a)
0.9973
b)
0.9545
c)
0.6826
d)
1
37.
If 'Annual saving in procurement expenses is managing point', then checking
points will be :-
a)
Price revision
b)
Credit period
c)
Transport expenses
d)
Productivity improvement
After finding out the solution & working on it, the
equally important job is
:-
Prepare for the presentation of your work
Explain the progress by presentation to steering
committee
Convince committee for your next project
Convince committee for financial help for running
the project
TechniquesForOperationsEfficiency_9
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Advantages of JIT :Correct Answer
Reduce incoming inspection , Reduce inventory , Lower
per unit cost
Your 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
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 , 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 factors
Your Answer
It helps to separate data into groups so that you can
draw connect & meaningful inference , It helps to diagnose & localize problem
, Finding out different reasons
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following
production inputs :Correct Answer
Men , Machine , Material
Page 1
Your Answer
TechniquesForOperationsEfficiency_9
Men , Machine , Management
Multiple Choice Single Answer
Question
The success indicators in quality, cost, delivery &
product development are :Correct Answer
Managing points
Your Answer
Accountability
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 external setups in to internal setups
Multiple Choice Multiple Answer
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/False
Question
standardization.
Correct Answer
Your Answer
Every department should make their own rules of
False
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 specific limits
Your Answer
It shows cause which affects the process , An idea of
Page 2
TechniquesForOperationsEfficiency_9
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
Question Correct Answer
Your Answer
Productivity performance measurement Turnover employee Sales of the
months
Financial performance measurement
per department
Sales of the months Cash saving
Customer satisfaction measurement
Customer complaints per period
Customer complaints per period
Staff attitude measurement
satisfaction index
Employee satisfaction index
Employee
Multiple Choice Single Answer
Question
TPM helps to reduce down time due to:Correct Answer
Breakdown of machine
Your Answer
Breakdown of machine
Multiple Choice Single Answer
Question
Kaizen emphasizes :Correct Answer
Implementation of ideas
Your Answer
Collection of ideas
Select The Blank
Question
Seiketsu.
Correct Answer
Your Answer
True/False
Question
defects
Correct Answer
Your Answer
Create as many ________ system as possible for better
Visual control
Visual control
Inadequate maintenance of machine leads to muda of
True
False
Select The Blank
Page 3
TechniquesForOperationsEfficiency_9
Question
The shape of histogram can provide a clue about the
________ of the lot.
Correct Answer
Quality
Your Answer
Distribution
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
Your Answer
Symmetrical
True/False
Question
Correct Answer
Your Answer
Inspection is poor method of assuring 100% quality.
True
False
True/False
Question
Correct Answer
Your Answer
A radar chart is combination of a circle & line graph
True
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/False
Question
Customer wise outstanding is discussed in daily work
management meeting by operations head.
Correct Answer
False
Your Answer
True
True/False
Question
Number of operation can change according to
production requirement in U-Line arrangement.
Correct Answer
False
Your Answer
True
Page 4
TechniquesForOperationsEfficiency_9
True/False
Question
setup process.
Correct Answer
Your Answer
Select The Blank
Question
Correct Answer
Your Answer
Automation can correct the basic faults of a improper
False
True
Cp for six sigma process is ________
2
1.66
Select The Blank
Question
Range ( R ) is obtained as the difference between the
highest and ________ measurement of a sample.
Correct Answer
Lowest
Your Answer
Second highest
Select The Blank
Question
purchasing.
Correct Answer
Your Answer
True/False
Question
Correct Answer
Your Answer
________is an important step toward successful JIT
JIT Contract
JIT Contract
U-Line layout is better than straight lime layout.
True
True
Multiple Choice Single Answer
Question
TQM applicable to :Correct Answer
Marketing, design & manufacturing
Your Answer
Quality Control department
Select The Blank
Question
of quality.
Correct Answer
Your Answer
Bar graph is display of data that facilitates ________
Comparison
Performance
Multiple Choice Single Answer
Question
Production kanban is presented by :Correct Answer
P-kanban
Page 5
Your Answer
TechniquesForOperationsEfficiency_9
R-kanban
Multiple Choice Single Answer
Question
Check sheet are also used as :Correct Answer
Data gathering & interpretation tool
Your Answer
Cause finding & effect finding tool
Select The Blank
Question
Japanese believe that when they are ________ they
are cleaning there minds too.
Correct Answer
Cleaning
Your Answer
Repairing machines
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
Your Answer
Counting device
Select The Blank
Question
Shitsuke means ________ all the previous 4-S
throughout the month/year.
Correct Answer
Sustaining
Your Answer
Implementing
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
PDCA meeting
True/False
Question
reduced.
Correct Answer
Your Answer
By TPM, consumption of electrical energy can be
True
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
Page 6
TechniquesForOperationsEfficiency_9
Your Answer
To develop easy to follow standards , Evolve standard
operating procedure , Reduction of wastage
True/False
Question
Correct Answer
Your Answer
Flow chart helps to stop an old process.
False
True
Multiple Choice Multiple Answer
Question
Training related to Quality includes:Correct Answer
Quality measures , Quality failure
Your Answer
Quality measures , Quality failure , Goal of business
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
Your Answer
(x - USL)/6 sigma
Select The Blank
Question
A histogram is a graphical display of distribution of
measurements & reveals the amounts of ________ within the process.
Correct Answer
Variation
Your Answer
Percentage defects
Match The Following
Question Correct Answer
Your Answer
Value analysis / value engineering
To eliminate MUDA of over production
SMED
defect
To eliminate MUDA of processing
To eliminate MUDA of over production
VMI ( Vendor Management Inventory) system
stock
To eliminate MUDA of stock
Flow / string diagram
To eliminate MUDA of
To eliminate MUDA of
To eliminate MUDA of transport
Page 7
To
TechniquesForOperationsEfficiency_9
eliminate MUDA of processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength
or weakness of the activity.
Correct Answer
Relative
Your Answer
Comparative
-----------------------------------------------------------LIST OF ATTEMPTED QUESTIONS AND ANSWERS
True/False
Question
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 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
Your Answer
Checking
Select The Blank
Question
Correct Answer
Your Answer
5 S audit result is discussed in ________ meeting.
Monthly
Shift beginning
Page 8
TechniquesForOperationsEfficiency_9
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
Your Answer
Strong negative
Select The Blank
Question
Correct Answer
Your Answer
Kaizen projects are managed by ________
Cross functional team
Management
Multiple Choice Single Answer
Question
Poka-yoke for employee not performing work as per
established method is :Correct Answer
Implement work standard
Your Answer
Implement work standard
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 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 , Collect information of short listed
partners
Your Answer
Decide level of benchmarking , Collect information of
short listed partners
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer
Lack of experience
Your Answer
Absent mindedness
True/False
Question
Correct Answer
Your Answer
Control chart is also called as run-chart.
True
True
Page 9
TechniquesForOperationsEfficiency_9
Match The Following
Question Correct Answer
Your Answer
Reduce clamping & declamping time
U-shaped washer
Use U-shaped washer
Use
Reduce time of external setup Improve work aids positioning method
Improve work aids positioning method
Convert internal setup into external setup Preparation of tools / dies as off
line activity
Preparation of tools / dies as off line activity
Eliminate adjustment
Pre setting of tool
Pre setting of tool
Multiple Choice Single Answer
Question
Muda of defect is very serious in case of:Correct Answer
High speed automatic machines
Your 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 overproduction
Your Answer
Muda of waiting
Multiple Choice Single Answer
Question
In India quality circle was first launched by :Correct Answer
Hyderabad unit of BHEL
Your 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 ,
Page 10
TechniquesForOperationsEfficiency_9
Environmental Management
Your 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/False
Question
Increase in defect rate is an example of 'Deviation from
an established norms'
Correct Answer
True
Your Answer
True
Select The Blank
Question
prevention.
Correct Answer
Your Answer
________ are implemented for defect detection &
Poka-Yokes
Poka-Yokes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer
Improve quality
Your Answer
Improve quality
Multiple Choice Single Answer
Question
Implication of Quality problem is:Correct Answer
Gap in performance
Your Answer
Lower efficiency
True/False
Question
Presentation of graphs in pictorial form of data
collection are for easy understanding.
Correct Answer
True
Your Answer
True
Select The Blank
Question
________ waste is probably the biggest waste in most
of the organizations.
Correct Answer
Time
Your Answer
Labor
Page 11
TechniquesForOperationsEfficiency_9
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
True/False
Question
Correct Answer
Your Answer
TQM improves the quality by improving processes.
True
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 machines
Your 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
3.4
Your Answer
6210
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 Single Answer
Question
To maintain smoothness in production :Correct Answer
Elimination of buffer stock is recommended
Your Answer
Maintenance of buffer stock is recommended.
Select The Blank
Question
process.
Correct Answer
________ should be used to exercise control on the
Control chart
Page 12
Your Answer
TechniquesForOperationsEfficiency_9
Latest checking instruments
Match The Following
Question Correct Answer
Your Answer
Ideally the histogram will have a bell shape
Tapering away on the
both sides from average value Tapering 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 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/False
Question
In single card kanban system production greater than
quantity withdrawn is permitted.
Correct Answer
False
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
Correct Answer
Your Answer
Cpk for six sigma process is ________
1.5
1.5
True/False
Question
Seiso prevents the potential problems by discovering
abnormalities while cleaning your own area.
Correct Answer
True
Your Answer
True
Page 13
TechniquesForOperationsEfficiency_9
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/False
Question
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
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 specification
Your 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 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 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
Page 14
TechniquesForOperationsEfficiency_9
segments & enter the percentage of each category into 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 Blank
Question
Poka Yoke designed to help operators to know
immediately ________ of the defeat called detection type Poka-Yoke.
Correct Answer
On occurrence
Your Answer
Before Occurrence
Select The Blank
Question
Flow chart helps to dissect a process for better
understanding & ________ of process.
Correct Answer
Analysis
Your 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
Question
Graphs convey a situation more ________ than
summary of data or figures.
Correct Answer
Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Number of Kaizen projects suggested and implemented
is checking point for :Correct Answer
Continual Improvement
Your Answer
Continual Improvement
Page 15
TechniquesForOperationsEfficiency_9
-------------------------------------------------------------------LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following
production inputs :Correct Answer
Material , Men , Machine
Your Answer
Material , Men , Machine
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer
Measure the current pattern & extent of variation ,
Assess current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Your Answer
Measure the current pattern & extent of variation ,
Assess current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Multiple Choice Single Answer
Question
In problem solving the best alternative is that :Correct Answer
Which best meets the criteria
Your Answer
Which best meets the criteria
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer
DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
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
Your Answer
Internal benchmarking
Select The Blank
Question
JIT advocates the philosophy at elimination of waste
from system which occurs due to ________.
Correct Answer
Over Production
Your Answer
Over Production
Page 16
TechniquesForOperationsEfficiency_9
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.
Correct Answer
Curvilinear
Your Answer
Curvilinear
True/False
Question
Kanban signals are required when assembly work,
subassembly work and manufacturing at parts is carried out at different
locations.
Correct Answer
True
Your Answer
True
Multiple Choice Multiple Answer
Question
Customers complaints may be segregated by :Correct Answer
Nature of compliant i.e. defective product , Delayed
delivery , Short/excess quantity
Your Answer
Nature of compliant i.e. defective product , Delayed
delivery , Short/excess quantity
True/False
Question
In case of more than one quality characteristics,
separate chart is made for each quality characteristics.
Correct Answer
True
Your Answer
True
True/False
Question
pillar of TPM.
Correct Answer
Your Answer
Safety, hygiene and environment control is one of the
True
True
Multiple Choice Single Answer
Question
5-S technique is useful to:
Correct Answer
To all places including homes
Your Answer
To all places including homes
Match The Following
Question Correct Answer
Reduce time of external setup
Your Answer
Improve work aids positioning method
Page 17
TechniquesForOperationsEfficiency_9
Improve work aids positioning method
Convert internal setup into external setup Preparation of tools / dies as off
line activity
Preparation of tools / dies as off line activity
Eliminate adjustment
Pre setting of tool
Reduce clamping & declamping time
U-shaped washer
Pre setting of tool
Use U-shaped washer
Use
Multiple Choice Single Answer
Question
The facilitator should be normally :Correct Answer
Senior officer /Shop incharge
Your Answer
Senior officer /Shop incharge
Match The Following
Question Correct Answer
Your Answer
Parato diagram always indicates
Magnitude of defects Philosophy of
20% of the activity causes 80% of the effect
Parato analysis underlines & operates on Philosophy of "vital few:trivial
many"
Philosophy of "vital few:trivial many"
Parato analysis is technique of identifying vital causes by
Arranging
data according to the descending order of their frequency of occurrence
Arranging data according to the descending order of their frequency of
occurrence
Parato diagram is a Bar graph with height or value drawn by Arranging
data in descending order
Magnitude of defects
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer
Improve quality
Your Answer
Make work easy
True/False
Question
Correct Answer
Pie chart is also called as angular diagram.
True
Page 18
Your Answer
TechniquesForOperationsEfficiency_9
True
Select The Blank
Question
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 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
Performance , Features , Cost
Your Answer
Performance , Features , Cost
Multiple Choice Multiple Answer
Question
Steps in construction of scatter diagram :Correct Answer
Collect paired data (X,Y) from two variables who's
relationship is to be studied , Find out max & min values for both X & Y and
these values to scale X & Y axis & plot the paired data , Examine the shape of
the cloud of points & discover type & strength of relationship
Your Answer
Collect paired data (X,Y) from two variables who's
relationship is to be studied , Find out max & min values for both X & Y and
these values to scale X & Y axis & plot the paired data , Examine the shape of
the cloud of points & discover type & strength of relationship
Multiple Choice Single Answer
Question
Implication of Quality problem is: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
Page 19
TechniquesForOperationsEfficiency_9
Select The Blank
Question
Correct Answer
Your Answer
Kaizen is ________ supported process.
Management
Management
True/False
Question
The flow charts are prepared to enhance the employees
understanding of the process by indicating interrelationship within the
process.
Correct Answer
True
Your Answer
False
True/False
Question
monthly meeting.
Correct Answer
Your Answer
Gap analysis for production & dispatches is discussed in
False
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
Your Answer
Strong negative
Select The Blank
Question
Correct Answer
Your Answer
________ is most difficult 'S' to implement & achieve.
Shitsuke
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
Question
Graphs convey a situation more ________ than
summary of data or figures.
Correct Answer
Effectively & clearly
Your Answer
Effectively & clearly
Page 20
TechniquesForOperationsEfficiency_9
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer
Lack of experience
Your 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
for full range , Scale selected should be right to avoid wrong conclusions ,
Data should be free from bias or undue importance
Your Answer
Data should be properly stratified & should be collected
for full range , Scale selected should be right to avoid wrong conclusions ,
Data should be free from bias or undue importance
True/False
Question
Globalization of trade and industrial operations have
forced Indian companies to become more & more competitive and customer
driven.
Correct Answer
True
Your Answer
True
Multiple Choice Multiple Answer
Question
If 'Annual saving in procurement expenses is managing
point', then checking points will be :Correct Answer
Price revision , Credit period , Transport expenses
Your 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/False
Question
Flow chart is pictorial representation of the steps in
production control.
Correct Answer
False
Your Answer
False
Multiple Choice Single Answer
Question
It is essential to convey customer's expectations to :Correct Answer
Top Management
Page 21
Your Answer
TechniquesForOperationsEfficiency_9
Supervisors & workmen
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer
Simplest tool
Your Answer
Simplest tool
Select The Blank
Question
Identification of non-value added operations & their
elimination is the first step to eliminate muda of ________.
Correct Answer
Processing
Your Answer
Processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength
or weakness of the activity.
Correct Answer
Relative
Your Answer
Relative
Multiple Choice Single Answer
Question
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 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 ,
Improved maintainability mean time to repair , Improvement in breakdown
Your Answer
Improved reliability mean time between failures ,
Improved maintainability mean time to repair
Multiple Choice Multiple Answer
Question
Gap analysis & problem identification is done during
converting internal setups into external setups in the areas like :Correct Answer
Equipment , Method , Human
Your Answer
Equipment , Method , Human
Page 22
TechniquesForOperationsEfficiency_9
Multiple Choice Single Answer
Question
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 Answer
Question
Sorting of usable items should be
Correct Answer
Planned storage based on frequency of use
Your 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 time
Your Answer
Reduction in customer quality complaints , Reduction in
inspection time
Page 23
TechniquesForOperationsEfficiency_10
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Advantages of JIT :Correct Answer
Reduce incoming inspection , Reduce inventory , Lower
per unit cost
Your 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
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 , 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 factors
Your Answer
It helps to separate data into groups so that you can
draw connect & meaningful inference , It helps to diagnose & localize problem
, Finding out different reasons
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following
production inputs :Correct Answer
Men , Machine , Material
Your Answer
Men , Machine , Management
Page 1
TechniquesForOperationsEfficiency_10
Multiple Choice Single Answer
Question
The success indicators in quality, cost, delivery &
product development are :Correct Answer
Managing points
Your Answer
Accountability
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 external setups in to internal setups
Multiple Choice Multiple Answer
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/False
Question
standardization.
Correct Answer
Your Answer
Every department should make their own rules of
False
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 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
Page 2
TechniquesForOperationsEfficiency_10
process or not i.e. around correct average & within specific limits
Match The Following
Question Correct Answer
Your Answer
Productivity performance measurement Turnover employee Sales of the
months
Financial performance measurement
per department
Sales of the months Cash saving
Customer satisfaction measurement
Customer complaints per period
Customer complaints per period
Staff attitude measurement
satisfaction index
Employee satisfaction index
Employee
Multiple Choice Single Answer
Question
TPM helps to reduce down time due to:Correct Answer
Breakdown of machine
Your Answer
Breakdown of machine
Multiple Choice Single Answer
Question
Kaizen emphasizes :Correct Answer
Implementation of ideas
Your Answer
Collection of ideas
Select The Blank
Question
Seiketsu.
Correct Answer
Your Answer
True/False
Question
defects
Correct Answer
Your Answer
Select The Blank
Question
Create as many ________ system as possible for better
Visual control
Visual control
Inadequate maintenance of machine leads to muda of
True
False
The shape of histogram can provide a clue about the
Page 3
TechniquesForOperationsEfficiency_10
________ of the lot.
Correct Answer
Quality
Your Answer
Distribution
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
Your Answer
Symmetrical
True/False
Question
Correct Answer
Your Answer
Inspection is poor method of assuring 100% quality.
True
False
True/False
Question
Correct Answer
Your Answer
A radar chart is combination of a circle & line graph
True
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/False
Question
Customer wise outstanding is discussed in daily work
management meeting by operations head.
Correct Answer
False
Your Answer
True
True/False
Question
Number of operation can change according to
production requirement in U-Line arrangement.
Correct Answer
False
Your Answer
True
True/False
Page 4
Question
setup process.
Correct Answer
Your Answer
Select The Blank
Question
Correct Answer
Your Answer
TechniquesForOperationsEfficiency_10
Automation can correct the basic faults of a improper
False
True
Cp for six sigma process is ________
2
1.66
Select The Blank
Question
Range ( R ) is obtained as the difference between the
highest and ________ measurement of a sample.
Correct Answer
Lowest
Your Answer
Second highest
Select The Blank
Question
purchasing.
Correct Answer
Your Answer
True/False
Question
Correct Answer
Your Answer
________is an important step toward successful JIT
JIT Contract
JIT Contract
U-Line layout is better than straight lime layout.
True
True
Multiple Choice Single Answer
Question
TQM applicable to :Correct Answer
Marketing, design & manufacturing
Your Answer
Quality Control department
Select The Blank
Question
of quality.
Correct Answer
Your Answer
Bar graph is display of data that facilitates ________
Comparison
Performance
Multiple Choice Single Answer
Question
Production kanban is presented by :Correct Answer
P-kanban
Your Answer
R-kanban
Page 5
TechniquesForOperationsEfficiency_10
Multiple Choice Single Answer
Question
Check sheet are also used as :Correct Answer
Data gathering & interpretation tool
Your Answer
Cause finding & effect finding tool
Select The Blank
Question
Japanese believe that when they are ________ they
are cleaning there minds too.
Correct Answer
Cleaning
Your Answer
Repairing machines
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
Your Answer
Counting device
Select The Blank
Question
Shitsuke means ________ all the previous 4-S
throughout the month/year.
Correct Answer
Sustaining
Your Answer
Implementing
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
PDCA meeting
True/False
Question
reduced.
Correct Answer
Your Answer
By TPM, consumption of electrical energy can be
True
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
Page 6
TechniquesForOperationsEfficiency_10
operating procedure , Reduction of wastage
True/False
Question
Correct Answer
Your Answer
Flow chart helps to stop an old process.
False
True
Multiple Choice Multiple Answer
Question
Training related to Quality includes:Correct Answer
Quality measures , Quality failure
Your Answer
Quality measures , Quality failure , Goal of business
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
Your Answer
(x - USL)/6 sigma
Select The Blank
Question
A histogram is a graphical display of distribution of
measurements & reveals the amounts of ________ within the process.
Correct Answer
Variation
Your Answer
Percentage defects
Match The Following
Question Correct Answer
Your Answer
Value analysis / value engineering
To eliminate MUDA of over production
SMED
defect
To eliminate MUDA of processing
To eliminate MUDA of over production
VMI ( Vendor Management Inventory) system
stock
To eliminate MUDA of stock
To eliminate MUDA of
To eliminate MUDA of
Flow / string diagram
To eliminate MUDA of transport
eliminate MUDA of processing
Page 7
To
TechniquesForOperationsEfficiency_10
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength
or weakness of the activity.
Correct Answer
Relative
Your Answer
Comparative
-----------------------------------------------------------LIST OF ATTEMPTED QUESTIONS AND ANSWERS
True/False
Question
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 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
Your Answer
Checking
Select The Blank
Question
Correct Answer
Your Answer
5 S audit result is discussed in ________ meeting.
Monthly
Shift beginning
Page 8
TechniquesForOperationsEfficiency_10
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
Your Answer
Strong negative
Select The Blank
Question
Correct Answer
Your Answer
Kaizen projects are managed by ________
Cross functional team
Management
Multiple Choice Single Answer
Question
Poka-yoke for employee not performing work as per
established method is :Correct Answer
Implement work standard
Your Answer
Implement work standard
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 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 , Collect information of short listed
partners
Your Answer
Decide level of benchmarking , Collect information of
short listed partners
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer
Lack of experience
Your Answer
Absent mindedness
True/False
Question
Correct Answer
Your Answer
Control chart is also called as run-chart.
True
True
Match The Following
Page 9
TechniquesForOperationsEfficiency_10
Question Correct Answer
Your Answer
Reduce clamping & declamping time
U-shaped washer
Use U-shaped washer
Use
Reduce time of external setup Improve work aids positioning method
Improve work aids positioning method
Convert internal setup into external setup Preparation of tools / dies as off
line activity
Preparation of tools / dies as off line activity
Eliminate adjustment
Pre setting of tool
Pre setting of tool
Multiple Choice Single Answer
Question
Muda of defect is very serious in case of:Correct Answer
High speed automatic machines
Your 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 overproduction
Your Answer
Muda of waiting
Multiple Choice Single Answer
Question
In India quality circle was first launched by :Correct Answer
Hyderabad unit of BHEL
Your 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
Page 10
TechniquesForOperationsEfficiency_10
Your 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/False
Question
Increase in defect rate is an example of 'Deviation from
an established norms'
Correct Answer
True
Your Answer
True
Select The Blank
Question
prevention.
Correct Answer
Your Answer
________ are implemented for defect detection &
Poka-Yokes
Poka-Yokes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer
Improve quality
Your Answer
Improve quality
Multiple Choice Single Answer
Question
Implication of Quality problem is:Correct Answer
Gap in performance
Your Answer
Lower efficiency
True/False
Question
Presentation of graphs in pictorial form of data
collection are for easy understanding.
Correct Answer
True
Your Answer
True
Select The Blank
Question
________ waste is probably the biggest waste in most
of the organizations.
Correct Answer
Time
Your Answer
Labor
Page 11
TechniquesForOperationsEfficiency_10
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
True/False
Question
Correct Answer
Your Answer
TQM improves the quality by improving processes.
True
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 machines
Your 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
3.4
Your Answer
6210
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 Single Answer
Question
To maintain smoothness in production :Correct Answer
Elimination of buffer stock is recommended
Your Answer
Maintenance of buffer stock is recommended.
Select The Blank
Question
process.
Correct Answer
Your Answer
________ should be used to exercise control on the
Control chart
Latest checking instruments
Page 12
TechniquesForOperationsEfficiency_10
Match The Following
Question Correct Answer
Your Answer
Ideally the histogram will have a bell shape
Tapering away on the
both sides from average value Tapering 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 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/False
Question
In single card kanban system production greater than
quantity withdrawn is permitted.
Correct Answer
False
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
Correct Answer
Your Answer
Cpk for six sigma process is ________
1.5
1.5
True/False
Question
Seiso prevents the potential problems by discovering
abnormalities while cleaning your own area.
Correct Answer
True
Your 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/False
Question
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
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 specification
Your 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 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 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 the percentage of each category into pie chart
Page 14
TechniquesForOperationsEfficiency_10
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 Blank
Question
Poka Yoke designed to help operators to know
immediately ________ of the defeat called detection type Poka-Yoke.
Correct Answer
On occurrence
Your Answer
Before Occurrence
Select The Blank
Question
Flow chart helps to dissect a process for better
understanding & ________ of process.
Correct Answer
Analysis
Your 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
Question
Graphs convey a situation more ________ than
summary of data or figures.
Correct Answer
Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Number of Kaizen projects suggested and implemented
is checking point for :Correct Answer
Continual Improvement
Your Answer
Continual Improvement
-------------------------------------------------------------------Page 15
TechniquesForOperationsEfficiency_10
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following
production inputs :Correct Answer
Material , Men , Machine
Your Answer
Material , Men , Machine
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer
Measure the current pattern & extent of variation ,
Assess current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Your Answer
Measure the current pattern & extent of variation ,
Assess current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Multiple Choice Single Answer
Question
In problem solving the best alternative is that :Correct Answer
Which best meets the criteria
Your Answer
Which best meets the criteria
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer
DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
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
Your Answer
Internal benchmarking
Select The Blank
Question
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
Page 16
TechniquesForOperationsEfficiency_10
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.
Correct Answer
Curvilinear
Your Answer
Curvilinear
True/False
Question
Kanban signals are required when assembly work,
subassembly work and manufacturing at parts is carried out at different
locations.
Correct Answer
True
Your Answer
True
Multiple Choice Multiple Answer
Question
Customers complaints may be segregated by :Correct Answer
Nature of compliant i.e. defective product , Delayed
delivery , Short/excess quantity
Your Answer
Nature of compliant i.e. defective product , Delayed
delivery , Short/excess quantity
True/False
Question
In case of more than one quality characteristics,
separate chart is made for each quality characteristics.
Correct Answer
True
Your Answer
True
True/False
Question
pillar of TPM.
Correct Answer
Your Answer
Safety, hygiene and environment control is one of the
True
True
Multiple Choice Single Answer
Question
5-S technique is useful to:
Correct Answer
To all places including homes
Your Answer
To all places including homes
Match The Following
Question Correct Answer
Your Answer
Reduce time of external setup Improve work aids positioning method
Improve work aids positioning method
Page 17
TechniquesForOperationsEfficiency_10
Convert internal setup into external setup Preparation of tools / dies as off
line activity
Preparation of tools / dies as off line activity
Eliminate adjustment
Pre setting of tool
Reduce clamping & declamping time
U-shaped washer
Pre setting of tool
Use U-shaped washer
Use
Multiple Choice Single Answer
Question
The facilitator should be normally :Correct Answer
Senior officer /Shop incharge
Your Answer
Senior officer /Shop incharge
Match The Following
Question Correct Answer
Your Answer
Parato diagram always indicates
Magnitude of defects Philosophy of
20% of the activity causes 80% of the effect
Parato analysis underlines & operates on Philosophy of "vital few:trivial
many"
Philosophy of "vital few:trivial many"
Parato analysis is technique of identifying vital causes by
Arranging
data according to the descending order of their frequency of occurrence
Arranging data according to the descending order of their frequency of
occurrence
Parato diagram is a Bar graph with height or value drawn by Arranging
data in descending order
Magnitude of defects
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer
Improve quality
Your Answer
Make work easy
True/False
Question
Correct Answer
Your Answer
Pie chart is also called as angular diagram.
True
True
Page 18
TechniquesForOperationsEfficiency_10
Select The Blank
Question
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 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
Performance , Features , Cost
Your Answer
Performance , Features , Cost
Multiple Choice Multiple Answer
Question
Steps in construction of scatter diagram :Correct Answer
Collect paired data (X,Y) from two variables who's
relationship is to be studied , Find out max & min values for both X & Y and
these values to scale X & Y axis & plot the paired data , Examine the shape of
the cloud of points & discover type & strength of relationship
Your Answer
Collect paired data (X,Y) from two variables who's
relationship is to be studied , Find out max & min values for both X & Y and
these values to scale X & Y axis & plot the paired data , Examine the shape of
the cloud of points & discover type & strength of relationship
Multiple Choice Single Answer
Question
Implication of Quality problem is: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
Page 19
TechniquesForOperationsEfficiency_10
Select The Blank
Question
Correct Answer
Your Answer
Kaizen is ________ supported process.
Management
Management
True/False
Question
The flow charts are prepared to enhance the employees
understanding of the process by indicating interrelationship within the
process.
Correct Answer
True
Your Answer
False
True/False
Question
monthly meeting.
Correct Answer
Your Answer
Gap analysis for production & dispatches is discussed in
False
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
Your Answer
Strong negative
Select The Blank
Question
Correct Answer
Your Answer
________ is most difficult 'S' to implement & achieve.
Shitsuke
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
Question
Graphs convey a situation more ________ than
summary of data or figures.
Correct Answer
Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Page 20
Question
Correct Answer
Your Answer
TechniquesForOperationsEfficiency_10
Errors by armatures is :Lack of experience
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
for full range , Scale selected should be right to avoid wrong conclusions ,
Data should be free from bias or undue importance
Your Answer
Data should be properly stratified & should be collected
for full range , Scale selected should be right to avoid wrong conclusions ,
Data should be free from bias or undue importance
True/False
Question
Globalization of trade and industrial operations have
forced Indian companies to become more & more competitive and customer
driven.
Correct Answer
True
Your Answer
True
Multiple Choice Multiple Answer
Question
If 'Annual saving in procurement expenses is managing
point', then checking points will be :Correct Answer
Price revision , Credit period , Transport expenses
Your 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/False
Question
Flow chart is pictorial representation of the steps in
production control.
Correct Answer
False
Your 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
TechniquesForOperationsEfficiency_10
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer
Simplest tool
Your Answer
Simplest tool
Select The Blank
Question
Identification of non-value added operations & their
elimination is the first step to eliminate muda of ________.
Correct Answer
Processing
Your Answer
Processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength
or weakness of the activity.
Correct Answer
Relative
Your Answer
Relative
Multiple Choice Single Answer
Question
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 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 ,
Improved maintainability mean time to repair , Improvement in breakdown
Your Answer
Improved reliability mean time between failures ,
Improved maintainability mean time to repair
Multiple Choice Multiple Answer
Question
Gap analysis & problem identification is done during
converting internal setups into external setups in the areas like :Correct Answer
Equipment , Method , Human
Your Answer
Equipment , Method , Human
Page 22
TechniquesForOperationsEfficiency_10
Multiple Choice Single Answer
Question
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 Answer
Question
Sorting of usable items should be
Correct Answer
Planned storage based on frequency of use
Your 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 time
Your Answer
Reduction in customer quality complaints , Reduction in
inspection time
Page 23
Skip Questions.
Sem – 3rd
Techniques for Operations Efficiency
1
Sem – 3rd
Techniques for Operations Efficiency
2
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
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
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
Multiple Choice Single Answer
Question
SMED means :Correct Answer Single minute exchange of dies
Your Answer
Single minute exchange of dies
Match The Following
Question
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
Staff attitude measurement
Employee satisfaction index
Employee satisfaction index
Select The Blank
Question
________ is an effect due to the muda of defect.
Sem – 3rd
Techniques for Operations Efficiency
3
Correct Answer Wear & tear of parts while disassembling
Your Answer
Poor production planning & control
Select The Blank
Question
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
Question
Correct Answer
Your Answer
Parato diagram always indicates
Magnitude of defects
Philosophy of 20% of the activity
causes 80% of the effect
Parato analysis underlines &
operates on
Philosophy of "vital few:trivial many" Philosophy of "vital few:trivial many"
Parato analysis is technique of
identifying vital causes by
Arranging data according to the
Arranging data according to the
descending order of their frequency descending order of their frequency
of occurrence
of occurrence
Parato diagram is a Bar graph with Arranging data in descending order Magnitude of defects
height or value drawn by
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 & divide
it 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 from
each gradiation using 'o' point as centre
Your Answer
Brainstorming to enlist characteristics which require to be evaluated & draw the circle & divide
it 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 from
each gradiation using 'o' point as centre
Select The Blank
Question
5 S audit result is discussed in ________ meeting.
Correct Answer Monthly
Your Answer
Monthly
True/False
Question
Fishbone analysis is used both in analysis & planning.
Sem – 3rd
Techniques for Operations Efficiency
4
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
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
Monitor progress of six sigma projects , Approve six sigma projects , Remove road block in
the 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 batch
Your 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 , Collect
information of short listed partners
Your Answer
Decide level of benchmarking , List down a few prospective candidates of partnership , Collect
information 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
Multiple Choice Single Answer
Question
Competitive benchmarking involves identifying key competitive product, services or processes
& comparing with those of :Correct Answer Main competitor
Sem – 3rd
Techniques for Operations Efficiency
5
Your Answer
Main competitor
Multiple Choice Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Gap in performance
Select The Blank
Question
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/False
Question
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 :Correct Answer Simplest tool
Your Answer
Simplest tool
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
True/False
Question
Flow chart is pictorial representation of the steps in production control.
Correct Answer False
Your Answer
True
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
Sem – 3rd
Sections , Machines , Type of breakdown (e.g mech. Or electrical)
Techniques for Operations Efficiency
6
Select The Blank
Question
A control chart to exhibit counted data on number of defect is called ________.
Correct Answer c-chart
Your Answer
c-chart
Select The Blank
Question
Procedure for implementation of TPM consists of ________ numbers of steps.
Correct Answer 12
Your Answer
8
Select The Blank
Question
Capability index Cp = ________
Correct Answer Specification width/process width
Your Answer
Specification width/process width
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer Vital few = trivial many
Your Answer
Vital few = trivial many
True/False
Question
Kanban signals are required when assembly work, subassembly work and manufacturing at
parts is carried out at different locations.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
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
Select The Blank
Question
Benchmarking allows exchange of ________ between the benchmarking partners.
Correct Answer Information
Your Answer
Information
Multiple Choice Multiple Answer
Question
TQM can never flourish if the staff are:Sem – 3rd
Techniques for Operations Efficiency
7
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.
Correct Answer False
Your Answer
False
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 , Preparation items (storage place , method)
analysis
True/False
Question
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 :Correct Answer Improve quality
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 Blank
Question
JIT advocates the philosophy at elimination of waste from system which occurs due to
________.
Correct Answer Over Production
Sem – 3rd
Techniques for Operations Efficiency
8
Your Answer
Over Production
True/False
Question
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
Your Answer
Defect in materials , Frequent adjustment of machines , Poorly trained operators
True/False
Question
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 & within
specific limits
Your Answer
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
Multiple Choice Single Answer
Question
Productivity improves by :Correct Answer Voluntary participants of everyone
Your Answer
Voluntary participants of everyone
nd
2 Copy
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question Training related to Quality includes:Correct Answer Quality measures , Quality failure
Your 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 little
Your Answer Very high
Sem – 3rd
Techniques for Operations Efficiency
9
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 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.
Correct Answer False
Your Answer False
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 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
Multiple Choice Single Answer
Question 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 Answer
Question Organizing the place is not enough , what is required is :
Correct Answer Planning storage based on Frequency of use
Your Answer Planning storage based on Frequency of use
Select The Blank
Question JIT helps to ________ the waste in the purchasing process.
Correct Answer Eliminates
Your Answer Eliminates
Multiple Choice Single Answer
Question In cellular manufacturing system, the cells are designed so that the material flow within the cell
and between the cells are :Correct Answer Minimized
Your 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
Multiple Choice Multiple Answer
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
Sem – 3rd
Techniques for Operations Efficiency
10
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 Monthly PDCA meeting , Daily PDCA meeting , Weekly PDCA meeting
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 ,
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 while cleaning you may find a
fault , Saving of further failure due to dust
Your Answer You know your self how to avoid dust , When you touch while cleaning you may find a fault ,
Saving of further failure due to dust , Utilization of spare time
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 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.
Correct Answer Performing
Your Answer Performing
True/False
Question Inspection is poor method of assuring 100% quality.
Correct Answer True
Your Answer False
Multiple Choice Multiple Answer
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
Your Answer Visual Management
True/False
Question 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 i nvolvement , Cost of quality
Your Answer Continuous improvement , People involvement , Cost of quality , Competitor focus
Select The Blank
Sem – 3rd
Techniques for Operations Efficiency
11
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 Evaluation
Your 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 maintenance
Your Answer Quality maintenance
Match The Following
Question 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
Staff attitude measurement Employee satisfaction index Employee satisfaction index
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
Your Answer Video recording
Match The Following
Question Correct Answer Your Answer
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
The scatter is also known as Correlation diagram Correlation diagram
Sem – 3rd
Techniques for Operations Efficiency
12
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 Flow chart helps to stop an old process.
Correct Answer False
Your 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 :Correct Answer Empowerment
Your Answer Empowerment
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.
Multiple Choice Single Answer
Question Kanban system is
Correct Answer 1. Pull System
Your Answer 1. Pull System
Multiple Choice Single Answer
Question Quality problem solving tool is used to :Correct Answer Improve quality
Your 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
Your 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 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 finding of the products
Select The Blank
Question ________ is the critical element of TQM.
Correct Answer Focus on customer
Your Answer Focus on customer
Sem – 3rd
Techniques for Operations Efficiency
13
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
Your Answer To all places including homes
True/False
Question Safety, hygiene and environment control is one of the pillar of TPM.
Correct Answer True
Your Answer True
Select The Blank
Question Inspection activity for semi finished & finished component should be ________ to reduce muda
of transport .
Correct Answer Decentralized
Your 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 Teamwork
Your Answer Teamwork
3rd Copy
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Advantages of JIT :Correct Answer Reduce incoming inspection , Reduce inventory , Lower per unit cost
Your 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
Multiple Choice Multiple Answer
Question
Benefits from SMED are :Correct Answer Reduce work in process , Better average daily production , Increase capacity
Sem – 3rd
Techniques for Operations Efficiency
14
Your 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
factors
Your Answer
It helps to separate data into groups so that you can draw connect & meaningful
inference , It helps to diagnose & localize problem , Finding out different reasons
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following production inputs :Correct Answer Men , Machine , Material
Your Answer
Men , Machine , Management
Multiple Choice Single Answer
Question
The success indicators in quality, cost, delivery & product development are :Correct Answer Managing points
Your Answer
Accountability
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 external
setups in to internal setups
Multiple Choice Multiple Answer
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
Sem – 3rd
Maintenance of equipment condition by eliminating lubricant leakage.
Techniques for Operations Efficiency
15
True/False
Question
Every department should make their own rules of standardization.
Correct Answer False
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 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
Question
Correct Answer
Your Answer
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
Staff attitude measurement
Employee satisfaction index
Employee satisfaction index
Multiple Choice Single Answer
Question
TPM helps to reduce down time due to:Correct Answer Breakdown of machine
Your Answer
Breakdown of machine
Multiple Choice Single Answer
Question
Kaizen emphasizes :Correct Answer Implementation of ideas
Your Answer
Collection of ideas
Select The Blank
Question
Create as many ________ system as possible for better Seiketsu.
Correct Answer Visual control
Your Answer
Visual control
True/False
Question
Inadequate maintenance of machine leads to muda of defects
Sem – 3rd
Techniques for Operations Efficiency
16
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
Your Answer
Distribution
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
Your Answer
Symmetrical
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 graph
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
Your 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.
Correct Answer False
Your Answer
Sem – 3rd
True
Techniques for Operations Efficiency
17
True/False
Question
Number of operation can change according to production requirement in U-Line
arrangement.
Correct Answer False
Your Answer
True
True/False
Question
Automation can correct the basic faults of a improper setup process.
Correct Answer False
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
Your Answer
Second highest
Select The Blank
Question
________is an important step toward successful JIT purchasing.
Correct Answer JIT Contract
Your Answer
JIT Contract
True/False
Question
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
Your Answer
Quality Control department
Select The Blank
Sem – 3rd
Techniques for Operations Efficiency
18
Question
Bar graph is display of data that facilitates ________ of quality.
Correct Answer Comparison
Your Answer
Performance
Multiple Choice Single Answer
Question
Production kanban is presented by :Correct Answer P-kanban
Your Answer
R-kanban
Multiple Choice Single Answer
Question
Check sheet are also used as :Correct Answer Data gathering & interpretation tool
Your Answer
Cause finding & effect finding tool
Select The Blank
Question
Japanese believe that when they are ________ they are cleaning there minds too.
Correct Answer Cleaning
Your Answer
Repairing machines
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
Your Answer
Counting device
Select The Blank
Question
Shitsuke means ________ all the previous 4-S throughout the month/year.
Correct Answer Sustaining
Your Answer
Implementing
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 PDCA meeting
True/False
Question
By TPM, consumption of electrical energy can be reduced.
Correct Answer True
Sem – 3rd
Techniques for Operations Efficiency
19
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 , Reduction
of wastage
True/False
Question
Flow chart helps to stop an old process.
Correct Answer False
Your Answer
True
Multiple Choice Multiple Answer
Question
Training related to Quality includes:Correct Answer Quality measures , Quality failure
Your Answer
Quality measures , Quality failure , Goal of business
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
Your Answer
(x - USL)/6 sigma
Select The Blank
Question
A histogram is a graphical display of distribution of measurements & reveals the
amounts of ________ within the process.
Correct Answer Variation
Your Answer
Percentage defects
Match The Following
Question
Correct Answer
Value analysis / value
engineering
To eliminate MUDA of processing To eliminate MUDA of over
production
SMED
To eliminate MUDA of over
production
Sem – 3rd
Techniques for Operations Efficiency
Your Answer
To eliminate MUDA of defect
20
VMI ( Vendor Management
Inventory) 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 Blank
Question
A 'Radar chart' is used to portray ________ strength or weakness of the activity.
Correct Answer Relative
Your Answer
th
4
Comparative
Copy
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
True/False
Question
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 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
Your Answer
Checking
Select The Blank
Question
5 S audit result is discussed in ________ meeting.
Correct Answer Monthly
Your Answer
Shift beginning
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
Sem – 3rd
Techniques for Operations Efficiency
21
Your Answer
Strong negative
Select The Blank
Question
Kaizen projects are managed by ________
Correct Answer Cross functional team
Your Answer
Management
Multiple Choice Single Answer
Question
Poka-yoke for employee not performing work as per established method is :Correct Answer Implement work standard
Your Answer
Implement work standard
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 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 ,
Collect information of short listed partners
Your Answer
Decide level of benchmarking , Collect information of short listed partners
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer Lack of experience
Your Answer
Absent mindedness
True/False
Question
Control chart is also called as run-chart.
Correct Answer True
Your Answer
True
Match The Following
Question
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
Improve work aids positioning
method
Sem – 3rd
Techniques for Operations Efficiency
22
Convert internal setup into
external setup
Preparation of tools / dies as off
line activity
Preparation of tools / dies as off
line activity
Eliminate adjustment
Pre setting of tool
Pre setting of tool
Multiple Choice Single Answer
Question
Muda of defect is very serious in case of:Correct Answer High speed automatic machines
Your 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 overproduction
Your Answer
Muda of waiting
Multiple Choice Single Answer
Question
In India quality circle was first launched by :Correct Answer Hyderabad unit of BHEL
Your 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
Your 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/False
Question
Increase in defect rate is an example of 'Deviation from an established norms'
Correct Answer True
Sem – 3rd
Techniques for Operations Efficiency
23
Your Answer
True
Select The Blank
Question
________ are implemented for defect detection & prevention.
Correct Answer Poka-Yokes
Your Answer
Poka-Yokes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer Improve quality
Your Answer
Improve quality
Multiple Choice Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Lower efficiency
True/False
Question
Presentation of graphs in pictorial form of data collection are for easy understanding.
Correct Answer True
Your Answer
True
Select The Blank
Question
________ waste is probably the biggest waste in most of the organizations.
Correct Answer Time
Your Answer
Labor
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
True/False
Question
TQM improves the quality by improving processes.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Sem – 3rd
Techniques for Operations Efficiency
24
Question
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 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
Your Answer
Multiskilled operators
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.
Select The Blank
Question
________ should be used to exercise control on the process.
Correct Answer Control chart
Your Answer
Latest checking instruments
Match The Following
Question
Correct Answer
Ideally the histogram will have a
bell shape
Tapering away on the both sides Tapering away on the both sides
from average value
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
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/False
Question
Your Answer
In single card kanban system production greater than quantity withdrawn is permitted.
Correct Answer False
Sem – 3rd
Techniques for Operations Efficiency
25
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
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/False
Question
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
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 specification
Sem – 3rd
Techniques for Operations Efficiency
26
Your 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 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 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 the percentage of each category into 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 Blank
Question
Poka Yoke designed to help operators to know immediately ________ of the defeat
called detection type Poka-Yoke.
Correct Answer On occurrence
Your Answer
Before Occurrence
Select The Blank
Question
Flow chart helps to dissect a process for better understanding & ________ of process.
Correct Answer Analysis
Your 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
Question
Graphs convey a situation more ________ than summary of data or figures.
Correct Answer Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Number of Kaizen projects suggested and implemented is checking point for :-
Sem – 3rd
Techniques for Operations Efficiency
27
Correct Answer Continual Improvement
Your Answer
Continual Improvement
5th Copy
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following production inputs :Correct Answer Material , Men , Machine
Your Answer
Material , Men , Machine
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer Measure the current pattern & extent of variation , Assess current conformance to
specification & scope of improvement , Determine whether or not the process is in the
state of control
Your Answer
Measure the current pattern & extent of variation , Assess current conformance to
specification & scope of improvement , Determine whether or not the process is in the
state of control
Multiple Choice Single Answer
Question
In problem solving the best alternative is that :Correct Answer Which best meets the criteria
Your Answer
Which best meets the criteria
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
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
Your Answer
Internal benchmarking
Select The Blank
Question
JIT advocates the philosophy at elimination of waste from system which occurs due to
________.
Correct Answer Over Production
Sem – 3rd
Techniques for Operations Efficiency
28
Your Answer
Over Production
Select The Blank
Question
In scatter diagram "________" relationship is said to exist when there is positive
relationship upto certain level & negative thereafter or negative relationship upto
certain level & positive thereafter.
Correct Answer Curvilinear
Your Answer
Curvilinear
True/False
Question
Kanban signals are required when assembly work, subassembly work and
manufacturing at parts is carried out at different locations.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
Customers complaints may be segregated by :Correct Answer Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity
Your Answer
Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity
True/False
Question
In case of more than one quality characteristics, separate chart is made for each
quality characteristics.
Correct Answer True
Your Answer
True
True/False
Question
Safety, hygiene and environment control is one of the pillar of TPM.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
5-S technique is useful to:
Correct Answer To all places including homes
Your Answer
To all places including homes
Match The Following
Question
Correct Answer
Your Answer
Reduce time of external setup
Improve work aids positioning
method
Improve work aids positioning
method
Convert internal setup into
external setup
Preparation of tools / dies as off
line activity
Preparation of tools / dies as off
line activity
Sem – 3rd
Techniques for Operations Efficiency
29
Eliminate adjustment
Pre setting of tool
Pre setting of tool
Reduce clamping & declamping
time
Use U-shaped washer
Use U-shaped washer
Multiple Choice Single Answer
Question
The facilitator should be normally :Correct Answer Senior officer /Shop incharge
Your Answer
Senior officer /Shop incharge
Match The Following
Question
Correct Answer
Your Answer
Parato diagram always indicates Magnitude of defects
Philosophy of 20% of the activity
causes 80% of the effect
Parato analysis underlines &
operates on
Philosophy of "vital few:trivial
many"
Philosophy of "vital few:trivial
many"
Parato analysis is technique of
identifying vital causes by
Arranging data according to the
descending order of their
frequency of occurrence
Arranging data according to the
descending order of their
frequency of occurrence
Parato diagram is a Bar graph
with height or value drawn by
Arranging data in descending
order
Magnitude of defects
Multiple Choice Single Answer
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 Blank
Question
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 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
Sem – 3rd
Cloud
Techniques for Operations Efficiency
30
Multiple Choice Multiple Answer
Question
Product benchmarking requires, comparison of product :Correct Answer Performance , Features , Cost
Your Answer
Performance , Features , Cost
Multiple Choice Multiple Answer
Question
Steps in construction of scatter diagram :Correct Answer Collect paired data (X,Y) from two variables who's relationship is to be studied , Find
out max & min values for both X & Y and these values to scale X & Y axis & plot the
paired data , Examine the shape of the cloud of points & discover type & strength of
relationship
Your Answer
Collect paired data (X,Y) from two variables who's relationship is to be studied , Find
out max & min values for both X & Y and these values to scale X & Y axis & plot the
paired data , Examine the shape of the cloud of points & discover type & strength of
relationship
Multiple Choice Single Answer
Question
Implication of Quality problem is: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 Blank
Question
Kaizen is ________ supported process.
Correct Answer Management
Your Answer
Management
True/False
Question
The flow charts are prepared to enhance the employees understanding of the process
by indicating interrelationship within the process.
Correct Answer True
Your Answer
False
True/False
Question
Gap analysis for production & dispatches is discussed in monthly meeting.
Correct Answer False
Your Answer
Sem – 3rd
False
Techniques for Operations Efficiency
31
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
Your Answer
Strong negative
Select The Blank
Question
________ is most difficult 'S' to implement & achieve.
Correct Answer Shitsuke
Your 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
Question
Graphs convey a situation more ________ than summary of data or figures.
Correct Answer Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer Lack of experience
Your 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 for full range , Scale selected
should be right to avoid wrong conclusions , Data should be free from bias or undue
importance
Your Answer
Data should be properly stratified & should be collected for full range , Scale selected
should be right to avoid wrong conclusions , Data should be free from bias or undue
importance
True/False
Question
Globalization of trade and industrial operations have forced Indian companies to
become more & more competitive and customer driven.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Sem – 3rd
Techniques for Operations Efficiency
32
Question
If 'Annual saving in procurement expenses is managing point', then checking points will
be :Correct Answer Price revision , Credit period , Transport expenses
Your Answer
Price revision , Credit period , Transport expenses
Multiple Choice Single 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/False
Question
Flow chart is pictorial representation of the steps in production control.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
It is essential to convey customer's expectations to :Correct Answer Top Management
Your Answer
Supervisors & workmen
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
Select The Blank
Question
Identification of non-value added operations & their elimination is the first step to
eliminate muda of ________.
Correct Answer Processing
Your Answer
Processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength or weakness of the activity.
Correct Answer Relative
Your Answer
Relative
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer Vital few = trivial many
Sem – 3rd
Techniques for Operations Efficiency
33
Your Answer
Vital few = trivial many
True/False
Question
In single card kanban system production greater than quantity withdrawn 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 , Improved maintainability mean time to
repair , Improvement in breakdown
Your Answer
Improved reliability mean time between failures , Improved maintainability mean time to
repair
Multiple Choice Multiple Answer
Question
Gap analysis & problem identification is done during converting internal setups into
external setups in the areas like :Correct Answer Equipment , Method , Human
Your Answer
Equipment , Method , Human
Multiple Choice Single Answer
Question
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 Answer
Question
Sorting of usable items should be
Correct Answer Planned storage based on frequency of use
Your 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 time
Your Answer
th
5
Reduction in customer quality complaints , Reduction in inspection time
Copy
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Advantages of JIT :Correct Answer
Reduce incoming inspection , Reduce inventory , Lower per unit cost
Your Answer
Reduce incoming inspection , Reduce inventory , Lower per unit cost
Sem – 3rd
Techniques for Operations Efficiency
34
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
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 , 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 factors
Your Answer
It helps to separate data into groups so that you can draw connect & meaningful
inference , It helps to diagnose & localize problem , Finding out different reasons
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following production inputs :Correct Answer
Men , Machine , Material
Your Answer
Men , Machine , Management
Multiple Choice Single Answer
Question
The success indicators in quality, cost, delivery & product development are :Correct Answer
Managing points
Your Answer
Accountability
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 external
setups in to internal setups
Multiple Choice Multiple Answer
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/False
Question
Every department should make their own rules of standardization.
Correct Answer
False
Your Answer
True
Multiple Choice Multiple Answer
Sem – 3rd
Techniques for Operations Efficiency
35
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
Question
Correct Answer
Your Answer
Productivity performance measurement
Turnover employee
Sales of the months
Financial performance measurement
Sales of the months Cash saving per department
Customer satisfaction measurement
period
Customer complaints per period
Customer complaints per
Staff attitude measurement Employee satisfaction index Employee satisfaction index
Multiple Choice Single Answer
Question
TPM helps to reduce down time due to:Correct Answer
Breakdown of machine
Your Answer
Breakdown of machine
Multiple Choice Single Answer
Question
Kaizen emphasizes :Correct Answer
Implementation of ideas
Your Answer
Collection of ideas
Select The Blank
Question
Create as many ________ system as possible for better Seiketsu.
Correct Answer
Visual control
Your 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
Your Answer
Distribution
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
Your Answer
Symmetrical
True/False
Question
Sem – 3rd
Inspection is poor method of assuring 100% quality.
Techniques for Operations Efficiency
36
Correct Answer
Your Answer
True
False
True/False
Question
A radar chart is combination of a circle & line graph
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
Your 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.
Correct Answer
False
Your Answer
True
True/False
Question
Number of operation can change according to production requirement in U-Line arrangement.
Correct Answer
False
Your Answer
True
True/False
Question
Automation can correct the basic faults of a improper setup process.
Correct Answer
False
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
Your Answer
Second highest
Select The Blank
Question
________is an important step toward successful JIT purchasing.
Correct Answer
JIT Contract
Your Answer
JIT Contract
True/False
Question
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
Your Answer
Quality Control department
Select The Blank
Question
Bar graph is display of data that facilitates ________ of quality.
Correct Answer
Comparison
Sem – 3rd
Techniques for Operations Efficiency
37
Your Answer
Performance
Multiple Choice Single Answer
Question
Production kanban is presented by :Correct Answer
P-kanban
Your Answer
R-kanban
Multiple Choice Single Answer
Question
Check sheet are also used as :Correct Answer
Data gathering & interpretation tool
Your Answer
Cause finding & effect finding tool
Select The Blank
Question
Japanese believe that when they are ________ they are cleaning there minds too.
Correct Answer
Cleaning
Your Answer
Repairing machines
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
Your Answer
Counting device
Select The Blank
Question
Shitsuke means ________ all the previous 4-S throughout the month/year.
Correct Answer
Sustaining
Your Answer
Implementing
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 PDCA meeting
True/False
Question
By TPM, consumption of electrical energy can be reduced.
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 , Reduction
of wastage
True/False
Question
Flow chart helps to stop an old process.
Correct Answer
False
Your Answer
True
Multiple Choice Multiple Answer
Question
Training related to Quality includes:Correct Answer
Quality measures , Quality failure
Your Answer
Quality measures , Quality failure , Goal of business
Multiple Choice Single Answer
Question
Total area under the normal curve is
Correct Answer
Unity
Sem – 3rd
Techniques for Operations Efficiency
38
Your Answer
Six
Multiple Choice Multiple Answer
Question
Cpk =
Correct Answer
(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 the amounts of
________ within the process.
Correct Answer
Variation
Your Answer
Percentage defects
Match The Following
Question
Correct Answer
Your Answer
Value analysis / value engineering To eliminate MUDA of processing
production
To eliminate MUDA of over
SMED To eliminate MUDA of over production
To eliminate MUDA of defect
VMI ( Vendor Management Inventory) system
To eliminate MUDA of stock To eliminate MUDA of stock
Flow / string diagramTo eliminate MUDA of transport
To eliminate MUDA of processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength or weakness of the activity.
Correct Answer
Relative
Your Answer
Comparative
-----------------------------------------------------------LIST OF ATTEMPTED QUESTIONS AND ANSWERS
True/False
Question
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 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
Your Answer
Checking
Select The Blank
Sem – 3rd
Techniques for Operations Efficiency
39
Question
5 S audit result is discussed in ________ meeting.
Correct Answer
Monthly
Your Answer
Shift beginning
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
Your Answer
Strong negative
Select The Blank
Question
Kaizen projects are managed by ________
Correct Answer
Cross functional team
Your Answer
Management
Multiple Choice Single Answer
Question
Poka-yoke for employee not performing work as per established method is :Correct Answer
Implement work standard
Your Answer
Implement work standard
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 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 ,
Collect information of short listed partners
Your Answer
Decide level of benchmarking , Collect information of short listed partners
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer
Lack of experience
Your Answer
Absent mindedness
True/False
Question
Control chart is also called as run-chart.
Correct Answer
True
Your Answer
True
Match The Following
Question
Correct Answer
Your Answer
Reduce clamping & declamping time
Reduce time of external setup
method
Use U-shaped washer
Use U-shaped washer
Improve work aids positioning method
Improve work aids positioning
Convert internal setup into external setup Preparation of tools / dies as off line activity
tools / dies as off line activity
Eliminate adjustmentPre setting of tool
Preparation of
Pre setting of tool
Multiple Choice Single Answer
Question
Muda of defect is very serious in case of:Correct Answer
High speed automatic machines
Sem – 3rd
Techniques for Operations Efficiency
40
Your 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 overproduction
Your Answer
Muda of waiting
Multiple Choice Single Answer
Question
In India quality circle was first launched by :Correct Answer
Hyderabad unit of BHEL
Your 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
Your 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/False
Question
Increase in defect rate is an example of 'Deviation from an established norms'
Correct Answer
True
Your Answer
True
Select The Blank
Question
________ are implemented for defect detection & prevention.
Correct Answer
Poka-Yokes
Your Answer
Poka-Yokes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer
Improve quality
Your Answer
Improve quality
Multiple Choice Single Answer
Question
Implication of Quality problem is:Correct Answer
Gap in performance
Your Answer
Lower efficiency
True/False
Question
Presentation of graphs in pictorial form of data collection are for easy understanding.
Correct Answer
True
Your Answer
True
Select The Blank
Question
________ waste is probably the biggest waste in most of the organizations.
Correct Answer
Time
Your Answer
Labor
Sem – 3rd
Techniques for Operations Efficiency
41
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
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 adjustment of machines
Your 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
3.4
Your Answer
6210
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 Single Answer
Question
To maintain smoothness in production :Correct Answer
Elimination of buffer stock is recommended
Your Answer
Maintenance of buffer stock is recommended.
Select The Blank
Question
________ should be used to exercise control on the process.
Correct Answer
Control chart
Your Answer
Latest checking instruments
Match The Following
Question
Correct Answer
Your Answer
Ideally the histogram will have a bell shape
Tapering away on the both sides from average value
Tapering 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
frequency distribution of a characteristics
The frequency distribution of a characteristics
The
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.
Correct Answer
False
Your Answer
False
Sem – 3rd
Techniques for Operations Efficiency
42
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
Multiple Choice Multiple Answer
Question
Some steps for stratification are :Correct Answer
Define the problem & identify the stratification variables , Sort out
& summarise information in each category , Present the information in graphical form &
further stratification is required?
Your Answer
Define the problem & identify the stratification variables , Sort out
& summarise information in each category , Present the information in graphical form &
further stratification is required?
data into categories
study, decide if
data into categories
study, decide if
True/False
Question
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
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 specification
Your 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 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 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 the
percentage of each category into 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
Sem – 3rd
Techniques for Operations Efficiency
43
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 Blank
Question
Poka Yoke designed to help operators to know immediately ________ of the defeat called
detection type Poka-Yoke.
Correct Answer
On occurrence
Your Answer
Before Occurrence
Select The Blank
Question
Flow chart helps to dissect a process for better understanding & ________ of process.
Correct Answer
Analysis
Your 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
Question
Graphs convey a situation more ________ than summary of data or figures.
Correct Answer
Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Number of Kaizen projects suggested and implemented is checking point for :Correct Answer
Continual Improvement
Your Answer
Continual Improvement
-------------------------------------------------------------------LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following production inputs :Correct Answer
Material , Men , Machine
Your Answer
Material , Men , Machine
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer
Measure the current pattern & extent
specification & scope of improvement , Determine whether
Your Answer
Measure the current pattern & extent
specification & scope of improvement , Determine whether
of variation , Assess current conformance to
or not the process is in the state of control
of variation , Assess current conformance to
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
Your Answer
Which best meets the criteria
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer
DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
Multiple Choice Single Answer
Sem – 3rd
Techniques for Operations Efficiency
44
Question
Identifying key preventive operational functions and comparing these operational functions
within the firm's own division & branches comes under :Correct Answer
Internal benchmarking
Your Answer
Internal benchmarking
Select The Blank
Question
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 is positive relationship
upto certain level & negative thereafter or negative relationship upto certain level & positive thereafter.
Correct Answer
Curvilinear
Your Answer
Curvilinear
True/False
Question
Kanban signals are required when assembly work, subassembly work and manufacturing at
parts is carried out at different locations.
Correct Answer
True
Your Answer
True
Multiple Choice Multiple Answer
Question
Customers complaints may be segregated by :Correct Answer
Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity
Your Answer
Nature of compliant i.e. defective product , Delayed delivery , Short/excess quantity
True/False
Question
In case of more than one quality characteristics, separate chart is made for each quality
characteristics.
Correct Answer
True
Your Answer
True
True/False
Question
Safety, hygiene and environment control is one of the pillar of TPM.
Correct Answer
True
Your Answer
True
Multiple Choice Single Answer
Question
5-S technique is useful to:
Correct Answer
To all places including homes
Your Answer
To all places including homes
Match The Following
Question
Correct Answer
Reduce time of external setup
method
Your Answer
Improve work aids positioning method
Improve work aids positioning
Convert internal setup into external setup Preparation of tools / dies as off line activity
tools / dies as off line activity
Eliminate adjustmentPre setting of tool
Pre setting of tool
Reduce clamping & declamping time
Use U-shaped washer
Sem – 3rd
Techniques for Operations Efficiency
Preparation of
Use U-shaped washer
45
Multiple Choice Single Answer
Question
The facilitator should be normally :Correct Answer
Senior officer /Shop incharge
Your Answer
Senior officer /Shop incharge
Match The Following
Question
Correct Answer
Parato diagram always indicates
the effect
Your Answer
Magnitude of defects Philosophy of 20% of the activity causes 80% of
Parato analysis underlines & operates on
few:trivial many"
Philosophy of "vital few:trivial many"
Philosophy of "vital
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
Magnitude of defects
Arranging data in descending order
Multiple Choice Single Answer
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 Blank
Question
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 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
Performance , Features , Cost
Your Answer
Performance , Features , Cost
Multiple Choice Multiple Answer
Question
Steps in construction of scatter diagram :Correct Answer
Collect paired data (X,Y) from two variables who's relationship is to be studied , Find
out max & min values for both X & Y and these values to scale X & Y axis & plot the paired data , Examine
the shape of the cloud of points & discover type & strength of relationship
Your Answer
Collect paired data (X,Y) from two variables who's relationship is to be studied , Find
out max & min values for both X & Y and these values to scale X & Y axis & plot the paired data , Examine
the shape of the cloud of points & discover type & strength of relationship
Sem – 3rd
Techniques for Operations Efficiency
46
Multiple Choice Single Answer
Question
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 Blank
Question
Kaizen is ________ supported process.
Correct Answer
Management
Your Answer
Management
True/False
Question
The flow charts are prepared to enhance the employees understanding of the process by
indicating interrelationship within the process.
Correct Answer
True
Your Answer
False
True/False
Question
Gap analysis for production & dispatches is discussed in monthly meeting.
Correct Answer
False
Your Answer
False
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
Your Answer
Strong negative
Select The Blank
Question
________ is most difficult 'S' to implement & achieve.
Correct Answer
Shitsuke
Your 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
Question
Graphs convey a situation more ________ than summary of data or figures.
Correct Answer
Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer
Lack of experience
Your 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 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
Sem – 3rd
Techniques for Operations Efficiency
47
True/False
Question
Globalization of trade and industrial operations have forced Indian companies to become more
& more competitive and customer driven.
Correct Answer
True
Your Answer
True
Multiple Choice Multiple Answer
Question
If 'Annual saving in procurement expenses is managing point', then checking points will be :Correct Answer
Price revision , Credit period , Transport expenses
Your 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/False
Question
Flow chart is pictorial representation of the steps in production control.
Correct Answer
False
Your Answer
False
Multiple Choice Single Answer
Question
It is essential to convey customer's expectations to :Correct Answer
Top Management
Your Answer
Supervisors & workmen
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer
Simplest tool
Your Answer
Simplest tool
Select The Blank
Question
Identification of non-value added operations & their elimination is the first step to eliminate
muda of ________.
Correct Answer
Processing
Your Answer
Processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength or weakness of the activity.
Correct Answer
Relative
Your Answer
Relative
Multiple Choice Single Answer
Question
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 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 , Improved maintainability mean time
to repair , Improvement in breakdown
Sem – 3rd
Techniques for Operations Efficiency
48
Your Answer
to repair
Improved reliability mean time between failures , Improved maintainability mean time
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
Multiple Choice Single Answer
Question
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 Answer
Question
Sorting of usable items should be
Correct Answer
Planned storage based on frequency of use
Your 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 time
Your Answer
Reduction in customer quality complaints , Reduction in inspection time
6th Copy
Sem – 3rd
Techniques for Operations Efficiency
49
1) What are the basics steps in the problem solving process? Explain them briefly.
Ans:
INTRODUCTION: Systematic problem solving provides a structured approach to
problem solving. Depending upon the nature of problem (i.e. maintenance or
improvement problem), some steps may be different.
SOLVING A MAINTENANCE PROBLEM: Maintenance problems as mentioned
earlier, surface when the status quo is distributed and decision make needs to
recommend/take measures to restore and maintain the status quo.
Fig: Steps to solve a maintenance problem.
Identify a maintenance problem
Collect data on “causes”
Perform Pareto Analysis
Identify root causes
Evolve alternatives & select
(Brain storming)
Implement best alternative
Monitor effect
Is the problem
resolved?
No
End
(a) Diagnose (define) the problem:
Sound diagnosis is the crucial step in the problem solving process. Defining the problem
sets the boundaries for that follows. Decision maker, like a doctor, must take into account
all symptoms before prescribing the medicines (i.e. recommending the decision). Peter
Drucker rightly states, “The books and articles on leadership are full of advice on how to
make fast, forceful and useful decisions, but there is no more foolish and no more time
wasting advice than to decide quickly what a problem really is. Defining the problem in
most instances is a time-consuming task, but it is time well spent.”
Sound diagnosis requires
(i)
Measurement of the gap between the desired performance and the actual
performance.
(ii)
Identification of the root cause for the gap.
(iii)
Identification of the restraints in the decision making process.
(b) Secure and analyse pertinent facts:
Once the problem has been diagnosed (defined), the next step is to collect data. Data
collection implies collecting background material, pertinent facts, decision taken in the
past and their outcome, previous solutions to similar problems etc.
General rules are:
(i)
The information should be collected from the most reliable source.
(ii)
All relevant facts, regardless of how disorganized or unrelated they seem at
the time of data gathering, should be recorded.
(iii)
The information should be subjected to checks and cross checks. The
conflicting data must be resolved. The temptation to accept first response to
inquiries should be avoided.
(iv)
The facts wherever possible should be supported by tangible evidence in the
form of copies of the appropriate documents. Facts when cannot be supported
by documentary evidence (i.e. facts which are bases on opinion of the
individuals) should carry the names of the contributors so that they
(individuals) can be contacted later if required.
Facts are next analysed to establish:
(i)
(ii)
(iii)
The length of time to which the decision should apply.
Effect of the decision on other functional areas.
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 unearth
these alternatives. Usually, a brain storming or interaction session with those, concerned
with the problem can highlight several alternatives. For example, the company was
considering purchase of a CNC machine. The general manager held a series of brain
storming session of his engineers and following alternatives got identified:
(a) continue to make the part by present method, or
(b) buy the proposed CNC machine, or
(c) buy a machine other than the proposed one, or
(d) improvise the current method of making part (e.g retrofitting the existing
machine improves tooling and gauging method etc.), or
(e) subcontract CNC – compatible operations to a good quality vendor, or
(f) discontinue manufacturing the part at company’s own plant and buy the
part from an outside source.
After evaluating all the alternatives for their merits and demerits, the general manager
opted for alternatives ‘d’, ‘e’ and ‘f’ and got the best results.
(d) Evaluate alternatives:
Once all the alternative solutions have been enumerated, they are next evaluated. This is
usually done by testing each alternative against a set of objectives or specified criteria
which the solution must meet. The steps involved are:
(i)
Each alternative is analysed to see whether or not it meets the “must”
objectives. An alternative which does not meet the “must” objective is
immediately removed from further study.
(ii)
Alternatives which meet the “must” objectives are next checked for “want”
objectives and those which are good in terms of “want” objectives are
examined for adverse consequences. Since each alternative usually entails
some risk, the decision maker next assesses the risk, the probability of risk,
the probability or risk, and /or seriousness of the risk.
(iii)
Every attempt is made to eliminate or minimize risk (or disadvantages). T
chart analysis is usually helpful.
(iv)
Alternatives are next weighed for their effectiveness by identifying their long
term and short term consequences. The advantages of the alternatives are
quantified in terms of common denominator, usually the money.
(e) Select the best alternative:
The alternative cleared at the evaluation stage are ranked according to their worth. Final
selection is then made of the alternative which provides the maximum advantages while
entailing acceptance risk (i.e. the alternative that best meets the solution criteria is
selected)
(f) Implement the selected decision:
Once the final choice has been made the next step is to implement the decision and
follow up for verification of the consequences (or effect of the decision)
Though the steps mentioned above are sequential and separate but usually there is
recycling among the steps. For example, while trying to evaluate alternatives, the
decision maker may have to ho back to data collection step if he finds that he does not
have all the information.
STEPS FOR SOLVING AN IMPROVEMENT PROBLEM:
The Japanese have provided a structured methodology for solving “improvement”
problem. The methodology is also known as QC story and it comprises of the following
six steps based on famous Deming Plan-Do-Check-Act (PDCA) cycle.
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)
Plan (P)
Implement counter
measure
Do (D)
Measure /analyse
achievement
No
Check (C)
Satisfactory
performance?
Yes
Stabilize/standardize (SDCA)
Yes
New target
No
Maintain status quo
End
2. (a) What is “Cause and effect” diagram? How is it useful in analyzing a problem?
How is it constructed?
Ans: INTRODUCTION: Every organization has contributory causes. The causes need to
be identified to eliminate problems or minimize the effect of the problems. All causes
including probable causes (i.e. which have not occurred earlier) should be identified so
that preventive action can be taken (After all, prevention is better than cure)
After the causes have been identified, they should be put into a systematic form that
facilitates presentation and analysis.
Cause and effect diagram is also called as “Ishikawa Diagram” or a fishbone diagram
(due to its shape) – an effective tool for diagnosis to a problem – was developed by Dr.
Kaoru Ishikawa, a professor of Tokyo University.
The diagram lists out in a classified and systematic manner all causes which are
responsible for the problem (called effect). The diagram consists of a main line to
represent the actual problem and few lines to represent the major causes – materials, men,
methods and machines – and horizontal or slanting arrows to represent sub-causes und
relying each main cause.
Procedure:
Step1 : Specify the problem to be solved
For eg:
(i)
Accidents
(ii)
Process defectives
(iii) Employer – employee relations
(iv)
Delayed delivery
(v)
Defective bills
(vi)
Labour efficiency
Step2: Brain storm to find all possible causes of the problem.
Step3: Organize/ arrange these causes in few major themes (i.e. rational categories)
Step4: Construct a cause and effect diagram that accurately displays the relationship of
all data in each category. Steps in the construction of the diagram are as follows:
(a) Draw a box on the far right hand side of a large sheet of paper and write inside the
box the description of the problem to be solved. Also draw a thick arrow that
points to the box and look up on this as a main trunk of a tree.
Problem
(b) Enter the titles of the categories (also called themes) above and below the
horizontal line and connect them to horizontal line by vertical or standing arrows.
Think of these as branches of the main truck of the tree.
Man
Machine
Problem
Method
Materials
(c) Enter the detailed cause data for each category / theme by arrows meeting the
horizontal or slanting lines (i.e. lines representing the main theme). Look upon
these as limbs or twigs of the branches.
Man
Machine
Cause A
Cause B
Cause A
Cause B
Cause D
Cause C
Cause C
Problem
Cause B
Cause A
Cause A
Cause C
Cause C
Cause B
Cause D
Method
Materials
(d) Review diagram drawn above to ensure that no cause has been missed.
A cross function team constituted to study problem of employees’ poor morale have
conducted on following probable causes. Draw a “cause and effect” diagram from
the given data…
Ans:
REWARD/RECOGNITION
HIRING
Poor selection
Poor Management selection
Poor Management selection
Low pay level
Incomplete job description
Wage differentials
Recruiting errors
Poor benefits
Favoritism
EMPLOYEE
Lack of discipline methods
Faulty working assignment
Lack of communication
Unclear company goals
Improper management training
Bad Lighting
Noise
Temperature
Long working hours
Public reprimands
Excessive Criticism
MANAGEMENT
WORKING CONDITIONS
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.
ii.
Express value of each category of component group as a percentage of total of
all categories or components or groups.
Calculate degree of the angle formed by each category/component/group as
under
Degree of particular category
iii.
iv.
=
Value of the group X 360
Total Value
Draw a circle of a suitable diameter (say diameter of 3”)
Segment the circle into angles calculated in step 2 with the help of a protractor
v.
Shade or color different segments suitable to make distinction between
different categories.
vi.
Enter the percentage of each category in to the pie chart.
b) Draw a Pie Chart to represent the following population in a village.
Males
2000
Females
1800
Girls
4200
Boys
2000
Total
10000
Sol:
S.No
1.
2.
3.
4.
Gender
Males
Females
Girls
Boys
Population
2000
1800
4200
2000
Population %
20%
18%
42%
20%
Total
10000
100%
Degree
72o
o
64.8
151.2 o
o
72
POPULATION
Boys
20%
Males
20%
Girls
42%
Males
Females
Females
18%
Girls
Boys
4. a) What is Pareto’s analysis? How is it used for problem solving?
Ans: Introduction: Every problem is the result of few causes and all causes are not
equally important. Some causes are more significant than others. Pareto’s analysis
underlines and operates his philosophy of “vital few: trivial many”. It is a technique of
identifying vital causes by arranging the data according to the descending order of their
frequency of occurrence.
Pareto’s diagram is the outcome of the study conducted by Vilfredo Pareto to study the
phenomenon of wealth in his country. Pareto observed that in his native country 80% of
the wealth was held by 20% of the population. He eventually realized that he had
discovered a universal law – around 20% of the activity causes 80% of the effect.
For Example:
 80% to 90% of the Italy’s wealth lay in the hands of 10% to 20% of the
population.
 80% of the accidents occur on 20% of the roads (i.e. some roads are more
dangerous than others)
 80% of the shopping that takes place is done in 20% of the time of the store are
open.(i.e. people try to shop at the same time).
 80% of the absenteeism in a company is generally on account of 20% of the work
force.
 20% of the machines are responsible for 80% of the total down time.
 20% of the end products generate 80% of sales revenue.
 20% of the clerks make 80% of the clerical errors.
 20% of the employees create 80% of the troubles.
 20% of the customers are responsible for 80% of the bad debts.
 20% of the total items in the stock account for 80% of the annual expenditure on
materials.
U.S Economist M.C. Lorenz presented this lop sided distribution in the form of
theoretical curve, called Lorenz’s curve. Dr. J. M. Juran observed similar phenomenon in
many other fields including quality. He names this phenomenon as Pareto Analysis in
honor of the originator of the concept.
We need to follow few steps in order to solve the problems using Pareto’s Chart. They
are listed as follows:
1) Select the problem and identify causes into a handful of categories. For example,
for a problem of “late coming to works”, possible categories of causes may be
heavy traffic oversleeping, sickness, vehicle problem, family problem etc.
2) Select the standard unit for measurement (e.g. frequency, cost, sales etc.)
3) Select the time period over which data will be collected (e.g. 8 hours, 5 days, 2
weeks, etc.)
4) Collect necessary data on each category and summarize results.
It is generally convenient to create a three-column-table having heading as “error
category”. “frequency (or cost)”, and “percentage of total”. This information can
be directly taken from the check sheet.
5) Rearrange the data in the descending order of the frequency or cost.
6) Organize the Pareto’s chart
(a) Draw two vertical axis, one on either side of a horizontal side axis (leaving
enough space on the horizontal axis to list the problem categories). Mark
the frequency of occurrence of the problem along left vertical axis and
percentage along right vertical axis.
(b) Divide the horizontal axis into intervals equal to the number of categories.
(c) List down the categories from left to right in their order of decreasing
frequency or cost.
(d) Construct a bar or rectangle above each category with height equal to
frequency or cost.
7) Draw the cumulative line /curve (Pareto’s curve) by plotting each point at the
right hand corner of each bar and them connecting these points.
8) Write all necessary information concerning the diagram.
b) Shrivastive, an administrative officer, working with Dattatreya Chemicals Ltd.
has been receiving frequent complaints from internal customers regarding late and
wrong receipt of mail delivered by his department. In order to correct the problem,
he called a meeting of a small group of his internal customers and with their help
identified five error categories, namely mail behind schedule, wrong deliveries, and
late delivery of outgoing mail to post office, rude clerks and incorrect charges.
The administrative officer then started tracking complaints. The data collected by
him in a 30-day span in the form of a check-sheet reproduced below.
Error Category
Behind schedule mail
Wrong delivery of mail
Late delivery of outgoing mail to P.O
Rude clerks
Incorrect charges
Tally Mark
lllll
ll
lllll
lllll
lllll
lllll
l
lllll
Total
lllll
ll
Frequency
7
20
12
1
5
45
Draw a Pareto’s Chart.
Sol:
1. Collect the data concerning the problem under study.
2. Rearrange the data in the descending order.
Error Category
Wrong delivery of mail
Late delivery…
Behind schedule mail
Incorrect charges
Rude clerks
Frequency
20
12
7
5
1
%of Error to total
44.44
26.67
15.55
11.11
2.22
PARETO's DIAGRAM
120
100
97.76
100
86.65
80
Frequency
72.1
%of Error to total
60
Cumulative%
44.44
40
20
20
12
0
0
Log. (Cumulative%)
26.67
2
15.55 11.11
7
5
4
2.22
1
6
Cumulative%
44.44
72.1
86.65
97.76
100.00
5. What are the quality circles? How are they formed? Explain briefly the
organization of quality circles.
Ans:
Introduction: Quality circle is basically a small group of employees – who volunteer to
meet regularly to undertake work related projects – quality, productivity, safety,
efficiency, cost, working conditions, etc., - and evolve recommendations to improve
effectiveness in the selected functional area.
The size of quality circle is important. Too big a size 9 (too many members) may not
provide enough time to each member to effectively participate and too small a size may
make a circle dormant. An ideal size of the circle is eight to ten members but in any case
it should not exceed fifteen members.
More than one circle may be formed if too many employees in a particular work area are
willing to participate in the quality circle activities. For example, if there are 25 clerks in
the organization doing identical jobs, 2 to 3 circles may be formed.
Participation in the circle activities is absolutely voluntary. Members are not selected
/nominated. They are not elected or rotated either. Employees, however, are encouraged
to form circles.
Ideally, members of a particular circle should be from the same area or who do similar
work so that problems that they select /analyse / discuss will be familiar to all of them.
Brief History: Japanese Union of Scientists and Engineers (JUSE) was established in
1946 after the World War II in which Japanese industries were completely destroyed.
JUSE worked for growth and development of quality and in 1950 it invited Dr. Edward
Deming, a renowned American expert on quality to visit Japan. Dr. Deming delivered a
series of lectures on various aspects of quality control to the top management of several
companies of Japan.
These circles have lifted war-ravaged Japan to its present dominant position and have
endangered even the very existence of American industry. A quality circle in Japan on
the average saves $56, 000. All this is achieved without any monetary incentives. Around
25% of the profitability of the Japanese industries is attributed to the quality circles.
Nissan motor, for example works with 57,000 employees, has 4,200 quality circles which
have helped the company to double its productivity in ten years.
Quality circles in India were first launched in the Hyderabad unit of BHEL in 1980 which
has now around 100 quality circles in its various branches throughout India. Quality
circles forum of India was formed in 1982 to propagate concept. The concept of quality
circles is gaining momentum and quite a few firms in the private and public sector –
Kirloskars, Alwayns, Tata’s, H.A., Bharat Forge, Balaji Auto, Vulcan Laval, Rourkela
Steel plant etc., have instituted quality circles.
Organization for quality circles: The Organization of circles consists of:
i.
Steering Committee: Steering committee is the apex body at the highest level
of the plant which is made up of heads of the major departments like
Production, Finance, Materials, Marketing, Engineering, Quality Assurance,
etc, and is headed by the Chief Executive of the plant. The committee meet
periodically and ito Evolves policies and guidelines for the formation, functioning and growth
of quality circles.
o Appoints facilitators and a co-coordinator.
o Identifies overall quality and productivity problems in the organization.
o Authorizes budget for quality circle activities
o Takes part in top management presentation and annual get-togethers
o Demonstrates, in visible manner, management commitment and support
o Reviews performance of the quality circles regularly on the basis of
reports from the coordinator and facilitators.
o Evolves guidelines for recognizing the good performance of quality
circles.
The head of the Quality Assurance department takes the responsibility of convening the
meeting of the committee.
ii.
Facilitators: The facilitators are selected by the steering committee to
supervise the activities of two, three or more circles. Facilitator is usually a
senior officer nominated by the management who is incharge of shop or
department. The facilitator acts as a teacher, a promoter, a catalyst, and a
guide to the quality circles. The responsibilities of the facilitators include:
o To co-ordinate the activities of quality circles under their supervision and
guidance
o To train QC leaders and lend help in training QC members.
o To interface between circles
o To render support and assistance to the circles under his control.
o To encourage employees to form more QC’s
o To demonstrate support of the management.
iii.
Leaders: A leader acts as an integral part of the quality circle. The leaders
should have good knowledge of statistical methods and approaches to be used
to identify and analysis problems. The leaders also, like other regular
members, participate in the discussions. The leader should preferably be the
first line supervisor but it not essential. Supervisors taking over the task of
leaders ensure some leadership quality inputs are already available.
Responsibilities of the leader are:
o To conduct training of members of the circle with the help of facilitator
and other agencies.
o To prepare agenda for the meetings.
o To organize and conduct meeting
o To evolve action plans and milestone charts to compare actual progress
with targets by periodic reviews and take mid-course correction.
o To assign roles to members and to guide them for effective contribution
towards the achievement of goals.
o To ensure participation and involvement of all members in the activities of
the circle.
o To ensure records and liaison with other agencies to obtain help in solving
the problem
o To catalyse attitudinal changes in his own and other related areas.
o To make management presentations
o To take sincere interest individually by active involvement in the progress
of quality circle movement.
o To endeavour to promote quality circles as a way of life in the
organization.
iv.
Members: Members form hard core of the quality circles; Members are
selected on “purely voluntarily basis” and are from the same or similar
functional areas. The group should basically be small, between 8 to 10
members. The members should have adequate education and experience in the
concerned field and should have the ability to express clearly and freely.
v.
Co-ordinator: In a large manufacturing organization, some agency – usually
Quality Assurance – is required to co-ordinate the activities of the quality
circles. The responsibility of the coordinating department includes:
o Rendering assistance as request by circles
o Disseminating literature relating to circle activities elsewhere
o Organizing training programmes
o Publishing newsletter to communicate circle activities
o Providing circles with necessary facilities for the meeting
o Organizing social get-together for circle members and senior executives
6. “5-S is an excellent technique to achieve good house-keeping”. Discuss.
Ans: Introduction: Good housekeeping is the foundation for and first step towards
quality achievement in a manufacturing organization. It boosts employee morale and
inspires customer confidence.
Good quality of work place is essential as –
1. Good environment has a strong influence on the people and the quality of product
they produce.
2. A customer visiting the plant sees in a quality work place a guarantee for the
product quality.
3. Good housekeeping helps to eliminate waste by identifying non-value added
activities, such as searching for tools, time lost in reaching out to retrieve items,
over production, etc.
4. Housekeeping reflects management’s general attitude towards work in the
organization.
Housekeeping is measured the way
- Factory floor are swept and machines are cleaned
- Tools are stored
- Scarp and chips from machines are handled
- Work tables are organized
- Personal items are stored
- Records are maintained
- Targets and achievements are displayed or communicated to employees.
Good housekeeping is simply the basic to a better workplace and to –
-
Reduce cost of products and service
Achieve discipline in manufacturing
Bring improvement in quality and productivity
5-S (Seiri, Seiton, Seiso, Seiketsu and Shitsuke) are considered in Japan the basics of any
job. 5-S principles have been practiced in Japan the basics of any job. 5-S principles have
been practiced in Japan to establish and maintain quality environment in the organization.
Japanese managements are of the view that if the housekeeping in a plant is weak, no
further diagnosis is needed to know as to why that plant produces poor quality products.
5-S technique has been defined as –
“A systematic and rational approach to work place organization and methodical
housekeeping with a sense of purpose”
Japanese
English
Meaning
How to apply it to the work place?
Seiri
Structurise
Sorting
Classify items into necessary and unnecessary,
retain only those which are required and
dispose off others. (i.e. those not needed)
Seiton
Systematise
Re-organise
Store things systematically to ensure safety,
quality and efficiency. Storage methods must
permit efficient use of space-accident free
stage, long shelf and easy retrievability of
items within pre-fixed target retrieval time.
Seiso
Sanitise
Cleanup
Maintain work place free of dirt/ dust and
garbage by fixing individuals’ cleaning
responsibility.
Seiketsu
Standardize
Shitsuke
Self-discipline
Standardization
Sustain
Maintain cleanliness through Seiri, Seiton and
Seiso by ensuring transparency and uniformly
of everything that is done in the organization.
Make a habit of doing things the way they are
supposed to be done (i.e. developing habit of
following rules/ practices) including 5-S
practices.
Relationship between 5-S’s:
SEIRI
(Organisation
)
SEIKETSU
(Standardisation)
SHITSUKE
(Discipline)
SEISO
(Clean Up)
SEITON
(Maintenance)
7. What is SMED? How is it used to reduce setup time of an operation?
Ans: Introduction: Every organization must increase line of its products, accept low
volume orders, shorten delivery lead time, and keep its cost low to maintain its market
share in a competitive market. The organization must cut production lead time and
decrease production batch sizes. It should also reduce inventory levels in the production
and inventory systems. Since small batches require frequent changeovers, production
capacity is expected to shrink unless setup times are reduced. Set up time reduction,
therefore, is the key to developing or monitoring a company’s competitiveness in today’s
market where more diversified products are desired at short production lead time.
Quick Die/ set up change is not restricted to set-up reduction of press shop alone, it can
be extended to all areas of manufacturing wherever there is requirement of tool change/
set up on a machine prior to manufacturing.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
Presses
Multi-spindle automats
Lathes, turret lathes
Milling machines
Drilling machines
Broaching machines.
Forging machines
Paint manufacturing equipment
Powder coating machines
Oil extracting mill
Meaning:
Set up time is the time required to prepare a machine or a group of machines to
changeover from one job to another. Time of a conventional set up consists of following
tasks.
(a) The time to study blue print , including time spent on receiving instructions from
supervisor or foreman.
(b) The time to go to tool crib to get necessary tools and gauges, etc and to return the
tools used to previous job.
(c) The time to select fixture (Vice, mandrel, suitable sized collets, face plate, etc)
and secure it to the bed of the machines.
(d) The time to install/ mount necessary tools on to the machine, make adjustments,
set longitudinal or traverse feed stoppers wherever necessary to ensure that each
tool cuts properly and to dimensions.
(e) The time to call the inspector and get inspection done (pilot piece inspection).
Alternatively it is the time necessary to deliver the part to the inspection booth for
inspection. Inspection time, however, does not include time to manufacture the
part.
(f) The time spent by the operative, over and above the unit standard time, to produce
first few pieces.
(g) The time to physically count the jobs produced, including time to sign the
completed work-order.
(h) The time to remove tools from their tool-holders after required quantity has been
manufactured, clean each tool and put it away in proper place.
(i) The time to clean measuring instruments and put them away in proper places.
(j) The time to release and remove fixture blow or brush it clean and keep it aside.
(k) The time to remove borings, turning, drilling etc, from the bed of the machine.
Normally, turnings/ drillings/ borings should be removed by a helper (even when
the production is in progress) when these gather in large quantity. However, burns
removal, would have to be considered part of set up operation if different material
is required on the next job (e.g. Steel for the job just completed and brass for the
job to be loaded).
Traditional set up operations involve several kinds of waste and SMED technique was
developed to eliminate waste and to reduce set up time from hours to minutes. SMED
also has interesting history of development.
Reduction in set up time results in the following benefits:
o Reduction in batch sizes
o Lowering of manufacturing lead times
o Drop in inventory levels
o Reduction in set-up scrap
o Increase in machine efficiency
o Increased flexibility to respond to changes.
The firm desiring to reduce change-over time may not achieve its target figure in one
attempt, but after a series of improvements. From its current level of set up time of
double digit on a particular machine, it may be able to reduce to single digit hours. And
subsequently on the same machine from single digit hours to double digit minutes, still
later from double digit minutes to single-digit ones and finally in to few extreme
situations one touch change over.
Comp.
A run
Study
blue
print
Remove Replace Install tools Sample
existing too at the for the new run
crib store job
Run for
component
A
SETUP
Component
A
Adjust
Sample
run
Elimination of sample
runs, inspection,
adjustments
Run for
component
B
Component
B
Setup
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 not
add any value while machine does (MUDA of Waiting)
o A maintenance engineer who walks over a long distance with tool in his hand,
does not add any value (value is added when he uses the tool to fix the machine) (
MUDA of Transport)
o Piles of material lying in racks in the stores don’t add any value but add to cost
(MUDA of Stock)
o A material handler while pushing a heavy trolley full of parts, even though
perspiring, adds no value (MUDA of Transport)
o An assembly operator, overstretching his hand to pick up parts for assembly, adds
no value but causes fatigue to himself (MUDA of Motion)
o A welding operation, performed to join metal parts of assembly constituent, does
add value but the welding operation performed to repair weld a blowhole in job is
a non-value added activity (MUDA of Processing)
Waste (MUDA) is the major element of company’s product cost and must be
continually identified and eliminated from its processes to stay competitive.
Since labour cost is hardly 8-10% of total cost (which also is on the decline due to
recent advances in manufacturing technologies), we also need to look at various other
hidden wastages, besides human waste, to improve productivity.
Types of MUDA:
There are seven types of MUDA in manufacturing:
1. MUDA of Over Production.
2. MUDA of Stock (inventory)
3. MUDA of Waiting
4. MUDA of Transport
5. MUDA of Defects
6. MUDA of Motion
7. MUDA of Processing
b) What Causes MUDA of “Motions”? How can it be eliminated?
Ans: Introduction: A workman while performing a task makes use of a number of
motions. The scrutiny of these motions may reveal that some of these motions –
o Are unnecessary and can be eliminated
o Can be combined / modified by changing their sequence
o Can be simplified by effecting changes in work bench layout
o Can be performed efficiently by other members of the body.
In the absence of the above mentioned actions, the workman makes motions which don’t
add any value. Typical examples are –
o
o
o
o
o
Walking to reach objects/ parts. Tools
Lifting or carrying objects
Picking up and putting down a work piece
Transferring objects from one hand to another
Searching to find the required object
While dealing with MUDA of motion it is recommended to get rid of operations that are
difficult dirty and / or dangerous (3D’s). such actions include –
o
o
o
o
Work that makes and employee move over long distances
Work that causes physical strain (i.e. use of undue physical effort)
Work that causes mental strain (e.g. work that needs memorizing lot of details)
Work that involves search or unnecessary sorting.
Tools and techniques to eliminate MUDA of Motion:
i)
ii)
iii)
Improvement in layout: Lifting or carrying a heavy object is undesirable on
two counts, firstly because it represents MUDA and secondly it causes
physical exertion. The need for the operator to carry a heavy object can be
eliminated by rearranging the work place.
Motion economy principles: Motions of the hands/ legs can be shortened and
some of them can be eliminated by rearranging the parts on work table and
development of tools and jigs.
Effective supervision: Finding workmen busy with their jobs may give
supervisor satisfaction but it may do no good to the company. A supervisor
must watch closely his people to find as to –
- What are they doing?
- How are they doing?
- Do they need to do what they are doing?
- Are they doing the right way?
- Are they doing work which adds value?
- Are they using motions of the lowest classification?
List down different kinds of human errors. How can they be eliminated? How is
PokaYoke technique useful to eliminate human errors?
Ans:
Type of
Error
Forgetfulness
Description of the
error
Typical examples
Remedial action
3. Operator skipping an
operation.
4. Operator forgetting to
tighten bolts
5. station master forgetting to
lower the crossing gate
Forgetting to do a
thing
6.
1. Altering operator in advance
2. Checking at regular intervals
3. Verification by another
employee
1.
1. Putting foot on clutch
thinking it is brake
Misunderstan
ding
Jumping to the
wrong conclusion
due to poor
familiarity with the
situation
Mistaken
identity
Misjudging a
situation
1. Mistaking Rs.500 note as
Errors by
amateurs
Lack of experience
1. Improper welding
2. Wrong measurements
1. On-the-job training
2. Work Standardisation
Willful errors
Ignoring rules/
deliberate wrong
actions
1. Ignoring safety rules
2. Crossing a street against
1. Attitude change.
2. Education
Inadvertent
errors
Absent mindedness
i.e. not knowing how
the problem / error
has occurred
1. Removing job before
completing drilling of all
holes
2. Crossing street without
noticing that the light is red
Judgmental
errors
Errors due to absence 1. Difference in method of
measurement used by
of instructions of
vendor and by buyer’s
work standards
Rs.100 note
a red light just because
there are no vehicles in
sight at the moment.
3. Not replacing blunt tool
on time
1. Training
2. Checking in advance
3. Standardizing work
procedures.
1. Improving attentiveness.
1. Improving attentiveness
2. Work standardization
1. Works instructions
2. Work standardization.
inspection
2. Operator deciding his own
Errors due to
absence of
standards
Lack of instructions
or absence of work
instructions
Measurements left to the
discretion of the workman
1. Works instructions
2. Work standardization.
“Poka-Yoke” is a combination of two Japanese words, “Poka” meaning “inadvertent
errors” and “Yoke” (derived from Japanese word Yokerie) meaning “to avoid” and
together they translate as “Error/ mistake proofing” or “Fool proofing” or “Failsafing” a
work process system to eliminate inadvertent errors.
Poka-Yoke is a powerful and comprehensive tool for identification, measurement and
analysis of mistakes/ defects at the Gemba (real piece of work) and implementation of
measure that prevent the activity from being incorrectly performed, thereby ensuring
production of quality goods and services.
Errors are inevitable but can be eliminated, using Poka-Yoke technique. This is the
technique that can help to analyse the kinds of mistakes employees make and to eliminate
these mistakes by implementing / installing simple Poka-Yoke devices.
Poka-Yoke Devices:
Poka-Yoke may be designed either to help the operator to recognize the defect before it is
about to occur called “Prevention type Poka-Yoke” or to help the operator to know
immediately on occurrence of the defect called “Detection type Poka-Yoke”.
Some of the Poka-Yoke devices which can help to avoid defects are –
1.
2.
3.
4.
5.
6.
Guide Pins / locators
Error detection buzzers/ alarms and blinking lights
Limit switches
Counters
Color coding
Checklist
9.a) What is Kaizen? What are different types of Kaizen?
Ans: Introduction: Kaizen is a combination of two Japanese words, “Kai” and “Zen”,
Kai means “to change or modify” and Zen means “to improve or make better” and
together they translate as “improvement”. Kaizen when used in the context of a
management process, has come to mean as continual and slow improvement in every
aspect of management (i.e. improvement in whatever company does and the way it does
things) through the active involvement of all company’s employees. Kaizen does not just
merely mean doing things better but it is an unending process to eliminate muda, improve
quality, cost and delivery, thereby creating more and more customers.
Few Definitions:
Kaizen is a management supported, employee driven process, where employees seek
development of their own capabilities by challenging existing system and finding
improvement in them
R.R. Asawa & Dr. D. R. Baheti
Kaizen is a program, a philosophy and a strategy to improve quality of goods and
services or an organization Samuel KHO
Kaizen means making a great number of continuous lasting improvements by discovering
small problems and eliminating them permanently (attacking root causes of the
problems) thereby helping the organization in setting and reaching higher standards of
performance.
Surindra Narang
The Spirit of kaizen is that whatever you are doing, you can do better. Kaizen thus helps
in setting and reaching higher standards of performance.
The word “Kaizen” was used for the first time by Maasaki Imai, who wrote a look of
same name. although a registered name of Kaizen Institute, the work is now widely used
and understood all over the world to mean “continuous improvement”. The word
“Kaizen” also now appears in the English dictionary. Recently, Imai has elaborated on
Kaizen in his book titled “Gemba Kaizen”
Types of Kaizen:
Kaizen depending upon the complexity and level, can be placed into one of three
categories
1) Management Kaizen
2) Group Kaizen
3) Individual Kaizen
1) Management oriented Kaizen: Concentrates on strategic issues and often
involves people from different departments working together on cross-functional
problems as project teams. Typical examples of management oriented Kaizen are:





Identification and elimination of waste in workers motions
Charges in plant layout for better efficienvy
Reduction in buffer stocks
Just-in-time production
System improvement
2) Group oriented Kaizen: Concentrates on improvement within the same
workplace or department brought about by employees working in small groups,
called quality circles. Typical areas of group Kaizen generally include –




Productivity improvement
Defect prevention
Accident prevention
Absenteeism
3) Individual oriented Kaizen: Concentrates on issues concerning worker’s own
work area and improvements are brought about through worker’s own
suggestions. Problems solved through individual Kaizen generally include –
 Improvement in machines and processes




Improvement in jigs and fixtures
Reduction in defect level
Customer service and customer complaints
Improvements in working environment.
b) Discuss in brief the Kaizen process and its steps.
Ans: Introduction:
Kaizen process provides a disciplined and analytical approach, sometimes called the
kaizen story to problems solving. It consists of a series of sequential steps that can be
used to guide a group (say an improvement team) for the process of identifying and
fixing problems. The Kaizen story (or Kaizen process) is built on PDCA mnemonic –
Plan, Do, Check and Act. The Kaizen process is a seven step basic procedure which
allows any individual or team to solve problems scientifically, rationally, effectively and
efficiently. These seven steps are –
1. Defining the problem
2. Understanding/ assessing the current status
3. Finding the root cause.
4. Planning counter measures
5. Implementing counter measure
6. Verifying results
7. Standardising and establishing control.
A brief of each of the steps in the Kaizen process is given.
Fig: Problem definition phase
Poka-yoke for
failsafing
Model machine
exercises in TPM
Spotting abnormalities at
Gemba
Cost of Quality
SMED/ JIT
Targets
Exercises to identify MURA,
MUDA and MURI
Problems
Internal customer’s
complaints
5-S Audits
External customer’s
complaints
ISO-9000, QS-9000
and ISO-14000 nonconformities
Define Problems
Enlist problems
Prioritize problems
Select topics for Kaizen
Assign themes to
Kaizen teams
problems
Conduct PDCA-SDCA
improvement cycles
When Deming cycle is used as a tool for systematic problem solving (improvement), the
PDCA activities take the form as shown below…
Process Steps
Objective
Element of PDCA
cycle
The “PLAN” element
Defining the problem
Identification of the problem
Understanding /
Assessing Current status
Establishing the base from which The “PLAN” element
you are trying to improve
Finding the root cause
Identifying underlying causes of The “PLAN” element
the problem
Planning counter
measures
Preparing action plan to fix the
problem
The “PLAN” element
Implementing counter
measures
Implementing the action plan
The “DO” element
Verifying results
Confirming the effect of
implementation
The “CHECK” element
Standardizing and
establishing control
Consolidating the change
The “ACT” element of
PDCA and / or + the
STANDARDIZE
element of SDCA
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Select The Blank
Question
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 inspection
Your 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 as
bell) shape tapering away on both sides from ________ value.
Correct Answer Average
Your Answer
Maximum
Select The Blank
Question
Capability index Cp = ________
Correct Answer Specification width/process width
Your Answer
Specification width/process width
Multiple Choice Single Answer
Question
Customer's return is an indicators of the MUDA of :Correct Answer Defect
Your Answer
Defect
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 , Payment problem
Select The Blank
Question
JIT helps to ________ the waste in the purchasing process.
Correct Answer Eliminates
Your Answer
Eliminates
True/False
Question
Pie chart is also called as angular diagram.
Correct Answer True
Your Answer
False
True/False
Question
Review is important step in problem solving.
Correct Answer True
Your Answer
True
Select The Blank
Question
To assess effectiveness of training ________ is essential.
Correct Answer Evaluation
Your Answer
Re training
Select The Blank
Question
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
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Your Answer
Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control ,
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/False
Question
Automation can correct the basic faults of a improper setup
process.
Correct Answer False
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 union
Your Answer
Problems headed by worker group must be simple & within their
limit , Unions in India are reluctant , Management is also not
open for union , Worker attitude only for financial benefit
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
True/False
Question
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 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 , Make your own methods for individual
success
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 com panies in industry
survey , Consultant
Your 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/False
Question
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 :Correct Answer Faulty layout , Over production
Your Answer
Faulty layout , Over production , Proper material handling
equipment , Low rejection / rework
True/False
Question
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 Blank
Question
________ is the root cause of the problems.
Correct Answer Variation
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 Blank
Question
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
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
Multiple Choice Single Answer
Question
The concept of quality circle was mooted by :Correct Answer Prof. Kaoishikawa
Your Answer
Japanese unit of scientist & engineers(JVSE)
True/False
Question
Seiso prevents the potential problems by discovering
abnormalities while cleaning your own area.
Correct Answer True
Your Answer
True
Match The Following
Question
Correct Answer
Your Answer
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 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 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 , 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 Blank
Question
Histogram is a diagrammatic presentation of the ________
distribution of characteristics such as strength, diameter, etc.
Correct Answer Frequency
Your Answer
Frequency
True/False
Question
A radar chart is combination of a circle & line graph
Correct Answer True
Your Answer
False
Select The Blank
Question
Kaizen is ________ supported process.
Correct Answer Management
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
Question
Correct Answer
Your Answer
Control chart can be used As process monitoring
tool
Stability of the process
Control chart is a
graphical method of
checking
For quality monitoring
Stability of the process
Control chart can be used How much variability in
How much variability in the
to determine
the process is due to
process is due to random
random causes & how
causes & how much is due
much is due to assignable to assignable causes
causes
Control chart is a chart
with UCL & LCL placed
At 3 Sigma distance on
At 6 Sigma distance on
either side of the process either side of the process
average
average
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 , Count
the tally marks i.e. frequency in each class & construct a
histogram 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 sheet
determining the cell or class into which each value falls , Count
the tally marks i.e. frequency in each class & construct a
histogram 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 as
per 80%=20% rule
True/False
Question
Exercise to identify MURA, MUDA & MURI is not helpful to
identify problems.
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 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' , Circulate
flowchart
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Select The Blank
Question
________ is management skill.
Correct Answer Delegation
Your Answer
Delegation
Multiple Choice Multiple Answer
Question
While preparing scatter diagram following precautions are to be
taken :Correct Answer Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
Your Answer
Data should be properly stratified & should be collected for full
range
True/False
Question
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
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
True/False
Question
Kanban signals are required when assembly work, subassembly
work and manufacturing at parts is carried out at different
locations.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
Histogram always indicates :Correct Answer Only height
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
Multiple Choice Multiple Answer
Question
Process can be made capable by :Correct Answer Examine possibility of relaxing specification , Reducing process
variability , Bringing target & average to fall at the same point
Your Answer
Reducing process variability , Bringing target & average to fall at
the same point , Examine possibility of relaxing specification
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
six sigma implementation , Monitor progress of six sigma
projects
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 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
Multiple Choice Single Answer
Question
JIT manufacturing emphasizes workplace improvement through
:Correct Answer 5 'S'
Your Answer
5 'S'
True/False
Question
Without review PDCA cycle not completed.
Correct Answer True
Your Answer
True
Select The Blank
Question
To eliminate muda of processing, ________ exercise is
essential.
Correct Answer ECRS
Your Answer
ECRS
True/False
Question
Control limits of control charts should be revised from time to
time as additional data is accumulated.
Correct Answer True
Your Answer
True
Select The Blank
Question
________ participants in monthly meeting(MRM)
Correct Answer GM, operation heads, corporate functional heads
Your Answer
GM, operation heads, corporate functional heads
Select The Blank
Question
Suppliers may________ their prices to cover for cost of delivery,
small production run etc.
Correct Answer Raise
Your Answer
Raise
True/False
Question
Create as many visual controls as possible to achieve visual
management is the principle of "Shitsuke"
Correct Answer True
Your Answer
False
True/False
Question
Flow charts are used to train new employees by providing
documented description of the task involved.
Correct Answer True
Your Answer
True
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
Your Answer
Color coding
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer Improve quality
Your Answer
Improve quality
Match The Following
Question
Correct Answer
Your Answer
Any thing misplaced
should be visual
immediately
Seiketsu
Display Colour codes
meanings
Unrepairable tool or
equipments
To be scrapped under
Seiri
To be scrapped under Seiri
Colour coding essential
throughout but
Display Colour codes
meanings
Colour codes as per
departments
Surprise Audit any time
should shout consistent
good housekeeping
Shitsuke for maintenance Seiketsu
of 4-S
Multiple Choice Single Answer
Question
5-S technique is useful to:
Correct Answer To all places including homes
Your Answer
To all places including homes
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
Select The Blank
Question
Kaizen is ________ supported process.
Correct Answer Management
Your Answer
Management
True/False
Question
By cutting the cost of quality, profitability decreases.
Correct Answer False
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 Blank
Question
Poka Yoke is ________.
Correct Answer Simple technique
Your Answer
Simple technique
Multiple Choice Single Answer
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 :Correct Answer Faulty layout , Over production
Your Answer
Faulty layout , Over production
Multiple Choice Multiple Answer
Question
For the presentation of the quality circle project what is required
is :Correct Answer Presentation skills , Graphical data , Progressive efforts of the
team work
Your Answer
Presentation skills , Graphical data
Select The Blank
Question
________ is responsible for effective implementation of action
plan's under TPM.
Correct Answer Steering committee
Your Answer
Steering committee
Match The Following
Question
Correct Answer
Your Answer
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
Multiple Choice Multiple Answer
Question
Benefits of TQM are :Correct Answer Greater customer satisfaction , Lower manufacturing cost
Your Answer
Greater customer satisfaction , Lower manufacturing cost
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
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 job
Your Answer
Lack of knowledge of the TPM , Resistance to change , Fear to
loss of job
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
Each quality characteristic has permitted variation & is equal to
________.
Correct Answer USL - LSL
Your Answer
USL - LSL
Select The Blank
Question
Flow chart helps to provide clarity of the ________ without
visiting actual spot.
Correct Answer Process
Your Answer
Process
True/False
Question
Automation can correct the basic faults of a improper setup
process.
Correct Answer False
Your Answer
True
Multiple Choice Single Answer
Question
In problem solving the best alternative is that :-
Correct Answer Which best meets the criteria
Your Answer
Which best meets the criteria
True/False
Question
Benefits of DWN is faster response to customer needs.
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
True/False
Question
Daily work management can also be extended to non
manufacturing areas like procurement, QA, HRD etc.
Correct Answer True
Your Answer
True
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
Quality maintenance & pillar focuses on following production
inputs :Correct Answer Material , Men , Machine
Your Answer
Material , Men , Machine
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Your Answer
Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Multiple Choice Single Answer
Question
In problem solving the best alternative is that :Correct Answer Which best meets the criteria
Your Answer
Which best meets the criteria
Multiple Choice Single Answer
Question
"Cause & effect" diagram was developed by :Correct Answer DR.Kaoru Ishikawa
Your Answer
DR.Kaoru Ishikawa
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
Your Answer
Internal benchmarking
Select The Blank
Question
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 is positive relationship upto certain level & negative
thereafter or negative relationship upto certain level & positive
thereafter.
Correct Answer Curvilinear
Your Answer
Curvilinear
True/False
Question
Kanban signals are required when assembly work, subassembly
work and manufacturing at parts is carried out at different
locations.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
Customers complaints may be segregated by :Correct Answer Nature of compliant i.e. defective product , Delayed delivery ,
Short/excess quantity
Your Answer
Nature of compliant i.e. defective product , Delayed delivery ,
Short/excess quantity
True/False
Question
In case of more than one quality characteristics, separate chart
is made for each quality characteristics.
Correct Answer True
Your Answer
True
True/False
Question
Safety, hygiene and environment control is one of the pillar of
TPM.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
5-S technique is useful to:
Correct Answer To all places including homes
Your Answer
To all places including homes
Match The Following
Question
Correct Answer
Your Answer
Reduce time of external
setup
Improve work aids
positioning method
Improve work aids
positioning method
Convert internal setup into Preparation of tools / dies Preparation of tools / dies
external setup
as off line activity
as off line activity
Eliminate adjustment
Pre setting of tool
Pre setting of tool
Reduce clamping &
declamping time
Use U-shaped washer
Use U-shaped washer
Multiple Choice Single Answer
Question
The facilitator should be normally :Correct Answer Senior officer /Shop incharge
Your Answer
Senior officer /Shop incharge
Match The Following
Question
Parato diagram always
indicates
Correct Answer
Your Answer
Magnitude of defects
Philosophy of 20% of the
activity causes 80% of the
effect
Parato analysis underlines Philosophy of "vital
& operates on
few:trivial many"
Philosophy of "vital
few:trivial many"
Parato analysis is
technique of identifying
vital causes by
Arranging data according
to the descending order of
their frequency of
occurrence
Arranging data according
to the descending order of
their frequency of
occurrence
Parato diagram is a Bar
Arranging data in
graph with height or value descending order
drawn by
Magnitude of defects
Multiple Choice Single Answer
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 Blank
Question
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 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 Performance , Features , Cost
Your Answer
Performance , Features , Cost
Multiple Choice Multiple Answer
Question
Steps in construction of scatter diagram :Correct Answer Collect paired data (X,Y) from two variables who's relationship is
to be studied , Find out max & min values for both X & Y and
these values to scale X & Y axis & plot the paired data , Examine
the shape of the cloud of points & discover type & strength of
relationship
Your Answer
Collect paired data (X,Y) from two variables who's relationship is
to be studied , Find out max & min values for both X & Y and
these values to scale X & Y axis & plot the paired data , Examine
the shape of the cloud of points & discover type & strength of
relationship
Multiple Choice Single Answer
Question
Implication of Quality problem is: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 Blank
Question
Kaizen is ________ supported process.
Correct Answer Management
Your Answer
Management
True/False
Question
The flow charts are prepared to enhance the employees
understanding of the process by indicating interrelationship
within the process.
Correct Answer True
Your Answer
False
True/False
Question
Gap analysis for production & dispatches is discussed in monthly
meeting.
Correct Answer False
Your Answer
False
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
Your Answer
Strong negative
Select The Blank
Question
________ is most difficult 'S' to implement & achieve.
Correct Answer Shitsuke
Your 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
Question
Graphs convey a situation more ________ than summary of
data or figures.
Correct Answer Effectively & clearly
Your Answer
Effectively & clearly
Multiple Choice Single Answer
Question
Errors by armatures is :Correct Answer Lack of experience
Your 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 for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
Your Answer
Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
True/False
Question
Globalization of trade and industrial operations have forced
Indian companies to become more & more competitive and
customer driven.
Correct Answer True
Your Answer
True
Multiple Choice Multiple Answer
Question
If 'Annual saving in procurement expenses is managing point',
then checking points will be :Correct Answer Price revision , Credit period , Transport expenses
Your 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
True/False
Question
Two to three per year
Flow chart is pictorial representation of the steps in production
control.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
It is essential to convey customer's expectations to :Correct Answer Top Management
Your Answer
Supervisors & workmen
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
Select The Blank
Question
Identification of non-value added operations & their elimination is
the first step to eliminate muda of ________.
Correct Answer Processing
Your Answer
Processing
Select The Blank
Question
A 'Radar chart' is used to portray ________ strength or
weakness of the activity.
Correct Answer Relative
Your Answer
Relative
Multiple Choice Single Answer
Question
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 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 , Improved
maintainability mean time to repair , Improvement in breakdown
Your Answer
Improved reliability mean time between failures , Improved
maintainability mean time to repair
Multiple Choice Multiple Answer
Question
Gap analysis & problem identification is done during converting
internal setups into external setups in the areas like :Correct Answer Equipment , Method , Human
Your Answer
Equipment , Method , Human
Multiple Choice Single Answer
Question
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 Answer
Question
Sorting of usable items should be
Correct Answer Planned storage based on frequency of use
Your 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 time
Your Answer
Reduction in customer quality complaints , Reduction in
inspection time
1. TPM
1. Waste elimination
2. JIT
2. Visual management
3. Kanban
3. Best way of doing job
4. Work standards
4. Reducing breakdown of machines
5. Pull system
6. Statistical process control
1. Parato analysis underlines &
operates on
1. Arranging data according to the
descending order of their frequency of
occurrence
2. Parato analysis is technique of
identifying vital causes by
2. Philosophy of 20% of the activity causes
80% of the effect
3. Parato diagram is a Bar graph
with height or value drawn by
3. Magnitude of defects
4. Parato diagram always
indicates
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)
Unity
b)
Zero
c)
Infinity
d)
Six
U shape arrangement of layout provides the operator
48.
Quality problems may be segregated by & regrouped by :-
a)
Machines
b)
Workers
c)
Materials
degree of mobility.
d)
Suggestion
LIST OF ATTEMPTED QUESTIONS AND ANSWERS
Multiple Choice Multiple Answer
Question
TQM can never flourish if the staff are:Correct Answer Scared of their bosses , Worried about losing jobs , Afraid of
being reprimanded if there are mistakes
Your Answer
Scared of their bosses , Worried about losing jobs , Afraid of
being reprimanded if there are mistakes
Multiple Choice Single Answer
Question
Quality problem solving tool is used to :Correct Answer Improve quality
Your Answer
Improve quality
Multiple Choice Single Answer
Question
The concept of quality circle was mooted by :Correct Answer Prof. Kaoishikawa
Your Answer
Prof. Kaoishikawa
Match The Following
Question
Correct Answer
Your Answer
SMED
Setup time reduction
Setup time reduction
5 'S
Cleanliness
Total productive
maintenance
Muda elimination
Waste elimination
Waste elimination
Poka-Yoke
Error proofing
Error proofing
Multiple Choice Single Answer
Question
Allowing worker's to stop machine / assembly line if they believe
that product quality is below standard' is an example of :Correct Answer Empowerment
Your Answer
Involvement
Select The Blank
Question
Kaizen is ________ supported process.
Correct Answer Management
Your Answer
Workmen
Select The Blank
Question
Ratio of ________ to the number of pieces inspected is called
fraction defectives.
Correct Answer Number of item rejected
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 Single Answer
Question
Implication of Quality problem is:Correct Answer Gap in performance
Your Answer
Gap in performance
Multiple Choice Multiple Answer
Question
Steps to six sigma process consists of :Correct Answer Identify the work you do , Identify your customers , Map the
process
Your Answer
Identify the work you do , Identify your customers , Map the
process
Multiple Choice Single Answer
Question
From scatter diagram the strength of relationship between two
variables or associated set of data can be inferred from the
examination of the shape of :-
Correct Answer Cloud
Your Answer
Cloud
True/False
Question
Non-availability of files /document in time is a problem to be
addressed by office TPM.
Correct Answer True
Your Answer
True
Select The Blank
Question
________ used to detect drop in air pressure.
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
Multiple Choice Multiple Answer
Question
The aim of education & training under TPM is :Correct Answer To develop abilities to respond quickly to abnormalities , To
develop abilities to discover analyze malfunction
Your Answer
To develop abilities to respond quickly to abnormalities , To
develop abilities to discover analyze malfunction , To have
multiskilled employees in all departments
Match The Following
Question
In scatter diagram, the
strength of relationship
can be determined
Correct Answer
Your Answer
By "correlation coefficient" By "correlation coefficient"
The scatter diagram
The possible relationship
provides the technique to between a pair of
establish
variables
The possible relationship
between a pair of variables
The scatter diagram
displays
The pair of data as a cloud
of points
The pair of data as a
cloud of points
The scatter is also known Correlation diagram
as
Correlation diagram
True/False
Question
Flow chart is pictorial representation of the steps in production
control.
Correct Answer False
Your Answer
True
Multiple Choice Single Answer
Question
Pareto's analysis underlines & operates philosophy of :Correct Answer Vital few = trivial many
Your Answer
Vital few = trivial many
Multiple Choice Single Answer
Question
Pareto diagram always indicate magnitude of :Correct Answer Defect
Your Answer
Influence of defect
True/False
Question
By cutting the cost of quality, profitability decreases.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
Check sheet is easy to use because it is :Correct Answer Simplest tool
Your Answer
Simplest tool
True/False
Question
The flow charts are prepared to enhance the employees
understanding of the process by indicating interrelationship
within the process.
Correct Answer True
Your Answer
True
Multiple Choice Single Answer
Question
Abnormal variations can occur if :-
Correct Answer There are assignable causes
Your Answer
There are assignable causes
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
True/False
Question
Control limits of control charts should be revised from time to
time as additional data is accumulated.
Correct Answer True
Your Answer
True
Select The Blank
Question
Kaizen is an excellent method to involve ________ to unearth &
eliminate hidden waste.
Correct Answer Employees
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
Select The Blank
Question
Cp for six sigma process is ________
Correct Answer 2
Your Answer
2
Select The Blank
Question
________ participants in monthly meeting(MRM)
Correct Answer GM, operation heads, corporate functional heads
Your Answer
True/False
Department heads & supervisors
Question
Processing cost of a product is mainly decided by conversion
process.
Correct Answer True
Your Answer
True
Select The Blank
Question
Production in last shift & production plan for next shift is
discussed during ________.
Correct Answer Shift beginning & shift end/change meeting
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 reduce
inspection
Your Answer
To eliminate handling , To reduce transporting , To reduce
inspection
True/False
Question
Inadequate maintenance of machine leads to muda of defects
Correct Answer True
Your Answer
True
True/False
Question
Most of the external setups are treated as internal setup.
Correct Answer True
Your Answer
False
Multiple Choice Multiple Answer
Question
Benefits from SMED are :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 Multiple Answer
Question
Typical examples of process benchmark are :Correct Answer Procurement procedures , Budgeting , Recruitment
Your Answer
Procurement procedures , Budgeting , Recruitment
True/False
Question
Low level of delegation is an example of muda in office.
Correct Answer True
Your Answer
False
Multiple Choice Multiple Answer
Question
Histograms are useful to :Correct Answer Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Your Answer
Measure the current pattern & extent of variation , Assess
current conformance to specification & scope of improvement ,
Determine whether or not the process is in the state of control
Multiple Choice Multiple Answer
Question
While preparing scatter diagram following precautions are to be
taken :Correct Answer Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
Your Answer
Data should be properly stratified & should be collected for full
range , Scale selected should be right to avoid wrong
conclusions , Data should be free from bias or undue importance
Multiple Choice Single Answer
Question
Through continuous improvement in the process & procedures,
kobetsu-kaizen is continuously improve utilization of :Correct Answer Worker, equipment & material
Your Answer
Workers & materials
True/False
Question
Every department should make their own rules of
standardization.
Correct Answer False
Your Answer
False
Multiple Choice Single Answer
Question
Quality circle should consist adequate experienced members
between :Correct Answer 8 to 10
Your Answer
8 to 10
Multiple Choice Single Answer
Question
Number of kaizen in Group kaizen categories are :Correct Answer Two to three per year
Your Answer
As many as management decides
Select The Blank
Question
Flow chart helps to provide clarity of the ________ without
visiting actual spot.
Correct Answer Process
Your Answer
Process
Multiple Choice Single Answer
Question
Gap in performance = Ideal situation minus :Correct Answer Current situation
Your Answer
Current situation
Select The Blank
Question
Seminar talks and video show are organized to introduce TPM
concept to ________
Correct Answer General employees
Your Answer
General employees