Quality Control MCQ Quiz - Objective Question with Answer for Quality Control - Download Free PDF

Explanation:

Flat Day Rate Basic Wage Incentive Plan:

• The flat day rate basic wage incentive plan is a wage payment system where employees are compensated based on the number of hours worked, irrespective of their individual performance or the quantity of output produced. This system ensures that employees receive a consistent and predictable wage for the time they spend working, promoting stability and fairness in compensation.
• In this system, the primary factor for determining the wages of an employee is the total number of hours they have worked. The hourly rate is predetermined, and employees are paid accordingly. For instance, if the agreed-upon hourly rate is ₹100 and an employee works for 8 hours in a day, they will receive ₹800 for that day, regardless of the tasks completed or the output delivered.

Advantages:

• Simplicity: This wage system is straightforward to understand and implement, as it eliminates the need for complex calculations based on performance metrics.
• Predictability: Employees can anticipate their earnings based on the number of hours worked, providing financial stability.
• Focus on Time Management: Since wages are tied to hours worked, employees are motivated to manage their time effectively.
• Equity: This method ensures that employees are paid equally for the same number of working hours, fostering a sense of fairness.

Disadvantages:

• No Incentive for High Performance: As wages are not linked to individual performance or output, employees may lack motivation to exceed expectations or deliver higher productivity.
• Potential for Time Mismanagement: Since wages are based on hours worked, there may be instances where employees prioritize time logged over actual productivity.
• Limited Flexibility: This system does not accommodate variations in workload or the complexity of tasks performed.

The correct answer is Option 1.

Key Points

• Implementing Total Productive Maintenance (TPM) involves several challenges and disadvantages that need to be considered.
  • It is a time-consuming process: Implementing TPM requires a significant amount of time and effort to train employees, set up new procedures, and ensure that they are followed consistently.
  • Cultural changes required are often difficult to implement: TPM often requires a shift in organizational culture towards proactive maintenance and continuous improvement, which can be difficult to achieve and sustain.

Additional Information

• Statement 3, "The process is self-initiating and doesn’t need convincing efforts," is incorrect because TPM typically requires significant effort to convince and motivate all employees to participate.
• Statement 4, "It can be introduced easily across all industries," is also incorrect as the ease of introducing TPM can vary greatly depending on the industry and specific organizational context.

The correct answer is Option 3.

Key Points

• Assertion (A): Total Productive Maintenance (TPM) significantly improves employee morale and teamwork.
  • TPM is a holistic approach that involves all employees in an organization, from top management to front-line workers.
  • By involving everyone in maintenance activities and continuous improvement, TPM fosters a sense of ownership and collaboration.
  • This leads to improved employee morale as everyone feels responsible for and contributes to the success of the organization.
• Reason (R): TPM is only implemented by maintenance staff and top management.
  • This statement is incorrect because TPM requires the involvement of all employees, not just the maintenance staff and top management.
  • Therefore, while TPM does improve employee morale and teamwork, the reason provided is false.

Additional Information

• TPM aims to achieve perfect production (zero defects) and zero breakdowns by involving all employees in proactive and preventive maintenance activities.
• It uses various pillars such as autonomous maintenance, focused improvement, and training to achieve these goals.
• TPM also emphasizes safety, health, and environment (SHE) as a fundamental aspect of its implementation.
• By promoting a culture of continuous improvement, TPM helps in reducing downtime, improving productivity, and enhancing the overall efficiency of the organization.

The correct answer is Option 2.

Key Points

• Seiri stands for sorting and separating needed items from unneeded ones.
• Seiketsu ensures cleanliness through cleanup campaigns.
• Shitsuke is about forming the habit to maintain the previous 4S processes.
• Seiton refers to setting things in order, not maintaining workplace discipline.

Additional Information

• The 5S methodology is part of Total Productive Maintenance (TPM) and focuses on organizing, cleaning, developing, and sustaining a productive work environment.
• The 5S's are derived from five Japanese words: Seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain).
• Correct implementation of the 5S principles can lead to improved efficiency, reduced waste, and a safer work environment.

Explanation:

Six-sigma:

• Six-sigma is an business statistical strategy.
• It is used to identify defects, and removing them from the process of products to improve quality.
• Bill Smith, "Father of six-sigma" introduces this quality improvement methodology to Motorola.

6M's of six-sigma:

Process variation in six-sigma is defined in terms of 6M's i.e. 6 elements contribute to variation in a process. They are:

• Method
• Man
• Machines
• Materials
• Measurement
• Mother nature

Explanation:

Bar chart:

• The bar chart is the technique of project management. It consists of two co-ordinate axes in which the time required for the completion of the activity is marked on the X-axis and actively involved in its execution of the project is marked on Y-axis in form of bars.
• A bar chart consists of a number of vertically or horizontally placed bars and the length of the bars defines the relative magnitude of the values. It uses rectangular bars with lengths proportional to the values that they represent. A Gantt chart is a horizontal bar chart used for project management

Characteristics of a bar chart:

• The start and endpoints of the bar indicate the time of the finish and start time of the activity.
• The length of the bar represents the time required for the completion of an activity.
• The width of the bar does not signify anything i.e. it can be of any size.

Gantt Chart:

• Gantt charts are mainly used to allocate resources to activities.
• The resources allocated to activities include staff, hardware, and software. Gantt charts are useful for resource planning.
• A Gantt chart is a special type of bar chart where each bar represents an activity. 
• This chart lists the tasks to be performed on the vertical axis, and time intervals on the horizontal axis.
• The bars are drawn along a timeline. The length of each bar is proportional to the duration of time planned for the corresponding activity.
• With the use of this chart, we can check the progress of the project with
  • A visual display of the whole project,
  • Timelines and deadlines of all tasks,
  • Relationships and dependencies between the various activities,
  • Project phases

Concept:

The C-chart is used when the quality of a product is evaluated by counting the number of blemishes, defects, or nonconformities on units of a product. It is also known as the “defects-per-unit” chart or “control chart for nonconformities.”

Control charts are a statistical tool, showing whether a process is in control or not.

Two types of process data:

• Variable is continuous data, things we can measure; Example includes length, weight, time, temperature, diameter, etc.
• The attribute is a discrete data, things we count; Examples include number or per cent defective items in a lot, number of defects per item etc.

Types of Control Charts:

Variable charts are meant for variable type of data. X bar and R Chart, X bar and sigma chart, chart for the individual units

Attribute charts are meant for attribute type of data. p chart, np chart, c chart, u chart, U chart

Control charts for the variable type of data (X bar and R charts)

• In the x bar chart, the sample means are plotted in order to control the mean value of a variable
• In R chart, the sample ranges are plotted in order to control the variability of a variable

Control charts for Attribute type data (p, c, u charts)

• p-charts calculates the percent defective in sample; p-charts are used when observations can be placed in two categories such as yes or no, good or bad, pass or fail etc.
• c-charts counts the number of defects in an item; c-charts are used only when the number of occurrences per unit of measure can be counted such as number of scratches, cracks etc.
• u-chart counts the number of defects per sample; The u chart is used when it is not possible to have a sample size of a fixed size

Explanation:

P-chart (Proportion or Fraction Defective Chart):

• It is used to monitor and control the fraction produced in a process that is defective or non-conforming.
• It follows a binomial distribution.
• This chart is best suited in cases where inspection is carried out to classify articles as either excepted or rejected.

\(Fraction\;defective = \frac{{Number\;of\;defective\;articles}}{{Size\;of\;sample}} \Rightarrow P = \frac{{\sum d}}{N}\)

Working rule

• Calculate the average fraction defective.
• Compute σ the standard error of fraction defective.
• \(Standard\;error\;of\;\vec p\;\left( {{\sigma _p}} \right) = \sqrt {\frac{{\vec p \times \vec q}}{{\vec n}}\;} ,\;(\vec q = \left( {1 - \vec p} \right)\)
• Now calculate both the limits.

Additional Information

Control charts:

• A control chart is a graphical representation of the collected information.
• It indicates whether a process is in control or out of control.
• It determines process variability and detects unusual variations taking place in a process.
• It ensures the product quality level.
• It provides information about the selection and setting of tolerance limits.

Types of Control Charts:

Variable charts are meant for the variable type of data. X bar and R Chart, X bar and sigma chart, the chart for the individual units

Attribute charts are meant for attribute type of data. p chart, np chart, c chart, u chart, U chart.

Control charts for the variable type of data (X bar and R charts)

• In the x bar chart, the sample means are plotted in order to control the mean value of a variable.
• In the R chart, the sample ranges are plotted in order to control the variability of a variable.
  • R charts are used to monitor the variation of a process based on samples taken from the process at given times (hours, shifts, days, weeks, months, etc.).
  • The measurements of the samples at a given time constitute a subgroup.

Control charts for Attribute type data (p, c, u charts)

• p-charts calculates the percentage defective in the sample; p-charts are used when observations can be placed in two categories such as yes or no, good or bad, pass or fail etc.
• c-charts counts the number of defects in an item; c-charts are used only when the number of occurrences per unit of measure can be counted such as the number of scratches, cracks etc.
• u-chart counts the number of defects per sample; The u chart is used when it is not possible to have a sample size of a fixed size.

Explanation:

Control charts:

• A control chart is a graphical representation of the collected information.
• It indicates whether a process is in control or out of control.
• It determines process variability and detects unusual variations taking place in a process.
• It ensures the product quality level.
• It provides information about the selection and setting of tolerance limits.

Types of Control Charts:

Variable charts are meant for the variable type of data. X bar and R Chart, X bar and sigma chart, the chart for the individual units

Attribute charts are meant for attribute type of data. p chart, np chart, c chart, u chart, U chart.

Control charts for the variable type of data (X bar and R charts)

• In the x bar chart, the sample means are plotted in order to control the mean value of a variable.
• In the R chart, the sample ranges are plotted in order to control the variability of a variable.

R charts:  

• R charts are used to monitor the variation of a process based on samples taken from the process at given times (hours, shifts, days, weeks, months, etc.).
• The measurements of the samples at a given time constitute a subgroup.

Additional Information 

Control charts for Attribute type data (p, c, u charts)

• p-charts calculates the percentage defective in the sample; p-charts are used when observations can be placed in two categories such as yes or no, good or bad, pass or fail etc.
• c-charts counts the number of defects in an item; c-charts are used only when the number of occurrences per unit of measure can be counted such as the number of scratches, cracks etc.
• u-chart counts the number of defects per sample; The u chart is used when it is not possible to have a sample size of a fixed size.

Explanation:

5S system:

• 5S is a Japanese methodology for workplace organization.
• It is a methodology of Total Productive Maintenance (TPM).
• It stands for Sort, Set, Shine, Standardization and Sustain.
• 5S is a simple tool for organizing your workplace in a clean, efficient and safe manner to enhance your productivity, visual management and to ensure the introduction of standardized working.

The list describes how to organize a workspace for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items, and sustaining the new order.

The benefits of the 5S system:

• Increases in productivity
• Increases in quality
• Reduction in cost

Additional Information

6σ technique: 

• Six Sigma is a set of techniques and tools for process improvement.
• Six Sigma is a data-driven methodology that provides tools and techniques to define and evaluate each step of a process.
• It provides methods to improve efficiencies in a business structure, improve the quality of the process and increase the bottom-line profit.

Explanation:

Control charts:

• Control chart is a graphical representation of the collected information.
• It indicates whether a process is in control or out of control.
• It determines process variability and detects unusual variations taking place in a process.
• It ensures product quality level.
• It provides information about the selection and setting of tolerance limits.

They are of two types:

• Variable control chart.
• Attribute control charts.

Explanation:

Cost of Quality: 

It is the cost of those activities which an organization has incurred in order to maintain the quality over and above the minimum cost required to do the job. It is broadly classified into two divisions:

(i) Cost of Conformance:

The cost incurred while providing the products or services of required standards is called the cost of conformance. It includes the cost of prevention and the cost of the appraisal.

(ii) Cost of Non-Conformance: 

It is also called the cost of failure and it takes place due to the products not operating as per the required specifications and standards. It includes the cost of internal failure and the cost of external failure. It is better to invest in the prevention cost as the cost of failure is too high and involves market risk as well.

Hence, Cost of quality = Prevention cost + Appraisal cost + Internal failure cost + External failure cost .

The establishment of a management system includes the cost of prevention. Prevention costs include the costs associated with quality planning, education, and training of the workforce, market research, and product design.

• Prevention costs: The costs incurred to avoid or minimize the number of defects in first place. E.g. - an improvement of manufacturing processes, workers training, quality engineering etc.
• Appraisal costs: Costs that are incurred to identify defective products before they are shipped to customers. These are also called 'Inspection Costs'. E.g. - Final product testing and inspection cost, QC cost.
• Internal failure costs: Costs are those costs that are incurred to remove defects from the products before shipping them to customers. Examples of internal failure costs include the cost of rework, rejected products, scrap etc.
• External failure costs: If defective products have been shipped to customers, external failure costs arise. External failure costs include warranties, replacements, lost sales because of a bad reputation, payment for damages arising from the use of defective products etc.

Explanation:

Total quality management (TQM)

• TQM is a systems approach to management that aims to continuously increase value to customers by designing and continuously improving the organizational process and systems.
• TQM involves all the employees and extends backward and forwards to include the supply chain and the customers. 
• TQM is concerned with managing the entire system, and not only subsystems or functional departments. 
• TQM continuously detects and reduces or eliminates errors.
• It is used to streamline supply chain management, improve customer service, and ensure that employees are trained.
• The focus is to improve the quality of an organization's outputs, including goods and services.
• Total quality management aims to hold all parties involved in the production process accountable for the overall quality of the final product or service.
• TQM shares some similarities with the Six Sigma improvement process.
• TQM ensuring that internal guidelines and process standards reduce errors, where Six Sigma used to reduce defects.

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Explanation:

Total quality management (TQM)

• TQM is a systems approach to management that aims to continuously increase value to customers by designing and continuously improving the organizational process and systems.
• TQM involves all the employees and extends backward and forwards to include the supply chain and the customers. 
• TQM is concerned with managing the entire system, and not only subsystems or functional departments. 
• TQM continuously detects and reduces or eliminates errors.
• It is used to streamline supply chain management, improve customer service, and ensure that employees are trained.
• The focus is to improve the quality of an organization's outputs, including goods and services.
• Total quality management aims to hold all parties involved in the production process accountable for the overall quality of the final product or service.
• TQM shares some similarities with the Six Sigma improvement process.
• TQM ensuring that internal guidelines and process standards reduce errors, where Six Sigma used to reduce defects.

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