Thanks to Apeetha
51. What are the types of appraisal formats?i. Ranking
ii. Narrative
iii. Graphic
iv. Forced choice
52. What are the benefits of employee involvement?Employee Involvement improves quality and increases productivity because
*Employees make better decisions using their expert knowledge of the process.
*Employees are more likely to implement and support decisions they had a part in making.
*Employees are better able to spot and pinpoint areas for improvement.
*Employees are better able to take immediate corrective action.
*Employee involvement reduces labor/management hassle by more effective communications and cooperation.
*Employee involvement increases morale by creating a feeling of belonging to the organization.
*Employees are better able to accept change because they control the work environment.
*Employees have an increased commitment to unit goals because they are involved.
53. What are the basic ways for a continuous process improvement?*Reduce resources
*Reduce errors
*Meet or exceed expectations of downstream customers
*Make the process safer
*Make the process more satisfying to the person doing it.
54. What are the three components of the Juran Trilogy?i. Planning
ii. Control
iii. Improvement
55. What are the steps in the PDSA cycle?The basic Plan-Do-Study-Act is an effective improvement technique.
1st. Plan carefully what is to be done
2nd. Carry out the plan
3rd. Study the results
4th. Act on the results by identifying what worked as planned and what didn’t.
56. What are the phases of a Continuous Process Improvement Cycle?a) Identify the opportunity
b) Analyze the process
c) Develop the optimal solutions
d) Implement
e) Study the results
f) Standardize the solution
g) Plan for the future
57. Define 5S?5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety.
*Sort – (Seiri) the first S focuses on eliminating unnecessary items from the workplace.
*Set In Order (Seiton) is the second of the 5Ss and focuses on efficient and effective storage methods.
*Shine: (Seiso) Once you have eliminated the clutter and junk that has been clogging your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area.
*Standardize: (Seiketsu) Once the first three 5S’s have been implemented, you should concentrate on standardizing best practice in your work area.
*Sustain: (Shitsuke) This is by far the most difficult S to implement and achieve.
Once fully implemented, the 5S process can increase morale, create positive impressions on customers, and increase efficiency and organization.
58. What is a Kaizen?Kaizen is a Japanese word for the philosophy that defines management’s role in continuously encouraging and implementing small improvements involving everyone. It is the process of continuous improvement in small increments that make the process more efficient, effective, under control and adaptable.
59. What are the three key elements to a partnering relationship?i. Long-term commitment
ii. Trust
iii. Shared vision
60. What are the three types of sourcing?a) Sole sourcing
b) Multiple sourcing
c) Single sourcing
61. What are the ten conditions for the selection and evaluation of suppliers?I. The supplier understands and appreciates the management philosophy of the organization.
II. The supplier has a stable management system.
III. The supplier maintains high technical standards and has the capability of dealing with future technological innovations.
IV. The supplier can supply precisely those raw materials and parts required by the purchaser, and those supplied meet the quality specifications.
V. The supplier has the capability to produce the amount of production needed or can attain that capability.
VI. There is no danger of the supplier breaching corporate secrets.
VII. The price is right and the delivery dates can be met. In addition, the supplier is easily accessible in terms of transportation and communication.
VIII. The supplier is sincere in implementing the contract provisions.
IX. The supplier has an effective quality system and improvement program such as ISO/QS 9000.
X. The supplier has a track record of customer satisfaction and organization credibility.
62. What are the four phases of inspection?i. 100% inspection
ii. Sampling
iii. Audit
iv. Identity check
63. What are the objectives of Performance measures?i. Establish baseline measures and reveal trends.
ii. Determine which processes need to be improved.
iii. Indicate process gains and losses.
iv. Compare goals with actual performance.
v. Provide information for individual and team evaluation.
vi. Provide information to make informed decisions.
vii. Determine the overall performance of the organization.
64. What are the characteristics used to measure the performance of a particular process?i. Quantity
ii. Cost
iii. Time
iv. Accuracy
v. Function
vi. Service
vii. Aesthetics
65. Give the six basic techniques for presenting performance measures?a) Time series graph
b) Control chart
c) Capability index
d) Taguchi’s Loss Function
e) Cost of poor quality
f) Malcolm Baldrige National Quality Award
66. Give the seven tools of quality?i. Pareto Diagram
ii. Process Flow Diagram
iii. Cause-and-Effect Diagram
iv. Check Sheets
v. Histogram
vi. Control Charts
vii. Scatter Diagrams
67. Define Statistics?Statistics is defined as the science that deals with the collection, tabulation, analysis, interpretation, and presentation of quantitative data.
68. What is a measure of central tendency?A measure of central tendency of a distribution is a numerical value that describes the central position of the data or how the data tend to build up in the center. There are three measures in common in use in quality viz, the average, the median and the mode.
69. What is Measures of dispersion?Measures of dispersion describe how the data are spread out or scattered on each side of the central value. The measures of dispersion used are range and standard deviation.
70. What is a normal curve?The normal curve is a symmetrical, unimodal, bell-shaped distribution with the mean, median and mode having the same value.
71. What is the use of the control chart?The control chart is used to keep a continuing record of a particular quality characteristic. It is a picture of process over time.
72. Give the objectives of the attribute charts?i. Determine the average quality level.
ii. Bring to the attention of management any changes in the average.
iii. Improve the product quality.
iv. Evaluate the quality performance of operating and management personnel.
v. Determine acceptance criteria of a product before shipment to the customer.
73. Define Six Sigma Problem Solving Method?Define - improvement opportunity with an emphasis on increasing customer satisfaction.
Measure - determine process capability (Cp/ Cpk) & dpmo (defects per million opportunities).
Analyze - identify the vital few process input variables that affect key product output variables (“Finding the knobs”).
Improve - Make changes to process settings, redesign processes, etc. to reduce the number of defects of key output variables.
Control - Implement process control plans, install real-time process monitoring tools, standardize processes to maintain levels.
74. What are the new seven management tools?i. Affinity Diagram
ii. Interrelationship Digraph
iii. Tree Diagram
iv. Matrix Diagram
v. Prioritization Matrices
vi. Process Decision Program Chart
vii. Activity Network diagram
75. Define Benchmarking?Benchmarking is a systematic method by which organizations can measure themselves against the best industry practices. The essence of benchmarking is the process of borrowing ideas and adapting them to gain competitive advantage. It is a tool for continuous improvement.
76. Enumerate the steps to benchmark?a) Decide what to benchmark
b) Understand current performance
c) Plan
d) Study others
e) Learn from the data
f) Use the findings
77. What are the types of benchmarking?i. Internal
ii. Competitive
iii. Process
78. What is a QFD?Quality Function Deployment is a planning tool used to fulfill customer expectations. It is a disciplined approach to product design, engineering, and production and provides in-depth evaluation of a product.
79. What are the benefits of QFD?i. Customer driven
ii. Reduces implementation time
iii. Promotes teamwork
iv. Provides documentation
80. What are the steps required to construct an affinity diagram?i. Phrase the objective
ii. Record all responses
iii. Group the responses
iv. Organize groups in an affinity diagram
81. What are the parts of house of quality?i. Customer requirements
ii. Prioritized customer requirements
iii. Technical descriptors
iv. Prioritized technical descriptors
v. Relationship between requirements and descriptors
vi. Interrelationship between technical descriptors
82. How will you build a house of quality?a) List customer requirements
b) List technical descriptors
c) Develop a relationship matrix between WHATs and HOWs
d) Develop an interrelationship matrix between HOWs
e) Competitive assessments
f) Develop prioritized customer requirements
g) Develop prioritized technical descriptors
83. Define FMEA?Failure Mode Effect Analysis is an analytical technique that combines the technology and experience of people in identifying foreseeable failure modes of a product or process and planning for its elimination.
84. What are the stages of FMEA?1. Specifying possibilities
a. Functions
b. Possible failure modes
c. Root causes
d. Effects
e. Detection/Prevention
2. Quantifying risk
a. Probability of cause
b. Severity of effect
c. Effectiveness of control to prevent cause
d. Risk priority number
3. Correcting high risk causes
a. Prioritizing work
b. Detailed action
c. Assigning action responsibility
d. Check points on completion
4. Revaluation of risk
85. What are the goals of TPM?The overall goals of Total Productive Maintenance, which is an extension of TQM are
i. Maintaining and improving equipment capacity
ii. Maintaining equipment for life
iii. Using support from all areas of the operation
iv. Encouraging input from all employees
v. Using teams for continuous improvement
86. Give the seven basic steps to get an organization started toward TPM?a) Management learns the new philosophy
b) Management promotes the new philosophy
c) Training is funded and developed for everyone in the organization
d) Areas of needed improvement are identified
e) Performance goals are formulated
f) An implementation plan is developed
g) Autonomous work groups are established
87. What are the major loss areas?i. Planned downtime
ii. Unplanned downtime
iii. Idling and minor stoppages
iv. Slow-downs
v. Process nonconformities
vi. Scrap
88. Give the ISO 9000 Series of Standards?i. ISO 9000, “Quality Management and Quality Assurance Standards Guidelines for Selection and Use”.
ii. ISO 9001, “Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation & Servicing”.
iii. ISO 9002, “Quality Systems – “Model for Quality Assurance in Production, Installation & Servicing”.
iv. ISO 9003, “Quality Systems – “Model for Quality Assurance in Final Inspection and Test”.
v. ISO 9004-1, “Quality Management and Quality System Elements – Guidelines”.
89. What is the need for ISO 9000?ISO 9000 is needed to unify the quality terms and definitions used by industrialized nations and use terms to demonstrate a supplier’s capability of controlling its processes.
90. Give some other quality systems?i. QS-9000
ii. TE-9000
iii. AS9000
will be continued in next post.. 
