(SEM VIII) THEORY EXAMINATION 2021-22 QUALITY MANAGEMENT

SECTION A

(Attempt all questions in brief – 2 × 7 = 14 marks)

(a) Define Quality

Quality is the degree to which a product or service meets customer requirements and expectations. It is often defined as “fitness for use” or “conformance to specifications.”

(b) What do you mean by procurement? Explain

Procurement is the process of purchasing raw materials, components, or services required for production. It includes supplier selection, ordering, inspection, and ensuring timely delivery at the right cost and quality.

(c) What is prototype?

A prototype is a sample or preliminary model of a product developed to test design, functionality, and performance before mass production.

(d) Define SWOT analysis

SWOT analysis is a strategic tool used to identify Strengths, Weaknesses, Opportunities, and Threats of an organization or project for better decision-making.

(e) What is R-chart?

An R-chart (Range chart) is a control chart used to monitor process variability by plotting the range of samples over time.

(f) Define Quality hierarchy

Quality hierarchy refers to different levels of quality responsibility, starting from top management commitment to operational quality control at the shop floor.

(g) What is Zero Defect? Explain

Zero Defect is a quality philosophy that aims at doing things right the first time, preventing defects rather than detecting them later.

SECTION B

(Attempt any THREE – 7 × 3 = 21 marks)

2(a) Evolution of Quality Control with example

Quality control evolved from simple inspection to statistical quality control, then to quality assurance, and finally to Total Quality Management (TQM).
For example, earlier defective products were inspected and rejected, but modern systems focus on preventing defects using control charts and process improvement.

2(b) Quality Management and its functions

Quality Management is the systematic approach to ensuring that products meet customer expectations.

Functions include:                                               Quality planning

Quality control                                                       Quality assurance

Quality improvement

These functions ensure customer satisfaction, cost reduction, and continuous improvement.

2(c) Human factors in quality attitude of top management

Top management plays a key role through leadership, commitment, motivation, training, communication, and employee involvement. Their attitude directly influences quality culture across the organization.

2(d) Control Charts

Control charts are statistical tools used to monitor process performance and detect variations.

Types include:

X-bar chart

R-chart

p-chart

c-chart

They help in identifying whether a process is under statistical control.

2(e) Obstacles in implementing TQM and solutions

Common obstacles include lack of management commitment, resistance to change, poor training, and weak communication.
These can be overcome by leadership support, employee involvement, continuous training, and a strong quality culture.

SECTION C

3(a) Methods to ensure manufacturing quality

Manufacturing quality is ensured through proper process planning, quality inspection, statistical process control, preventive maintenance, employee training, and continuous improvement techniques like Kaizen.

3(b) Evaluation of supplies with example

Evaluation of supplies involves assessing suppliers based on quality, cost, delivery, and reliability.
For example, a supplier delivering defect-free raw material on time consistently will be rated higher than others.

4(a) Organization structure and design of quality management

Quality management structure defines roles and responsibilities for quality at various levels. It includes quality managers, inspectors, engineers, and top management to ensure coordinated quality control and improvement.

4(b) Quality value & contribution and Quality cost optimization

Quality value and contribution:
Quality adds value by increasing customer satisfaction and market reputation.

Quality cost and optimization:
Quality cost includes prevention, appraisal, internal failure, and external failure costs. Optimization aims to minimize total quality cost by investing more in prevention.

5(a) Process capability study with example

Process capability study measures the ability of a process to produce products within specification limits using indices like Cp and Cpk.
For example, if a machine consistently produces parts within tolerance, it has high process capability.

5(b) Construction of X-bar and R control charts

X-bar chart monitors process mean, while R-chart monitors process variation.
They are constructed using sample averages and ranges and are widely used in manufacturing industries.

6(a) p-chart construction and comment on process

A p-chart is used to control fraction defective. Average fraction defective and control limits are calculated, plotted, and analyzed to check whether the process is under control.

6(b) Suitable control chart & sample size determination

For defectives, a p-chart is suitable.
Sample size is determined based on acceptable quality level (AQL) and producer’s risk to ensure defective rate remains within limits.

7(a) Short notes

(i) MTTF:
Mean Time To Failure is the average time a product operates before failure.

(ii) Maintainability:
Maintainability is the ease with which a system can be repaired or maintained.

(iii) Quality Circle:
A quality circle is a group of employees who meet regularly to identify and solve quality problems.

7(b) ISO-9000 and its concept

ISO-9000 is an international quality standard that ensures consistent product quality, customer satisfaction, and systematic quality management through documented procedures.