1.

State the need of inspection

Here's a refined version for better clarity:
To ensure that a part, material, or component conforms to the established standard.
To achieve interchangeability in manufacturing.
To maintain customer relations by ensuring that no faulty product reaches the customer.

2. Enlist the types of sampling plans

1. Single sampling plan
2. Double sampling plan
3. Multiple sampling plan

3. State objectives of quality control

1. Improved Income
2. Cost Reduction
3. Interchangeability
4. Customer’s Satisfaction
5. Optimum Quality
6. Integration of Quality Effects
7. Quality Mildness

4. Define six sigma with an example.

Definition of Six Sigma

Six Sigma is a disciplined and data-driven approach used to eliminate defects in manufacturing
and service industries. It focuses on process improvement and reducing variations to achieve
high-quality products or services.

Example:

• When measuring a variable characteristic (e.g., shaft diameter in manufacturing), the

observations form a normal distribution curve on a frequency polygon.
• Six Sigma ensures that most of the produced shafts fall within the acceptable tolerance limits,
reducing defects.
5. State the application of p chart and c chart
Applications of P Chart & C Chart

P Chart (Proportion Defective Chart) Applications:

1. Determine average defect rate over time.

2. Used in sampling inspection of large lots.
3. Alerts management to changes in quality levels.
4. Helps identify & fix defects in processes.
5. Maintains a record of quality trends for analysis.

C Chart (Count of Defects Chart) Applications:

1. Detect surface defects in aircraft wings.

2. Identify defects like blowholes & cracks in castings.
3. Track imperfections in textiles per unit area.
4. Check surface defects in galvanized sheets.
5. Monitor small holes in glass bottles.

6. State different S.Q.C tools

1. Histogram
2. Check sheet
3. Pareto diagram
4. Brainstorming
5. Cause and effect diagram

7. List advantages of S.Q.C

Advantages S.Q.C

(a) Efficiency and cost red" (Reduction)

(0) Hou effective pressure

(2) Reduction snap

(d) Improvement in inspection std

(e) Improves productivity

 8. Define T.Q.M and state four pillar/ principles of T.Q.M.
TQM (Total Quality Management) is a business philosophy that focuses on:
• Managing the entire organization to ensure excellence in products and services.
• Customer satisfaction as the ultimate goal, beginning and ending with the customer.
• Continuous improvement in processes, employee involvement, and quality control.

Pillars of T.Q.M
1. Customer satisfaction

2. Do work right the first time

3. Continuous Improvement

4. Commitment of Top Management

5. Employee Involvement and Empowerment

6. Process centered

7. Integrated system

Define inspection. List stages/types of inspection.

It is defined as the act of checking of materials, products and components of
products at various stages of manufacturing

1. Incoming inspection

2. In-process inspection

1.first piece 2. Floor 3. Operator 4. Last piece inspection

3. Final inspection

state the factors affecting the quality of product(any-2)

9. State disadvantages of 100% inspection. (any-2)

1. High cost of inspection
2. Inspection fatigue
 3. Time required is more
4. Equipment investment is high

4 marks question

1. List objectives of Quality control (any -4)

Objectives of quality control

• Improved income
• Cost reduction
• Interchangeability
• Customer satisfaction
• Optimum quality
• Integration of quality effects

2. With the help of graph explain optimum quality of design.

Optimum quality of design is called as the balance between cost of quality and value of
quality'.
Data collected during market surveys, such as expected sales of product, profit, competition
in the
market etc. is used to design the component or product, which will meet the needs of
consumers.
But it is not necessary that a company produce 100% quality products (l.e. products being
extremely
high quality) because, the more the quality is expected, the more the production cost will
be.
Therefore, the aim of the company should be to produce products which will meet the
requirements of consumers at lower cost.
 3. Differentiate between variable control chart and attribute control
chart based on any four parameters
Sr. Comparative
Variable Charts Attribute Charts
No. Point
P, np, C, U charts (pass/fail
1 Examples X̄ & R charts (measured data)
data)
Controls proportion of
2 Extent of Control Controls individual quality characteristics
defectives
Information Provides detailed data on process Does not provide detailed
3
Obtained variation individual data
Easy to understand, no special
4 Training Need Requires special training
training needed
More time-consuming (measuring,
5 Time Required Less time needed
calculating, plotting)
6 Sample Size Smaller sample size Larger sample size
High (measuring instruments wear out &
7 Maintenance Cost Lower (GO/NO-GO gauges)
need recalibration)
 4. Apply 5S principle to an automobile service station
Sr. 5S English
Application in Service Station
No. Principle Meaning
1 SEIRI Sort Remove unnecessary items like scrap parts and waste oil.
Organize tools and equipment for easy access based on usage
2 SEITON Set in Order
frequency.
Clean the workplace regularly to maintain hygiene and
3 SEISO Shine
efficiency.
Set rules for cleanliness and assign responsibilities for
4 SEIKETSU Standardize
maintaining 5S.
Make 5S a habit through regular checks and continuous
5 SHITSUKE Sustain
improvement.

State any-4 tools of quality control. Explain fish bone diagram.

Tools for Quality
Control
Check Sheets
Pareto Charts
Why-Why
Diagrams
Cause & Effect
Diagrams
Flowcharts
Histograms
Scatter Diagram
Control Charts
State any two similarities and differences between six sigma and T.Q.M
Here’s a simple comparison of Six Sigma vs. TQM:
Comparison: Six Sigma vs. TQM
TQM (Total Quality
Aspect Six Sigma
Management)
Based on worker improvement &
Approach Led by business leaders (Champions)
teamwork
Workplace & departmental
Focus Cross-functional projects
improvements
Tools Used Simple improvement tools Advanced statistical tools
Financial Requires measurable ROI (Return on
Little financial accountability
Accountability Investment)

Similarities Between Six Sigma & TQM

1. Both aim to reduce defects and improve quality.

Both link to profitability by cutting costs from rejections, rework, and customer complaints.

Explain P.D.C.A cycle.

PDCA Cycle (Plan-Do-Check-Act)

1. Plan
o Identify the problem.
o Analyze the issue using quality control tools.
o Generate possible solutions.
o Select the best solution and create a detailed action plan.
2. Do
Implement the plan on a small scale.
o
o Provide necessary training to employees.
o Conduct brainstorming and education sessions.
3. Check
o Evaluate the results by analyzing collected data.
o If results are positive, move to the next step.
o If negative, refine the plan and repeat until the desired results are achieved.
4. Act
o Standardize successful changes.
o Fully implement improvements across the organization.
o Monitor continuously for further enhancements.

If the results of measurement and analysis are found satisfactory during the 'Check' stage,
the next step is to adopt the changed process through standardization and incorporate it
into regular procedures or work instructions.

Explain the methodology of six sigma

Six Sigma Methodology:-

DMAIC vs. DMADV in Six Sigma

1. DMAIC (Define, Measure, Analyze, Improve, Control)
Used for improving existing processes.
• Define: Identify and select projects, set goals, and form teams.
• Measure: Collect data, identify key customer needs, and process characteristics.
• Analyse: Determine critical performance factors and validate causes.
• Improve: Develop solutions, test improvements, and optimize processes.
• Control: Implement controls, monitor progress, and evaluate financial impact.
 2. DMADV (Define, Measure, Analyze, Design, Validate)
Used for designing new processes or products.
• Define: Set goals and project objectives.
• Measure: Collect key data on customer needs and process characteristics.
• Analyze: Evaluate options and validate the best approach.
• Design: Develop a new optimized process or product.
• Validate: Test with a pilot run and implement at full scale.

State various certifications used in six sigma

Six Sigma Certifications
1. Green Belt
o Project leaders trained in Six Sigma for two weeks.
o Use statistical tools and assist in Six Sigma projects.
o Spend 50% of their time on projects (4-6 months).
2. Black Belt
o Advanced project leaders trained for four weeks.
o Focus on Six Sigma strategies and statistical methodologies.
o Spend 75% of their time on projects (4-6 months).
3. Master Black Belt
o Technical expert and mentor for Black Belts & Green Belts.
o Provides guidance and training in Six Sigma methodologies.
4. Champions
o Executive-level leaders responsible for Six Sigma implementation.
o Facilitate leadership and deployment of Six Sigma strategies.
 With the help of O.C Curve explain consumer risk and
producer risk.

Key Terms in Sampling Inspection

1. AQL (Acceptable Quality Level)
o Maximum proportion of defectives that is considered acceptable.
o Ensures quality meets consumer expectations.
2. LTPD (Lot Tolerance Percent Defective) / RQL (Rejectable Quality Level)
o Maximum defect rate beyond which the lot is rejected.
o Represents unsatisfactory quality (low probability of acceptance).
o Also called Consumer’s Risk, as it protects the customer from bad products.
3. OC Curve (Operating Characteristic Curve)
o A graph showing the probability of accepting a lot based on its defect rate.
o Helps in evaluating sampling plans.
4. Sampling Plan Parameters
o N = Lot size (total items in a batch).
o n = Sample size (number of items inspected).
o c = Acceptance number (maximum defects allowed in the sample).
o Changing these parameters alters the OC curve.
5. AGL (Acceptable Quality Limit)
o Maximum defect rate considered satisfactory for process control.
6. IQL (Indifference Quality Level)
o A quality level between AQL and RQL.
o Has a 50% probability of acceptance, meaning it’s neither clearly acceptable nor
rejectable.
 Explain procedure of USR and consumer Risk
Producer’s Risk (α - Type I Error)
o The risk that a good quality lot is rejected by the sampling plan.
o Occurs when the product meets quality standards, but due to sampling variation, it gets
rejected.
o Leads to losses for the producer as they have to rework or discard good products.
o Can be reduced by improving product quality and adjusting sampling plans.
Consumer’s Risk (β - Type II Error)
o The risk that a bad quality lot is accepted by the sampling plan.
o Happens when a defective lot passes inspection, causing the consumer to receive poor-
quality products.
o Leads to customer dissatisfaction and complaints.
o Can be reduced by stricter sampling criteria and improved inspection methods.

Explain AOQL
AOQL (Average Outgoing Quality Limit)
• Represents the average defect level in outgoing products after inspection.
• Includes both accepted lots and 100% inspected rejected lots (where defects are replaced with
good items).
Helps in determining the effectiveness of an inspection process in maintaining quality standards.

Compare single and double sampling plan

Double
Comparison Point Single Sampling Multiple Sampling
Sampling
In between
Average No. of Pieces
Largest Single & Lowest
Inspected per Lot
Multiple
Highest (due to multiple
Cost of Administration Lowest Moderate
stages)
Information on Quality Largest (one-time Least (inspection spread
Moderate
Level inspection) over multiple stages)
Acceptability to Less acceptable Most acceptable
More acceptable
Producers (strict) (flexible process)
Longest (continues for a
Inspection Duration Shortest Moderate
long time)
The following X and R values of 10 samples of 5 each.
The specification limits for the component are 59+/-
3.5. Establish the control limits for X and R chart will
the product be able to meet its specification given
A2=.577, D3=0, D4=2.111.
Sr.no X R
1 57.8 1.50
2 58.8 1.75
3 58.8 2.00
4 59.8 2.25
5 59.8 2.2
6 60 2.00
7 60.3 1.00
8 60.4 1.50
9 60.9 2.00
10 61.8 1.75

The following table gives the number of missing

rivets noted at aircraft final inspection find C
compute trial control limits and plot control
charts for C. What values of C would you suggest
for the subsequent period.
Air No of Air No of Air No of
plane missing plane missing plane missing
no rivets no rivets no rivets
1 8 11 23 21 10
2 16 12 16 22 22
3 14 13 9 23 7
4 19 14 25 24 28
5 11 15 15 25 9
6 15 16 9
7 8 17 9
8 11 18 14
9 21 19 11
10 12 20 9