MQA UNIT-5

  UNIT 5. MQA  PYQ QUESTIONS 

Q.1)  State Seven QC tools & explain any three with neat sketch.

The seven basic quality control (QC) tools, also known as the seven management and planning (MP) tools, are widely used in quality management to analyze and solve problems. These tools help identify and address issues in processes, products, or services, allowing organizations to improve quality and efficiency. The seven QC tools are:

1. Check Sheet: A check sheet is a simple data collection tool used to gather and record data in a systematic and organized manner. It helps in understanding the frequency and distribution of problems or defects. Check sheets typically consist of a table with predefined categories or items to be checked, and marks or tallies are made in each category whenever a specific event or defect occurs.

2. Pareto Chart: A Pareto chart is a graphical tool that displays data in descending order of frequency or magnitude. It helps identify and prioritize the most significant issues or causes contributing to a problem. The chart consists of bars representing each category or cause, arranged in decreasing order, with the cumulative percentage plotted on the secondary vertical axis. This allows teams to focus their efforts on the vital few factors that contribute to the majority of the problems.

3. Cause-and-Effect Diagram (Fishbone or Ishikawa Diagram): A cause-and-effect diagram is a visual tool used to identify and analyze the potential causes leading to a particular problem or effect. It helps in understanding the root causes and relationships among different factors. The diagram resembles a fishbone, with the effect or problem being the "head" and the potential causes represented as "bones" branching off the main line. The main branches typically represent categories such as people, methods, materials, machines, measurement, and environment.

Q.2)  Write a short note on: 

 i) Quality Circle

 ii) Kaizen

 iii) Kanban

i) Quality Circle:

A quality circle is a small group of employees who voluntarily come together to identify, analyze, and solve work-related problems within their organization. Quality circles aim to improve the quality of products, processes, and services through employee participation and teamwork. These circles typically consist of frontline workers from different departments or functions, facilitated by a supervisor or manager.

The primary objectives of quality circles include promoting employee involvement, fostering a culture of continuous improvement, and enhancing overall organizational performance. Members of a quality circle meet regularly to discuss and brainstorm solutions for specific problems or challenges. They employ various problem-solving techniques and tools to analyze root causes and develop effective countermeasures.

Quality circles provide several benefits to organizations, such as increased employee engagement and morale, improved teamwork and communication, and enhanced problem-solving capabilities. They can contribute to a more proactive and empowered workforce, leading to higher productivity and quality standards. By involving employees at all levels in decision-making and problem-solving processes, quality circles foster a sense of ownership and collective responsibility for quality improvement.

ii) Kaizen:

Kaizen is a Japanese term that translates to "continuous improvement." It is a philosophy and methodology focused on making incremental and continuous improvements in all aspects of an organization. Kaizen emphasizes the involvement of all employees, from frontline workers to top management, in identifying and implementing improvements in processes, products, and services.

The key principles of kaizen include teamwork, personal discipline, quality focus, and waste reduction. It encourages a culture of continuous learning and improvement, where small, incremental changes are implemented on a regular basis to achieve significant long-term improvements. Kaizen places importance on gathering data, analyzing processes, and engaging employees in problem-solving activities.

Kaizen techniques and tools, such as PDCA (Plan-Do-Check-Act) cycles, value stream mapping, and 5S (Sort, Set in Order, Shine, Standardize, Sustain), are commonly used to support continuous improvement efforts. By implementing kaizen, organizations can optimize their processes, eliminate waste, reduce defects and errors, enhance productivity, and deliver better value to customers.

iii) Kanban:

Kanban is a visual system and scheduling tool used to manage workflow and improve efficiency in manufacturing, project management, and various other processes. Originating from the Toyota Production System, kanban aims to establish a smooth and balanced flow of work by visualizing work items and limiting work in progress (WIP).

The core concept of kanban revolves around using visual cues, often represented as cards or sticky notes, to signal the status and movement of work items. These visual signals provide real-time information about the demand, availability, and progress of tasks, enabling teams to manage their work effectively.

Kanban boards typically consist of columns representing different stages of the workflow, and cards or sticky notes representing individual tasks or work items. As work progresses, the cards are moved across the board from one column to the next, indicating the current status of each task. Limiting the number of cards in each column helps prevent overloading and ensures a steady flow of work.

Q.3) Explain in detail TQM and its importance.

Total Quality Management (TQM) is a management approach that aims to improve the quality and performance of an organization by involving all members, from top-level executives to frontline employees, in continuous improvement efforts. TQM emphasizes a customer-centric focus, employee involvement, and data-driven decision making to achieve excellence in products, processes, and services.

Key principles of TQM:

1. Customer Focus

2. Continuous Improvement

3. Employee Empowerment

4. Process-Oriented Approach

5. Data-Driven Decision Making

Importance of TQM:

1. Improved Customer Satisfaction

2. Enhanced Efficiency and Productivity

3. Employee Engagement and Empowerment

4. Stronger Supplier Relationships

5. Continuous Learning and Innovation

6. Risk Mitigation

7. Organizational Excellence

Q.4)  Explain Juran’s Trilogy with neat sketch.

Juran's Trilogy is a quality management framework developed by Dr. Joseph M. Juran, a renowned quality guru. It consists of three key components that are essential for achieving and maintaining quality excellence within an organization. 

The components of Juran's Trilogy are:

1. Quality Planning:

Quality Planning involves the systematic process of defining quality objectives and creating a roadmap to achieve those objectives. It focuses on understanding customer needs, setting quality goals, and developing strategies to meet those goals. 

Quality Planning consists of the following steps:

a) Establishing Quality Policies

b) Identifying Customers

c) Translating Customer Needs

d) Developing Product/Process Features

e) Establishing Process Control

The output of Quality Planning feeds into the next component of Juran's Trilogy.

2. Quality Control:

Quality Control focuses on monitoring and verifying that products and processes are performing as intended and meeting quality standards. It involves measuring, analyzing, and controlling quality throughout the production or service delivery process. 

The steps involved in Quality Control are:

a) Establishing Quality Control Systems

b) Measurement

c) Comparing with Standards

d) Taking Corrective Actions

The insights and data collected during Quality Control are essential for the final component of Juran's Trilogy.

3. Quality Improvement:

Quality Improvement focuses on continuously enhancing processes, products, and services to achieve higher levels of quality and customer satisfaction. It involves proactive problem-solving, process optimization, and the elimination of root causes of quality issues. 

The key steps in Quality Improvement are:

a) Identifying Improvement Opportunities

b) Problem Solving

c) Project-by-Project Approach

d) Training and Education

The continuous cycle of Quality Planning, Quality Control, and Quality Improvement forms the foundation of Juran's Trilogy, ensuring that organizations establish and maintain a robust quality management system.

Q.5) Explain function, methodology, and advantages of quality audit.

Function of Quality Audit:

The primary function of a quality audit is to assess and evaluate the effectiveness and compliance of an organization's quality management system. It aims to determine whether the organization's processes, procedures, and practices align with established quality standards and requirements. Quality audits serve as a tool to identify areas of improvement, verify conformance, and ensure continuous compliance with quality guidelines.

Methodology of Quality Audit:

1. Planning

2. Preparation

3. Conducting the Audit

4. Reporting

5. Follow-up

Advantages of Quality Audit:

1. Evaluation of Compliance

2. Identification of Non-Conformities

3. Process Improvement

4. Risk Mitigation

5. Enhanced Customer Satisfaction

6. Continuous Improvement

7. Regulatory Compliance

Q.6) Explain ISO 9000 standards in detail.

ISO 9000 is a set of international standards developed by the International Organization for Standardization (ISO) that focuses on quality management systems (QMS). The ISO 9000 standards provide a framework for organizations to establish and maintain effective QMS to consistently deliver products and services that meet customer requirements. The ISO 9000 family of standards includes the following key documents:

The main elements of ISO 9001 include:

a) Context of the Organization: Organizations are required to identify the internal and external factors that can impact their QMS, understand the needs and expectations of interested parties, and define the scope of the QMS.

b) Leadership: Top management is responsible for establishing a quality policy, defining quality objectives, and ensuring that the QMS is aligned with the organization's strategic direction.

c) Planning: Organizations need to set quality objectives, establish a systematic approach to risk management, and plan processes necessary for delivering products and services that meet customer requirements.

d) Support: This section covers resource management, including the provision of adequate infrastructure, competent personnel, and appropriate monitoring and measuring resources. It also addresses the need for effective communication, documented information, and control of external providers.

e) Operation: This section outlines the processes involved in delivering products and services, including planning and controlling operational activities, managing changes, and addressing customer requirements.

f) Performance Evaluation: Organizations are required to monitor, measure, analyze, and evaluate their QMS performance. This includes conducting internal audits, collecting customer feedback, and implementing appropriate corrective and preventive actions.

g) Improvement: ISO 9001 emphasizes the importance of continuous improvement. Organizations need to identify opportunities for improvement, take actions to address non-conformities, and enhance the effectiveness of the QMS.