SARDAR VALLABHBHAL NATIONAL INSTITUTE OF TECHNOLOGY, SURAT MECHANICAL ENGINEERING DEPARTMENT End Semester Examination ~ May 2018 B. Tech. ~ IV (Mechanical) 8th Semester Sub: ME 426 Total Quality Management (Elective —II) Time: 3 Hr Marks: 100 Q.1 (A) A cross functional team of an organization is assigned to develop new (08) model of a Motorbike with the help of a TQM technique. Suggest which TQM technique the team should use? Describe this technique in detail (8) Explain the meaning of Poka - Yoke. Give Examples of 5 Poka - Yoke (07) practices. OR What do you understand by zero defect? Describe the procedure for achieving zero ~ defects in process. Q.2 (A). Following data is given for a manufacturing process: - (05) No of units produced = 12,005 Total no. of units detected = 310 No. of opportunities per unit = 4 Determine the sigma level of the process and give your comments. Use data given in table: (B) Excessive rejections in the final products are observed in a manufacturing (06) concern. State the technique to be adopted in this case. Explain the technique in detail with the help of its related curve. OR (8) What are the meaning of “Total”, “Quality” and "Management" in “TQM”? State tangible and intangible benefits of TQM. Q.3 (A). What is the meaning of Kaizen? Explain implementation of Kaizen with (08) the help of a Kaizen work sheet OR (A) Give road map for implementing TQM in a manufacturing organization Poge 1 of 3(B) Q4 (A) (B) (8) Represent following by means of a diagram. (06) i, 5S Model Kaizen Umbrella PDCA cycle QM Building Block Model for Technical Education System Definition of TQM (by diagram) vi Process Management in TQM What is Lean Manufacturing? State 7 kind of wastes. Explain (08) implementation of tean Manufacturing in an industry, (06) ip(waste) Inspecti Tdentity the prevention, appraisal and failure cost and give your comments as a Manager - TQM, OR Details on a machining center are given as below; - panedule operation = 8 hours per day (6 days 7 week) Processed amount = 5000 units jheoretical (standard) cycle time = 1.2 min/unit Non-conformities (Defects) = 120 units Manufacturing downtime due to training, scheduled problems, meetings, breaks, etc. = 250 mins / week Maintenance downtime, schedule and equipment breakdown = 180 mins / week Downtime due to lack of materials, idling and minor stoppages = 30 mins / week As a part of TPM activity, the target set for improvement is 95% gaulbment effectiveness. Give your comments after making analysis of the data, State advantages of 5 S activity for workshop. (03) A company manufactures a part for which the specification is 40 £ 4mm, (06) The cost of repairing or resetting is Rs, 30. The process average is produce at the target value with a standard deviation of 1.43, The annual Production is 50,000 parts. Calculate the Quality Loss by Defect and Quality Loss by Dispersion, Page 2 of 3(8) A customer wants to compare the life of electric bulbs of four different (08) brands (A, B, C and D) of same wattage and price. The output characteristics for life is 1000 hours and the customer loss is Rs. 10. The data on the life of bulbs has been obtained for the four brands which are given in table below. Which brand would you recommend based on quality loss?_ o _A_ | 800 | 850 750 | 950 | 700 | 600 B | 950 | 750 900 790 | 800 c_ | 860 | 650 920 910 D 75 Q.6 (A) Differentiate the ANY THREE of following terms (15) (i) TQM and ISO 9000 (ii) Quality Management and Quality Assurance (ii) Quality Control! and Quality Management (iv) Objectives vs. Policies (B) Compare the fourteen points to Quality Improvement of Crosby’s and W (08) Edwards Deming. (C) Discuss the following QC tools with construction procedure, block (06) diagrams, advantages and disadvantages. (i) Arrow Diagrams (i) Process Decision Program Charts Page 3 of 3