Birla Institute of Technology & Science, Pilani

Work-Integrated Learning Programmes Division

First Semester 2023-2024

Comprehensive Examination
(EC-3 Regular)

Course No. : MBA ZG522

Course Title : TOTAL QUALITY MANAGEMENT
Pattern of Exam : SCAN AND UPLOAD
Nature of Exam : Open Book
Weightage : 40% No. of Pages =3
Duration : 2 ½ Hours No. of Questions = 6
Date of Exam : Saturday, 25/11/2023 (FN)
Note:
1. Please follow all the Instructions to Candidates given on the cover page of the answer book.
2. All parts of a question should be answered consecutively. Each answer should start from a fresh page.
3. Assumptions made if any, should be stated clearly at the beginning of your answer.

Q.1Set. (A) A Tablet assembled machine is initially working with the following conditions:
Shift time: 450 Mins
Planned down time: 60 Mins
Running Time losses: 78 Mins
Output: 180 components per shift
Machine speed (No. of the components per min): 0.75
Rejection: 8 components per shift.
The organization has decided to improve machine performance and implemented 5S and other
relevant TPM principles. Finally, they are able to bring down running time losses to 58 mins and
rejection rate to 2 components per shift. They are able to increase output of the machine to 207
components per shift. How much percentage of OEE increases as compared to the initial stage?
[6]

Q.1Set. (B) Calculate the overall equipment effectiveness of the production machine with the following
data. [6]

S Planned Shutdown Hours or Count Gross Time 24 Hours (or

No Minutes)

1 No production, Breaks, Shift 2.66 Hours Meeting and Shift Change

change

2 Planned Maintenance 2.00 Hours Monthly Plant Maintenance

3 Waiting for Operator 1.66 Hours

4 Failure or breakdowns 1.33 Hours Mechanical drive coupling

5 Minor Stops 10 events Jams!

6 Reduced Speed 100 Units produced Vs. 167 Design rate: 12.5 Units/hour
 Units planned production

7 Yield/ Transition 5 count Startup and adjustment related

8 Defects, rework 1 count

9 Scrap product/output 2 count Waste, non-salvageable

10 Material Flow: output (Kanban full) 0 Output not needed, no room in

queue

11 Start up and Adjustment 1 Hour 1st shift on Monday

12 Tooling and Part Change 0.83 Hour Screw station bits

13 Material flow : Input ( No Material) 0 Waiting for raw materials

14 Setup and changeover 1.16 Hours 2 size changes

Q.1Set. (C) Calculate the overall equipment effectiveness of the production machine with the following
data. [6]

S Planned Shutdown Hours or Count Gross Time 24 Hours (or

No Minutes)

1 No production, Breaks, Shift 2.66 Hours Meeting and Shift Change

change

2 Planned Maintenance 2.00 Hours Monthly Plant Maintenance

3 Waiting for Operator 1.66 Hours

4 Failure or breakdowns 1.33 Hours Mechanical drive coupling

5 Minor Stops 10 events Jams!

6 Reduced Speed 100 Units produced Vs. 167 Design rate: 12.5 Units/hour
Units planned production

7 Yield/ Transition 5 count Startup and adjustment related

8 Defects, rework 1 count

9 Scrap product/output 2 count Waste, non-salvageable

10 Material Flow: output (Kanban full) 0 Output not needed, no room in

queue

11 Start up and Adjustment 1 Hour 1st shift on Monday

12 Tooling and Part Change 0.83 Hour Screw station bits

13 Material flow : Input ( No Material) 0 Waiting for raw materials

14 Setup and changeover 1.16 Hours 3 size changes

Q.2Set. (A) Consider a process by which coils are manufactured. Sample of sizes 5 are randomly
selected from the process, and the resistance values (in Ohms) of the coils are measured.
The data values are given in Table. 1. Plot control charts, 2. Find out whether the process is
in control, 3. If the process is out of control, assuming special causes for out of control
points, find the revised control limits. [10]

Observations
Sample 1 2 3 4 5
1 22.00 22.50 22.50 24.00 23.50
2 20.50 22.50 22.50 23.00 21.50
3 20.00 20.50 23.00 22.00 21.50
4 21.00 22.00 22.00 23.00 22.00
5 22.50 19.50 22.50 22.00 21.00
6 23.00 23.50 21.00 22.00 20.00
7 19.00 20.00 22.00 20.50 22.50
8 21.50 20.50 19.00 19.50 19.50
9 21.00 22.50 20.00 22.00 22.00
10 21.50 23.00 22.00 23.00 18.50
11 20.00 19.50 21.00 20.00 20.50
12 19.00 21.00 21.00 21.00 20.50
13 19.50 20.50 21.00 20.50 21.00
14 20.00 21.50 23.00 24.00 20.00
15 22.50 19.50 21.00 21.50 21.00
16 21.50 20.50 22.00 21.50 23.50
17 19.00 21.50 23.00 21.00 23.50
18 21.00 20.50 19.50 22.00 21.00
19 20.00 23.50 24.00 20.50 21.50
20 22.00 20.50 21.00 22.50 20.00
21 19.00 20.50 21.00 20.50 22.50
22 21.50 25.00 21.00 18.00 21.00
23 22.50 22.00 23.00 22.00 23.50
24 22.50 22.00 22.00 19.50 20.50

Q.2Set. (B) The number of defectives found in inspection of 10 lots of 100 items each is shown in
below table. [10]

Lot No 1 2 3 4 5 6 7 8 9 10

No of 7 2 1 5 3 0 12 4 2 3
defectives
 I. Find out suitable control charts to make judgement on acceptance of the lots.
II. Determine the controlled limits and state whether the process is under control.
III. If the process is out of control, assuming special causes for out of control points, find the
revised control limits.

Q.2Set. (C) Twenty-five samples of size 50 are chosen from a plastic injection molding machine
producing small containers. The number of nonconforming containers for each sample is
shown in Table, as is proportion nonconforming for each sample. Plot a Proportion
nonconforming chart and comment on results. [10]
Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Number of 4 2 5 3 2 1 3 2 5 4 3 5 5 2 3 2 4 10 4 3 2 5 4 3 4
Nonconformin
g Items

Q.3Set. (A) The Information of the cloth inspected in one rim and number of non-conformities found
are shown in table. Plot suitable control chart and comment on the process. [6]

Cloth Inspected (m2) 200 80 100 300 120 90 250 50 100 70

Non-conformities found 5 7 3 15 4 6 10 1 6 2

Q.3Set. (B) The Information of the cloth inspected in one rim and number of non-conformities found
are shown in table. Plot suitable control chart and comment on the process. [6]

Cloth Inspected (m2) 200 80 100 300 120 90 250 50 100 70

Non-conformities found 5 7 3 15 4 6 10 1 6 2

Q.3Set. (C) In automobile filling process, 500g of certain liquid was to be filled in bags. The
permissible variation is +/- 5g. for investigating the process capability, 5 bags were
taken at random from each batch for 10successive batches and results were plotted
as follows: [6]
Batch 1 2 3 4 5 6 7 8 9 10

Mean(g) 502 497 501 502 501 500 498 501 501 497

Range 3 4 2 4 2 4 5 2 6 4
Establish control chart limits. Plot the charts and interpret the meaning. Will the process able to
meet the specifications?

Q.4Set. (A) How do you construct a house of quality of your organization product against to the
competitor products? Explain with case study [6]
Q.4Set. (B) What is performance measure presentation? Develop a performance measure presentation
for your organization project? [6]
Q.4Set. (C) What is performance measure presentation? Develop a performance measure presentation
for your organization project? [6]

Q.5Set. (A) How do you perform failure mode effective analysis on the product or service which you
offer at your organization? Explain with example [6]
Q.5Set. (B) What are the differences between tool and technique? How combination of tools become
technique? Explain with case study [6]
Q.5Set. (C) What are the differences between tool and technique? How combination of tools become
technique? Explain with case study [6]

Q.6Set. (A) “TPM is one of the critical elements in TQM or Lean Manufacturing”? Comment with
example [6]
Q.6Set. (B) List out improvement strategies? Explain with your industry case? [6]
Q.6Set. (C) What are the conditions force you to apply the following tools: [6]

Quality functional deployment Failure mode effective analysis Benchmarking

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