PGDM (2016 - 18) Term - IV

END - TERM EXAMINATION

Quality Management System
Time: 2 hours Max Marks: 40

NAME INVIGILATOR’S SIGN

ROLL NO.

SECTION

 ANSWER ANY FOUR QUESTIONS

 ALL QUESTIONS ARE OF EQUAL MARKS (4*10 EACH = 40)
 NO EXTRA SHEETS WOULD BE GIVEN
 USE OF SCIENTIFIC CALCULATOR IS PERMITTED
 ALL IMPORTANT TABLES ARE GIVEN AT THE END OF QUESTION-PAPER-CUM-ANSWER-SHEET

1. (i) Control charts for X and R are kept on the weight in kilograms of a colour pigment for a batch
process. After 25 subgroups with a subgroup size of 4, ∑X = 52.08 KGS and ∑R = 11.82 KGS.
Assuming the process in a state of control, compute the X and R Chart central line and control limits for
the production period. (4)
(ii) Refer to the table below with various cost heads, with the help of various cost heads calculate the Cost of
Quality under various categories and their percentage. (4)
On the basis of your results – devise a brief plan for the organisation. (2)

VARIOUS COST HEADS in Rupees

1. MATERIAL INSPECTION 6000
2. QUALITY EDUCATION AND TRAINING 9600
3. SCRAP 6400
4. DOWNTIME 6000
5. RELIABILITY CONSULTING 6700
6. CHECKING AND TESTING PURCHASED EQUIPMENTS 4300
7. SYSTEM DEVELOPMENT 8000
8. FAILURE ANALYSIS 4600
9. WARRANTY COST 7700
10. LABORATORY TESTING 2500
11. CAPABILITY EVALUATIONS 2400
12. PRODUCT, PROCESS AND SERVIE AUDITS 7500
13. LACK OF FLEXIBILITY AND ADAPTABILITY 9800
14. INPROCESS AND FINAL INSPECTION/TESTS 8200
15. REWORK 5100
16. TRANSPORTATION LOSSES 5000
17. PRODUCT LIABILTIY 7900
18. REPAIR WORK 4700
19. PILOT PRODUCTION RUN 5000
20. SUPPLIES INSPECTION 3000
21. CUSTOMER COMPLAINTS 3000
22. WARRANTY REPAIRS AND REPLACEMENTS 6000
23. QUALITY IMPROVMENTS TEAM MEETINGS 5600
24. RELIABILITY TESTING 5000
25. DELAYS 3500
26. RE-DESIGNING 2100
27. QUALITY IMPROVEMENT PROJECTS 7300
28. ENVIRONMENTAL COSTS 5600
29. NEW PRODUCT REVIEW 4500
30. FIELD/SAMPLE TESTING OF VARIOUS PRODUCTS 4200
31. ERROR PROOFING 3200
32. QUALITY PLANNING 8000
33. DOWNGRADING 5900
34. SUPPLIER EVALUATION 3800
35. CALIBRATION OF MEASURING AND TESTING EQUIPMENTS 6400

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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
2. Plastic strips that are used in a sensitive electronic device are manufactured to a maximum specification of
305.70 mm and a min of 304.55 mm. If the stirps are less than minimum specification, they are scrapped; if
they are greater than maximum specification, they are reworked. The part dimensions are normally
distributed with a population mean of 305.20 mm and std deviation of 0.25 mm.
a. What percentage of product is scrap? (2)
b. What percentage is reworked? (2)
c. How the process could be centred to eliminate all but 0.1% of the scrap? (3)
d. What is the rework percentage after (c)? (3)

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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
3. Prepare a QFD Matrix with not more than 4 CRs and 4 ECs for any tangible low cost/value product, and fill in
all the data in hypothetical form following the standard scales in the end calculate the values of raw weights of
each CR and priority scores for each EC.

(i) Put the Product selected, CRs and ECs in this table. (4)

PRODUCT

CR1 EC1

CR2 EC2

CR3 EC3

CR4 EC4

(ii) Put all other values in this table and compute RW and PS. (6)

RAW
CIR CSR SPR EC1 EC2 EC3 EC4 GOAL IR WEIGHTS

CR1

CR2

CR3

CR4

PRIORITY
SCORE

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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
4. Consider a data entry operation that makes numerous daily entries. On each of 24 days, subgroups of 200
entries are inspected. Table below shows the raw data collected. Use an appropriate chart to figure out
whether the process is under control or not, if not what should be the final trial control limits that you will
suggest. Do plot the data on the chart used. (10)

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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
5. (i) Tabulate with the help of Six Sigma Tables:
a. For a production of 10000 and a RTY of 95% and having 20 opportunities. Find the number of
defects, DPU, DPO, DPMO and Sigma level. [4]
b. Find DPMO and Sigma level for a 100% inspection process where 300 units are checked. Each can
be rejected for 5 different reasons. On a day, 7 units were rejected such that 3 units had 3 defects & 3
unit had 2 defects rest all had 1 defect. [3]

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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems
5 (ii) 500 Disposable Syringes are inspected per day from a stable process. The best estimate of fraction non-
conforming is 0.055. Determine the central line and the control limits. On a particular day, 5 non-conforming
Disposable Syringes were discovered. Is this in control? [3 Marks]

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PGDM (2016-18) Term-IV: End Term Examination – Quality Management Systems