1 1.

       What perspective does Crosby adopt when defining quality??

(a)   Setting and meeting specifications is the critical issue.
(b) Quality must be defined subjectively. (C) Fitness for purpose
Ans. (a)

2 2.       If "quality is free", why do authorities recognise that an improvement programm

(a)   It is never free.

(b) Reductions in prevention and appraisal costs lag behind investment in prevention. (C) Z
Ans. (b)
3 3.       What does the term kaizen mean when applied to quality?
(a)    Continuous improvement (d) None of the above.
(b) Quality is everyo (c) Maintain a steady flow
Ans. (a)

4 4.       Which was not among the weaknesses of the 1987 and 1994 versions of ISO 900

(a)   Including broad dimensions of customer satisfaction within the quality definition. (b) In

Ans. (a)

5 5.       Which of the following was not given as a key feature of Total Quality Ma
(a)    Using quality tools and techniques (b) Continuous improvement (c) Teamwork,
Ans. (d)
6 6.       What do the initials of the PDCA cycle stand for?
(a)    Plan, do, check, act (b) Plan, diagnose, conclude, act (c) Plan, desig
Ans. (a)
7 7.       Name the practice of examining the best practices in an industry or in the world
(a)    Calibration (b) Brainstorming (c) Pareto analysis (d) Benchmarking

Ans. (d)

8 8.       A control chart to record process performance usually identifies control limits an
(a)    Control charts require complex statistical analysis to set them up. (b) Control charts d

Ans. (b)

9 9.       What do the initials of the SMED stand for?

(A)  Single Minute Exchange of Dies (b) Small Medium Enterprises Division (c) Single Manufacturin
Ans. (a)

10 10.   What do the initials of the FPS, TPS stand for?

(a)   Failed Productive System, Total Productive System (b) Ford Production System , Toyo
Ans. (d)
11 11.   Which of the following statement is correct regarding Supply Price & Manufacturi
(a)   S.P. = M.C. + Profit (b) S.P. = M.C. - Profit (c) S.P. = Profit - M.C. (d) M.C. = S.P.+Profit

Ans. (a)
12 12.   Levelled scheduling (heijunka) is the Japanese-derived term for levelling the pro
(a)   Mix and volume level are even over time. (b) Mix and quality level are even over time.

Ans. (a)
13 13.   Which of the following statements about Just-in-Time is correct?

(a) JIT is only useful in a high product variety environment. (b) JIT will overcome poor com
Ans. (c)
14 14.   Just-in-Time production implies:
(a)    That increased complexity means that processes must be controlled using computer-ba
Ans. (d)
15 15.   Which one of the following would NOT be considered a prerequisite for successfu

(a)    Low variety of product range (b) Sophisticated production and materials planning com

Ans. (b)
16 16.   The lean approach to people management has also been called the:
(a)    Multi-skills system (b) Employee-comes-first system (c) People empowerment syste

Ans. (d)

17 17.   Which of the following issues does NOT define the lean philosophy?

(a)   Elimination of waste (b) Continuous improvement (c) Involvement of everyone (d) Cu
Ans. (d)

18 18.  In an assembly line, if an operator detects some kind of quality problem,

(a)   Aston light (b) Alton light (c) Andon light (d) Arden light

Ans. (c)

Test Paper on Quality Management, Lean Manufacturing Tools & Techniques:

19 1.       What is the full form of ISO?

i)                    Indian Standardization Organization ii) Indian Standardization O
ii)                   International Standardization Organization iv) International Organizatio

20 2.       ISO14001 stands for:

i) Quality Management Syst ii) Environment Management System
iii) Occupational Health & Safety Assessment Serie iv) None of the above

21 3.       In which year Latest Revision of ISO9001 takes place

i) 2008 ii) 2015
iii) 2000 iv) 2016

22 4.       Which one of these is one of the quality management principle

 i) Mutually Beneficial Supplier Customer Relationship ii) Beneficial Supplier
iii) Beneficial Customer iv) All the above

23 5.       PDCA cycle is also known as

i) Juran Learning Cycle ii) Henry Ford Cycle
iii) Deming Cycle iv) None of the above

24 6.       Leanphilosophy follows:

i) Pull ii) Push
iii) Push-Pull iv) None of the above

25 7.       Lean philosophy is derived mostly from:

i) Motorola Produ ii) Ford Production System
iii) Toyota Production System iv) All the above

26 8.       Which is not a type of waste as defined under lean terminology:

i) Overproduction ii) Inventory
iii) Transportation iv) Productivity

27 9.       Workplace Organization tool is commonly known as:

i) TPM ii) Six-Sigma
iii) Poka Yoke iv) 5’S

28 10.   Third S (3S) stands for:

i) Sort ii) Standardize
iii) Shine iv) None of the above

29 11.   Word Heijunka stands for:

i) Leveling ii) Automation
iii) Standardizing iv) None of the above

30 12.   Meaning of Poka Yoke:

i) Standardizing ii) Mistake Proofing
iii) Policy Making iv) None of the above

31 13.   TPM Stands for:

i) Total Plant Mai ii) Total Preventive Maintenance
iii) Total Productive Maintenance iv) Total Plant Management

32 14.   Defects Corresponding to Six-Sigma level:

i) 3.4 per billion ii) 3.4 per million
iii) 3.4 per trillion iv) None of the above

33 15.   VOC stands for:

i) Voice of Customer ii) Voice of Complaint
iii) Voice of cost iv) None of the above

34 16.   DPMO Stands for:

 i) Delay per million opportuni ii) Defects per million opportunities
iii) Defects per million offers iv) None of the above

35 17.   Which of these activity is a Non-Value AddedActivity?

i) Sorting ii) Purchase
iii) Inventory Management iv) All the above

36 18.   Process Variability is denoted by:

i) Standard-Deviation ii) Variance
iii) Both (i) & (ii) iv) None of the above

37 19.   DMAIC stands for:

i) Define, Measure, Analyze, ii) Design, Measure, Analyze, Improve & Control
iii) Define, Measure, Analyze, Install& Control iv) None of the above

38 20.   Kaizen stands for:

i) Small Improvements ii) Drastic Improvements
iii) Mistake-Proofi iv) None of the above

39 2. Process control is carried out

a. before production
b. during production
c. after production control
d. All of the above
(Ans:b)

40 4-Total Quality Management (TQM) focuses on

a. Employee
b. Customer
c. Both (a) and (b)
d. None of the above
(Ans:c) 

41 5-Which of the following is responsible for quality objective?

a. Top level management
b. Middle level management
c. Frontline management
d. All of the above
(Ans:a)

42 7-TQM & ISO both focuses on

a. Customer
b. Employee
c. Supplier
d. All of the above
 (Ans:a)

43 16-With the increase in preventive maintenance cost, breakdown maintenance cost

(A) Increases
(B) Decreases
(C) Remain same
(D) Any of the above
16-(B)

44 17-A systematic approach for maintenance is

(A) Problem – Cause – Diagnosis – Rectification
(B) Problem– Diagnosis – Cause – Rectification
(C) Problem – Measure – Diagnosis – Rectification
(D) Problem– Diagnosis – Measure – Rectification
17-(A)

45 18-(Down time in hours / Available hours) =

(A) Maintenance effectiveness
(B) Frequency of breakdown
(C) Effectiveness of maintenance planning
(D) None of the above
18-(A)

46 20-The following eases the process of stock control

(A) Standardization
(B) Simplification
(C) Both ‘A’ and ‘B’
(D) None of the above
(Ans: C)

47 22. Kaizen relates to continuous improvement.

(A) True
(B) False
(Ans: A)

48 23. Kanban is a visual system for controlling production.

(A) True
(B) False
(Ans: A)

49 24. Inventory is considered a waste in a lean system.

(A) True
 (B) False
(Ans: A)

50 29-Work study examines

a. method
b. duration of work
c. both ‘a’ and ‘b’
d. None of the above
(Ans: c)

51 38-Decibel (db) is a unit used to measure

(A) Light
(B) Sound
(C) Frequency
(D) None of the above
(Ans: B)

52 39-The following is (are) are generally provided with limit switch to prevent motion beyond preset limit
(A) Hoists
(B) Conveyors
(C) Machine tables
(D) All of the above
(Ans: D)

53 40-The following is (are) used as safety device(s) in machines

(A) Fail safe
(B) Safety interlocks
(C) Limit switches
(D) All of the above
(Ans: D)

54 46 What you meant by a startup.

55 48. Work sampling is applied for

(A) Estimation of the percentage utilization of machine tools
(B) Estimating the percentage of the time consumed by various job activities
(C) Finding out time standards, specially where the job is not repetitive and where time study by stop watch me
(D) All of the above
Correct Answer - d

56 51. For a product layout the material handling equipment must

(A) Have full flexibility
(B) Employ conveyor belts, trucks, tractors etc.
(C) Be a general purpose type
(D) Be designed as special purpose for a particular application
Correct Answer D
57 54. Work study involves
(A) Only method study
(B) Only work measurement
(C) Method study and work measurement
(D) Only motion study
Correct Answer C

58 55. An activity of the project is graphically represented by ________ on the network diagram.
(A) A circle
(B) A straight line
(C) An arrow
(D) None of these
Correct Answer C

59 56. Break-even analysis consists of

(A) Fixed cost
(B) Variable cost
(C) Fixed and variable costs
(D) Operation costs
Correct Answer C

60 60. Material handling in automobile industry is done by

(A) Overhead crane
(B) Trolley
(C) Belt conveyor
(D) All of the above
Correct Answer A

61 62. String diagram is used when

(A) Team of workers is working at a place
(B) Material handling is to be done
(C) Idle time is to be reduced
(D) All of the above
Correct Answer A

62 63. Father of industrial engineering is

(A) Jack Gilbert
(B) Gantt
(C) Taylor
(D) Newton
Correct Answer c

63 66. In product layout

(A) Specialized and strict supervision is required
(B) Machines can not be used to their maximum capacity
(C) Manufacturing cost rises with a fall in the volume of production
(D) All of the above
 Correct Answer D

64 69. Material handling and plant location is analysed by

(A) Gantt chart
(B) Bin chart
(C) Emerson chart
(D) Travel chart
Correct Answer D

65 70. The population of a town increases every year by 4%. If its present population is 50,000, then after 2 y
A.
53,900
B.
54,000
C.
54,080
D.
54,900
Answer: Option C

66 71-Which of the following is for Environment management?

a.       ISO-9000
b.      ISO-14000
c.       ISO-26000
d.      ISO-31000
(Ans:b)

67 72-Match The Following

A. TQM promotes 1. Small change
B. Kaizen is 2. Continuous improvement
C. Quality circle can solve problem related to 3. Employee participation
D. Quality circle benefit to 4. Employee
The correct order is
a.       A-3, B-1, C-2, D-4
b.      A-1, B-3, C-2, D-4
c.       A-3, B-1, C-4, D-2
d.      A-3, B-2, C-1, D-4

68 73-The following is (are) the machine down time.

a.       Waste
b.      No material
c.       Breakdown
d.      All of the above
(Ans:d)

69 74-Control chart is a
a.       Process monitoring tool
 b.      Process control tool
c.       Both (a) and (b)
d.      None of the above
(Ans:c)

70 75-The objective of ISO-9000 family of Quality management is

a.       Customer satisfaction
b.      Employee satisfaction
c.       Skill enhancement
d.      Environmental issues
(Ans:a)

71 78. A low unit cost can be obtained by following

(A) Product layout
(B) Functional layout
(C) Automatic material handling equipment
(D) Specialization of operation
Correct Answer A

72 81. Micro-motion study is

(A) Analysis of one stage of motion chart
(B) Motion study, when seen on a time chart
(C) Subdivision of an operation into therbligs and their analysis
(D) Enlarged view of motion study
Correct Answer
Answer: Option C

73 82. In jobbing production

(A) Highly skilled workers are needed
(B) Unit costs are high
(C) Operations are labour-intensive
(D) All of these
Correct Answer
Answer: Option D

74 85 A can do a work in 15 days and B in 20 days. If they work on it together for 4 days, then the
A. 1
4
B. 1
10
C. 7
15
D. 8
15

Correct Answer
Answer: Option D
75 86 A hollow iron pipe is 21 cm long and its external diameter is 8 cm. If the thickness of the pipe
A. 3.6 kg
B. 3.696 kg
C. 36 kg
D. 36.9 kg
Answer: Option B

76 87 A metallic sheet is of rectangular shape with dimensions 48 m x 36 m. From each of its corn
A. 4830
B. 5120
C. 6420
D. 8960
Answer: Option B

77 Few Questions from

Step 1 Mind set to take full advantage of training.

Step 2 Create good first impression by being disciplined, regualr and well behaving.

Step 3 Show readiness to learn and proactively take interest to do the work.

Step 4 Observe Carefully

. Every process of the organization.
. Every role of the organization.
. Working of all the departments
. Engineering operations Prododuction
Utility
Maintenance
. Technical skills at the shop floor.
. Managerial skills of the seniors

Step 5 Carefully take note of all your observations and instructions.

. Processes
. Machine Operations
. Role and Responsibilities
. Overall understanding of business
. What appeals to your more

Step 6 Take initiative to take a study/analysis of the project

Prepare report as advised by your guide

Periodic submission of training report to your guide.

 y. (C) Fitness for purpose is the key. (d) All of these (e) none of these.

mprovement programme needs investment?

tment in prevention. (C) Zero defects is not possible. (d) There is an inevitable worsening of quality during periods of change.

tain a steady flow

94 versions of ISO 9000?

he quality definition. (b) Insufficient guidance on improvement. (c) Universality meant average. (d) Weak links between product and proc

e of Total Quality Management?

ovement (c) Teamwork, trust and empowerment (d) Establishing clear specifications

nclude, act (c) Plan, design, control, act (d) Purpose, develop, carry out, assess

dustry or in the world and using this knowledge as a basis for improvement.

ntifies control limits and specification limits. Which one of the following is true?
m up. (b) Control charts do not prevent poor quality output. (c) Control limits should equal specification limits to prevent any output outsid

on (c) Single Manufacturing Engineering Division (d) Small Miniaturized Equipment Die.

d Production System , Toyota Precise System (c) Ford Precision System , Toyota Precision System (d) Ford Production System , Toyota Prod

ply Price & Manufacturing Cost?

) M.C. = S.P.+Profit
m for levelling the production schedule so that:
y level are even over time. (c) Mix and yield level are even over time. (d) Volume and yield are even over time.

JIT will overcome poor component manufacture. (c) JIT seeks to reduce inventory in an effort to reduce waste. (d) JIT pushes inventory thr

ntrolled using computer-based production systems. (b) A wide range of suppliers will be needed to meet increased demand. (c) Large batc

requisite for successful Just-in-Time production?

nd materials planning computer systems (c) Reliable deliveries of defect-free materials (d) Preventive maintenance of equipment

eople empowerment system (d) Respect-for-humans system

ement of everyone (d) Customer involvement

of quality problem, he/she could activate a signal that could illuminate a light above the work station whi

Techniques:

Indian Standardization Organization

) International Organization for Standardization

ne of the above

iv) 2016
ii) Six-Sigma

ii) Standardize
e, Improve & Control
on beyond preset limit

e study by stop watch method is not possible

rk diagram.
n is 50,000, then after 2 years it will be
her for 4 days, then the fraction of the work that is left is :
the thickness of the pipe is 1 cm and iron weighs 8 g/cm 3, then the weight of the pipe is:

m. From each of its corners, a square is cut off so as to make an open box. If the length of the square is 8 m, the volume of t
ods of change.

s between product and process standards.

o prevent any output outside specification. (d) Control limits are set outside the specification limits.

ction System , Toyota Production System

d) JIT pushes inventory through the operations process.

sed demand. (c) Large batches of similar products will need to be manufactured to increase efficiency. (d) That products will be pulled throu

ance of equipment

the work station which stops the line. This is called an:
e is 8 m, the volume of the box (in m 3) is:
products will be pulled through the operations system to meet customer demand.