Evaultion Test

Operator Name:

level : I II III IV Score Result

1 Purpose of dummy plate?
a.Leak testing
b.To avoid dust contamination
c.To avoid the powder coating inner surface of the tank
d.all of the above
2 What does PPE stand for?
a. Protective Preventitive Equipment
b. Personal Protective Equipment
c. Personal Preventative Equipment
d. People's Protective Equipment
3 What is the correct order of 5S ?
a.Sort, Shine, Set in order, Sustain, Standardize
b.Sort, Set in order, Shine, Sustain, Standardize
c.Sort, Set in order, Shine, Standardize, Sustain
d.Sort, Standardize, Set in order, Shine, Sustain
4 What does SR stands for?
a.safety and regulatory
b.Safe Retraction
c.Sensitivity Range
d.Stage Review
5 What does OPD stands for?
a.Out patient department
b.Object process diagram
c.Object process description
d.Operation data sheet
6 What does WI stands for?
a. Work Instruments
b. Wireless Fidelity
c. Work Instruction
d.Writing Intensive
7 What is mean by Poka Yoke?
a.Cleaning process
b.Mistake-proofing
c.Improvement
d.Errors
8 If Machine Breakdown what to do?
a.Continue production
b.Inform to concern department
c.Shutdown the machine
d.Try to Repair the machine without any supervision.
9 What do you do If any NC part came?
a.Directly rejected
b.Isolate in red bin with NC mark
c.Isolate in red bin without NC mark
d.Stop the production
10 Who is our customer?
a.Renault Nissan Automotive India Private Ltd.
b.Hyundai Motors
c.Tata Motors
d.Ashok Layland
11 What is the Air Pressure range required for bolt tightning ?
a.1 to 2 Bar
b.3 to 4 Bar
c.5 to 6 Bar
d.8 to 9 Bar
 Evaultion Test

Operator Name:

level : I II III IV Score Result

12 Type of nut runner used.
a.Electric nut runner
b.Pneumatic nut runner
c.Battery powered nut runner
d.Mechanical nut runner
13 How many Head scerw are using in dummy plate process ?
a. 6
b. 4
c. 8
d. 10
14 Important checking spot in dummy plate operation.
a.Coating surface
b.Thread area in plate lock
c.Brazing area
d.Seam welding area
15 Type of the bolt used in dummy plate operation.
a.M6
b.M7
c.M5
d.M4
 Evaultion Test

Operator Name:

level : I II III IV Score Result

1 Instrument used to clean inner surface of the fuel tank?
a.Vaccum Cleaner
b.Box Sweeper
c.Polishing Machine
d.Grinding machine
2 What does PPE stand for?
a. Protective Preventitive Equipment
b. Personal Protective Equipment
c. Personal Preventative Equipment
d. People's Protective Equipment
3 What is the correct order of 5S ?
a.Sort, Shine, Set in order, Sustain, Standardize
b.Sort, Set in order, Shine, Sustain, Standardize
c.Sort, Set in order, Shine, Standardize, Sustain
d.Sort, Standardize, Set in order, Shine, Sustain
4 What does SR stands for?
a.safety and regulatory
b.Safe Retraction
c.Sensitivity Range
d.Stage Review
5 What does OPD stands for?
a.Out patient department
b.Object process diagram
c.Object process description
d.Operation data sheet
6 What does WI stands for?
a. Work Instruments
b. Wireless Fidelity
c. Work Instruction
d.Writing Intensive
7 What is mean by Poka Yoke?
a.Cleaning process
b.Mistake-proofing
c.Improvement
d.Errors
8 What do you do If any NC part came?
a.Directly rejected
b.Isolate in red bin with NC mark
c.Isolate in red bin without NC mark
d.Stop the production
9 Who is our customer?
a.Renault Nissan Automotive India Private Ltd.
b.Hyundai Motors
c.Tata Motors
d.Ashok Layland
10 What is the colour mark placed after cleaning process of the tank?
a.Red
b.White
c.Green
d.Blue
 Evaultion Test

Operator Name:

level : I II III IV Score Result

1 CMFA+ & XBA pump fitting instrument.
a.Mechanical Torque wrench
b.Electrical Torque wrench
c.Pneumatic Torque wrench
d.Battery powered Torque wrench
2 What does PPE stand for?
a. Protective Preventitive Equipment
b. Personal Protective Equipment
c. Personal Preventative Equipment
d. People's Protective Equipment
3 What is the correct order of 5S ?
a.Sort, Shine, Set in order, Sustain, Standardize
b.Sort, Set in order, Shine, Sustain, Standardize
c.Sort, Set in order, Shine, Standardize, Sustain
d.Sort, Standardize, Set in order, Shine, Sustain
4 What does OPD stands for?
a.Out patient department
b.Object process diagram
c.Object process description
d.Operation data sheet
5 What does WI stands for?
a. Work Instruments
b. Wireless Fidelity
c. Work Instruction
d.Writing Intensive
6 What is mean by Poka Yoke?
a.Cleaning process
b.Mistake-proofing
c.Improvement
d.Errors
7 If Machine Breakdown what to do?
a.Continue production
b.Inform to concern department
c.Shutdown the machine
d.Try to Repair the machine without any supervision.
8 Who is our customer?
a.Tata Motors
b.Hyundai Motors
c.Renault Nissan Automotive India Private Ltd.
d.Ashok Layland
9 Pump orientation should be?
a.Rib of the tank and fuel line to match each other
b.Rib of the tank and fuel line to not match each other
10 Pump identification number for XBA and CMFA respectively.
a.PW2531, PW2533
b.PW2530, PW2532
c.PW2530, PW2531
d.PW2530, PW2534
11 Child parts uded for pump fitting
a.M6 & M5*2mm bolt, dummy plate,sealing gasket
b.M6 & M5 nut, square M6 bolt,Clip mounting & Ret and seal
c.Mounting bracket,M6 bolt, Dust caps
d.M5 & M6*1mm bolt, Sealing gasket, Ret and seal & clip mounting
 Evaultion Test

Operator Name:

level : I II III IV Score Result

12 Min. Torque of XBA and CMFA pump fitting process respectively.
a.2 Nm & 6 Nm
b.3 Nm & 7 Nm
c.2 Nm & 8 Nm
4.4 Nm & 9 Nm
13 Number of bolts used
a.6
b.8
c.7
d.5
14 Red colour identification mark done ______ torque process.
a.Before the process
b.After the process
c.During the process

15 After pump fitting what colour should be placed on pump for identification?
a.Red
b.Blue
c.Green
d.Yellow
 Evaultion Test

Operator Name:

level : I II III IV Score Result

1 What does PPE stand for?
a. Protective Preventitive Equipment
b. Personal Protective Equipment
c. Personal Preventative Equipment
d. People's Protective Equipment
2 What is the correct order of 5S ?
a.Sort, Shine, Set in order, Sustain, Standardize
b.Sort, Set in order, Shine, Sustain, Standardize
c.Sort, Set in order, Shine, Standardize, Sustain
d.Sort, Standardize, Set in order, Shine, Sustain
3 What does OPD stands for?
a.Out patient department
b.Object process diagram
c.Object process description
d.Operation data sheet
4 What does WI stands for?
a. Work Instruments
b. Wireless Fidelity
c. Work Instruction
d.Writing Intensive
5 What is mean by Poka Yoke?
a.Cleaning process
b.Mistake-proofing
c.Improvement
d.Errors
6 What do you do If any NC part came?
a.Directly rejected
b.Isolate in red bin with NC mark
c.Isolate in red bin without NC mark
d.Stop the production
7 Who is our customer?
a.Renault Nissan Automotive India Private Ltd.
b.Hyundai Motors
c.Tata Motors
d.Ashok Layland
8 In stamp pad what should be changed on daily basis?
a.Part No.
b.Date
c.Customer Name
d.Company name
9 Where should be placed stamping mark?
a.Bottom of the tank
b.Top of the tank
c.Lower Brackts side(Pkb and Heat shield)
d.None of these
10 Write the details specified in stamping pad____________________________
 Evaultion Test

Operator Name:

level : I II III IV Score Result

1 What does PPE stand for?
a. Protective Preventitive Equipment
b. Personal Protective Equipment
c. Personal Preventative Equipment
d. People's Protective Equipment
2 What is the correct order of 5S ?
a.Sort, Shine, Set in order, Sustain, Standardize
b.Sort, Set in order, Shine, Sustain, Standardize
c.Sort, Set in order, Shine, Standardize, Sustain
d.Sort, Standardize, Set in order, Shine, Sustain
3 What does OPD stands for?
a.Out patient department
b.Object process diagram
c.Object process description
d.Operation data sheet
4 What does WI stands for?
a. Work Instruments
b. Wireless Fidelity
c. Work Instruction
d.Writing Intensive
5 What is mean by Poka Yoke?
a.Cleaning process
b.Mistake-proofing
c.Improvement
d.Errors
6 What do you do If any NC part came?
a.Directly rejected
b.Isolate in red bin with NC mark
c.Isolate in red bin without NC mark
d.Stop the production
7 Who is our customer?
a.Renault Nissan Automotive India Private Ltd.
b.Hyundai Motors
c.Tata Motors
d.Ashok Layland
8 What is the XBA and CMFA Resistance value of the Full tank condition?
a.22±2.5Ω , 20±2.5Ω
b.23±2.5Ω , 21±2.5Ω
c.24±2.5Ω , 22±2.5Ω
d.25±2.5Ω , 23±2.5Ω
9 What is colour mark used for all child part marking in final inspection?
a.Red
b.Blue
c.Green
d.Yellow
10 Total number of brackets in XBA and CMFA respectively?
a.3 & 6
b.3 & 5
c.4 & 5
d.4 & 6
11 What is the XBA and CMFA Resistance value of the Empty tank condition?
a.140±2.5Ω , 201±2.5Ω
b.141±2.5Ω , 200±2.5Ω
c.140±2.5Ω , 200±2.5Ω
d.142±2.5Ω , 200±2.5Ω
 Evaultion Test

Operator Name:

level : I II III IV Score Result

12 What should be the numbers and condition of connector pin in pump?
a.5 & Should be bend and damage
b.4 & Shouldn't bend and damage
c.3 & Should be bend and damage
d.2 & Shouldn't bend and damage
13 How to identify whether a fuel tank pass leak test?
a.Look for Red mark
b.Look for Yellow mark
c.Look for White mark
d.Look for Green mark
14 What's the Min. length of Filler and vent tube, that should be without powder coating?
a.Min. 10mm
b.Min. 15mm
c.Min. 25mm
d.Min. 20mm
15 What to do, if any child part is missing ?
a.Tag and Keep in rej. Trolley, Which is yellow painted
b.Tag and Keep in rework Trolley, Which is yellow painted
c.Tag and Keep in rej. Trolley, Which is red painted
d.Tag and Keep in rework Trolley, Which is red painted
 Evaultion Test

Operator Name:

level : I II III IV Score Result

1 What does PPE stand for?
a. Protective Preventitive Equipment
b. Personal Protective Equipment
c. Personal Preventative Equipment
d. People's Protective Equipment
2 What is the correct order of 5S ?
a.Sort, Shine, Set in order, Sustain, Standardize
b.Sort, Set in order, Shine, Sustain, Standardize
c.Sort, Set in order, Shine, Standardize, Sustain
d.Sort, Standardize, Set in order, Shine, Sustain
3 What does OPD stands for?
a.Out patient department
b.Object process diagram
c.Object process description
d.Operation data sheet
4 What does WI stands for?
a. Work Instruments
b. Wireless Fidelity
c. Work Instruction
d.Writing Intensive
5 What is mean by Poka Yoke?
a.Cleaning process
b.Mistake-proofing
c.Improvement
d.Errors
6 Who is our customer?
a.Renault Nissan Automotive India Private Ltd.
b.Hyundai Motors
c.Tata Motors
d.Ashok Layland
7 If you found any spot bur in the tank, what should you do?
a.Tag and Keep in rej. Trolley, Which is yellow painted
b.Tag and Keep in rework Trolley, Which is yellow painted
c.Tag and Keep in rej. Trolley, Which is red painted
d.Tag and Keep in rework Trolley, Which is red painted
8 Which defect can't be reworked?
a.Incomplete brazing
b.No overlap
c.Brazing missing
d.Excess brazing
9 Which defect can be reworked?
a.Seam incomplete
b.Seam burr
c.Seam overlap
d.Seam burn
10 If you found any Water spot(Paint defect) in the tank, what should you do?
a.Tag and Keep in rej. Trolley, Which is yellow painted
b.Tag and Keep in rework Trolley, Which is yellow painted
c.Tag and Keep in rej. Trolley, Which is red painted
d.Tag and Keep in rework Trolley, Which is red painted
11 What should be the result of continuity checking?
a.Continuity should not be there between pump connector and tank ground
b.Continuity should be there between pump connector and tank ground
 Evaultion Test

Operator Name:

level : I II III IV Score Result

12 Total number of Upper brackets in XBA and CMFA respectively?
a.0 & 2
b.1 & 3
c.2 & 4
d.3 & 5
13 What should be the minimum lux level (Light) at firewall station?
a.600 lux
b.500 lux
c.700 lux
d.550 lux
14 Match the following
1. CMFA+(FG part) - a) Red trolley
2. XBA (FG part) - b) Green trolley
3. H79 (FG part) - c) White trolley
4. Rejection part - d) Brown trolley
15 Which colour tag should be used If thread washout(defect) identified?
a.White tag
b.Red tag
c.Yellow tag
d.Blue tag