GE8077 Total Quality Management L T P C 3 0 0 3
GE8077 Total Quality Management L T P C 3 0 0 3
GE8077 Total Quality Management L T P C 3 0 0 3
UNIT I INTRODUCTION 9
Introduction - Need for quality - Evolution of quality - Definitions of quality - Dimensions of product
and service quality - Basic concepts of TQM - TQM Framework - Contributions of Deming, Juran and
Crosby - Barriers to TQM - Customer focus - Customer orientation, Customer satisfaction, Customer
complaints, Customer retention.
TOTAL: 45 PERIODS
OUTCOME:
The student would be able to apply the tools and techniques of quality management to
manufacturing and services processes.
TEXT BOOK:
1. Dale H.Besterfiled, Carol B.Michna,Glen H. Besterfield,Mary B.Sacre,Hemant Urdhwareshe and
Rashmi Urdhwareshe, “Total Quality Management”, Pearson Education Asia, Revised Third
Edition, Indian Reprint, Sixth Impression, 2013.
REFERENCES:
1. James R. Evans and William M. Lindsay, "The Management and Control of Quality", 8th Edition,
First Indian Edition, Cengage Learning, 2012.
2. Janakiraman. B and Gopal .R.K., "Total Quality Management - Text and Cases", Prentice Hall
(India) Pvt. Ltd., 2006.
3. Suganthi.L and Anand Samuel, "Total Quality Management", Prentice Hall (India) Pvt. Ltd., 2006.
4. ISO 9001-2015 standards
Sl.
Knowledge level Contents COs
No.
UNIT I INTRODUCTION
Introduction, Need for quality , Evolution of quality,
1 U/R C404.1
Definitions of quality
2 U/R/Ap Dimensions of product and service quality C404.1
3 U/R Basic concepts of TQM and TQM Framework C404.1
4 U/R/Ap Contributions of Deming, Juran and Crosby C404.1
5 U/R Barriers to TQM, Costs of quality, Quality statements C404.1
Customer focus, Customer orientation, Customer satisfaction,
6 U/AP C404.1
Customer complaints, Customer retention
UNIT II TQM PRINCIPLES
1 U/R/Ap Leadership - Strategic quality planning, Quality Councils C404.2
2 U/Ap Employee involvement - Motivation, Empowerment C404.2
3 U/Ap Team and Teamwork and Quality circles C404.2
4 U/Ap Recognition and Reward, Performance appraisal C404.2
Continuous process improvement - PDCA cycle, 5S,
5 U/Ap C404.2
Kaizen
Supplier partnership - Partnering, Supplier selection,
6 U/R/Ap C404.2
Supplier rating
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GE 8077 – Total Quality Management Department of Mechanical Engineering 2020-2021
9 Under what situations, one can use cause and effect diagram?
The cause and effect diagram has unlimited application in research manufacturing, marketing, office
operations, services, etc.
10 What are the uses of CE diagram?
The cause and effect diagrams are used: 1. to analyse cause and effect relationships, 2. to facilitate
the search for solutions of related problems, 3. to standardize existing and proposed operations and
4. to educate and train personnel in decision-making and corrective action activities.
11 What are the various types of histogram?
1. Bell-shaped, 2. Double-peaked, 3. Plateau, 4. Comb, 5. Skewed, 6. Truncated, 7. Isolated peak and
8. Edged peak.
12 What is pareto diagram? State the pareto principle.
A pareto diagram is a diagnostic tool commonly used for separating the vital few causes that
account for a dominant share of quality loss.
Pareto principle states that a few of the defects accounts for most of the effects.
13 What are the purposes of pareto principle?
Pareto analysis can be used in a wide range of situations, where one need to priorities problems
based on its relative importance.
14 What is stratification?
Pareto analysis can be used in a wide range of situations, where one need to priorities problems
based on its relative importance.
15 What is scatter diagram?
The scatter diagram is a simple graphical device to depict the relationship between two
variables.
16 When do you use the scatter diagram?
The purpose of the scatter diagram is to display what happens to one variable when another
variable is changed.
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GE 8077 – Total Quality Management Department of Mechanical Engineering 2020-2021
17 Define statistics applications of statistical techniques.
Statistics is defined as the science that deals with the collection, tabulation, analysis, interpretation
and presentation of quantitative data.
18 What are major functions of statistical analysis? Write down the applications of statistical
techniques.
The major functions of statistical analysis are: 1. reducing the complexity of the situation, 2. making
comparisons and drawing conclusions, 3. estimating and predicating, and Decision-making.
Statistical techniques are applicable in all situations where quantification is possible. The statistical
analysis has become indispensable to practically every field that exists.
19 What are the types of graphs used in representing frequency distribution?
Histogram, Frequency polygon and frequency curve, and Cumulative frequency or the ‘Ogive’.
20 How do obtain frequency curve?
A frequency curve is obtained by drawing a smooth freehand curve through the points of the
frequency polygon. The cumulative frequency curve (also called an Ogive) obtained by plotting
upper class limits (or lower class limits) against the ‘less than’ (or ‘more than’) cumulative
frequencies is known as ‘less than’ Ogive (or ‘more than’ Ogive).
21 What do you mean by measure of central tendency? What are the three measures of central
tendency?
A measure of central tendency of a distribution is a numerical value that describes the central
position of the data.
Three measures of central tendency are 1. Mean, 2. Median and 3. Mode.
22 What are the three measures of dispersion?
Measures of dispersion tell us how the individual observations are spread on either side of the
center.
1. Range, 2. Mean deviation and 3. Standard deviation.
23 What is meant by attribute? What is the use of control charts for attributes?
1. An attribute refers to those quality characteristics that confirm to specifications or do not conform
to specifications.
2. Control charts for attributes monitor the number of defects or fraction defects or fraction defect
rate present in the sample.
3. p chart: The chart for fraction rejected as non-conforming to specification
4. np chart: The control chart for number of non-conforming items.
5. c chart: The control chart for number of defects.
6. u chart: The control chart for number of defects per unit.
24 Define fraction defective (p).
It is defined as the ratio of the number of defective articles found in any inspection to the total
number of articles actually inspected.
Mathematically, P = np/n Where, P= Fraction defective, np = Number of defectives, and
n = Number of items inspected in the sub-group
25 Write the specific use of np chart. (Nov/Dec 2016)
Np-charts are used to determine if the process is stable and predictable, as well as to monitor the
effects of process improvement theories.
26 Write down the difference between a defect and defective.
An item is said to be defective if it fails to conform to the specifications in any of the characteristics.
Each characteristics that does not meet the specifications is called defect. For example, if a casting
contains undesirable hard sports, below holes, etc., the casting is defective and the hard spots, below
holes, etc., are the defects.
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GE 8077 – Total Quality Management Department of Mechanical Engineering 2020-2021
27 Differentiate between producer’s risk and consumer’s risk.
Producer’s risk: It is the probability of rejecting a good lot which otherwise would have been
accepted. Consumer’s risk: It is the probability of accepting a defective lot which otherwise would
have been rejected.
28 What are the five phases in six sigma process?
The five phases in six sigma process are:
1. Define, 2. Measure, 3. Analyze, 4. Improve and 5. Control
29 Brief the scope of six sigma principle.
The six sigma concept is originated from manufacturing field. Now it is applied to non-
manufacturing processes also. Today one can apply six sigma to many fields such as services,
medical and insurance procedures, call centres, etc.
30 What are the types of check sheets commonly used?
1. Process distribution check sheet, 2. Defective item check sheet, 3. Defect location check sheet and
4. Defect factor check sheet.
31 State the primary objectives of six sigma. (April/May 2017)
The primary objective of six sigma is to reduce the process variability (standard deviation) from
the target (mean µ).
32 Mention the use of Stratification chart in TQM. (April/May 2017)
Stratification chart is a used for data analysis. When data from variety of sources have been lumped
together this chart separates the data so that patterns can be seen.
Stratification is a method of analysis of data by grouping it in different ways. It is a simple, very
effective QC tool for improving the quality.
PART – B
1 What is six sigma concept? How can it be effective in a service organization? (Nov/Dec 2016)
2 Define histogram. Mention its types. Illustrate with an example. / Discuss about types of
histograms and their interpretations.
3 Explain the cause and effect diagram (or) fishbone diagram.
4 Define pareto diagram. Explain how to construct it? Also explain the stratification analysis.
What is it?
5 Define the scatter diagram. Mention its types. What is it?
6 Explain briefly about check sheet (or) data collection sheet with an example.
7 Explain in seven traditional quality tools with suitable examples / Explain any three new
management tools. (April/May 2014; April/May 2016; Nov/Dec 2016; Nov/Dec 2017)
8 What is bench marking? Explain its Types.
20 What is QFD?
Quality function development may be defined as a system for translating consumer requirements
into appropriate requirements at every stage, from research through product design and
development, to manufacture, distribution, installation and marketing, sales and service.
21 What is control chart? List the types of control charts. (Nov/Dec 2017)
A control chart is a graph that displays data taken over time and the variation of this data.
Control charts for variables – for measurable data such as time, length, temperature, weight,
pressure, etc.
Control charts for characteristics- for quantifiable data such as number of defects, typing errors in a
report, etc.
22 When do you use control chart?
The purpose of control chart is to identify when the process has gone out of statistical control, thus
signaling the need for some corrective action to be taken.
23 What are some factors affecting the success of BPR implementation?
1. Critical/core processes, 2. Strong leadership, 3. Cross-functional teams, 4. Information technology,
5. Clean slate’ philosophy and 6. Process analysis.
24 What are the performance measures of TQM?
Customer orientation, value based operations, performance compatibility, teamwork, development
and monitoring.
25 What is meant by process capability? (April/May 2016)
Process capability may be defined as the “minimum spread of a specific measurement variation
which will include 99.7% of the measurements from the given process”.
Process capability=6. Since 99.7% area in the normal curve is between -3 and +3.
26 What are the benefits of TPM? (or) List out the benefits of total productive maintenance.
(April/May 2016; April/May 2017)
Increased equipment productivity, Improvement equipment reliability, Reduced equipment
downtime, Increased plant capacity, Extended machine time, Lower maintenance and production
costs, Approaching zero equipment-caused defects, Improved team work between operators and
maintenance people, Enhanced job satisfaction, Improved return on investment, Improved safety.
27 Define process capability index. (Nov/Dec 2016)
The process capability index or process capability ratio is a statistical measure of process capability;
the ability of a process to produce output within specification limits. The concept of process
capability only holds meaning for processes that are in a state of statistical control. Process capability
indices measure how much "natural variation" a process experiences relative to its specification
limits and allows different processes to be compared with respect to how well an organization
controls them.
28. Write down the various stages of FMEA. (April/May 2016; Nov/Dec 2017))
The FMEA methodology has four stages. They are: Stage1: Specifying possibilities,
Stage2: Quantifying risk, Stage3: Correcting high risk causes and Stage4: Re-evaluation of risks.
PART – B
1 Explain control chart (or) Shewhart chart. / Explain with an example of any three control charts.
(April/May 2016; Nov/Dec 2016)
2 Compare the variable charts and attribute charts.
3 Briefly outline the six sigma DMAIC process.
4 Briefly explain the steps involved in QFD. (Nov/Dec 2010; April/May 2016)
5. Internal audit – periodic review of the Quality Management System and how it is being
implemented, including a review of non-conformities
6. Management review – a review by senior management of the internal audit results and other
quality data, including whether the KPIs have been achieved and any tends in data
28 What are the important requirements of QS9000? (April/May 2017)
1. Quality systems assessment guide, 2. Advanced product quality planning and control plan
reference manual, 3. Production part approval process manual, 4. Measurement system analysis
reference manual and 5. Fundamental statistical process control reference manual.
29 Mention the different types of quality audits. (April/May 2017)
Quality auditing is done by both internal and external bodies.
Based on the type of auditor, it is classified as: 1. First party audit, 2. Second party audit and
3. Third party audit
It is also classified based on the area of coverage as: 1. System audit, 2. Process audit and 3. Product
audit.
PART – B
1 Explain documentation in quality standard.
2 Explain the requirements of ISO system to documentation. (April/May 2016)
3 Explain quality audits in detail. (Nov/Dec 2011)
4 List and explain the elements of ISO 9000 quality system. (April/May 2013; April/May 2014)
5 Discuss about implementation of ISO 9001. (Nov/Dec 2016)
6 Discuss the benefits of ISO 9000 certification. (April/May 2013)
7 Explain various divisions of ISO 14000 Standards. (Nov/Dec 2016).
8 Explain the major elements of environmental management system. (April/May 2014)
9 Explain the benefits of EMS. (Nov/Dec 2011)
10 Explain ISO 14000 standards and list the benefits. / What are the requirements, objectives and
benefits of ISO 14000 system? (April/May 2016; Nov/Dec 2017)
PART – C
11 Discuss the need for standardization procedures for quality assurance. (April/May 2016)
12 Enumerate the various aspects of ISO 14000 environmental management system. Brief the
various principles of ISO 14000 series. (April/May 2017)
13 Illustrate the detailed procedure for quality auditing. Brief the attributes of a good auditor.
(April/May 2017)
14 Explain how each element of TQM contributes to products and services of superior quality.
(Nov/Dec 2017)