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Question Bank for KInematics of Machinery

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TQM UNIT-III 2 MARKS

1. Give the seven tools of quality?
i. Pareto Diagram
ii. Process Flow Diagram
iii. Cause-and-Effect Diagram
iv. Check Sheets
v. Histogram
vi. Control Charts
vii. Scatter Diagrams

2. Define Statistics?
Statistics is defined as the science that deals with the collection, tabulation, analysis, interpretation, and presentation of quantitative data.

3. What is a measure of central tendency?
A measure of central tendency of a distribution is a numerical value that describes the central position of the data or how the data tend to build up in the center. There are three measures in common in use in quality viz, the average, the median and the mode.

4. What is Measures of dispersion?
Measures of dispersion describe how the data are spread out or scattered on each side of the central value. The measures of dispersion used are range and standard deviation.

5. What is a normal curve?
The normal curve is a symmetrical, unimodal, bell-shaped distribution with the mean, median and mode having the same value.

6. What is the use of the control chart?
The control chart is used to keep a continuing record of a particular quality characteristic. It is a picture of process over time.

7. Give the objectives of the attribute charts?
i. Determine the average quality level.
ii. Bring to the attention of management any changes in the average.
iii. Improve the product quality.
iv. Evaluate the quality performance of operating and management personnel.
v. Determine acceptance criteria of a product before shipment to the customer.

8. Define Six Sigma Problem Solving Method?
Define - improvement opportunity with an emphasis on increasing customer satisfaction.
Measure - determine process capability (Cp/ Cpk) & dpmo (defects per million opportunities).
Analyze - identify the vital few process input variables that affect key product output variables (“Finding the knobs”).
Improve - Make changes to process settings, redesign processes, etc. to reduce the number of defects of key output variables.
Control - Implement process control plans, install real-time process monitoring tools, standardize processes to maintain levels.

9. What are the new seven management tools?
i. Affinity Diagram
ii. Interrelationship Digraph
iii. Tree Diagram
iv. Matrix Diagram
v. Prioritization Matrices
vi. Process Decision Program Chart
vii. Activity Network diagram

                                                                                                                      COURTESY: Dr.Manikandan

TQM Unit- II 2 mark questions

1. What are the important factors that influenced purchases?

i. Performance

ii. Features

iii. Service

iv. Warranty

v. Price

vi. Reputation

2. Give the need for a feedback in an organization?

 Discover customer dissatisfaction.

 Discover relative priorities of quality.

 Compare performance with the competition.

 Identify customer’s needs.

 Determine opportunities for improvement.

3. List the tools used for feedback?

 Comment cards

 Surveys

 Focus groups

 Toll-free telephone lines

 Customer visits

 Report cards

 The internet

 Employee feedback

 American Customer Satisfaction Index

4. What are the activities to be done using customer complaints?

 Investigate customer’s experience by actively soliciting feedback, both positive and negative, and then acting on it promptly.

 Develop procedures for complaint resolution that include empowering front-line personnel.

 Analyze complaints, but understand that complaints that do not always fit into neat categories.

 Work to identify process and material variations and then eliminate the root cause. “More inspection” is not corrective action.

 When a survey response is received, a senior manager should contact the customer and strive to resolve the concern.

 Establish customer satisfaction measures and constantly monitor them.

 Communicate complaint information, as well as the results of all investigations and solutions, to all people in the organization.

 Provide a monthly complain report to the quality council for their evaluation and, if needed, the assignment of process improvement teams.

 Identify customer’s expectations beforehand rather than afterward through complaint analysis.

5. What are the elements of customer service?

 Organization

 Customer care

 Communication

 Front-line people

 Leadership

6. Define customer retention?

Customer retention represents the activities that produce the necessary customer satisfaction that creates customer loyalty, which actually improves the bottom line. It is the nexus between the customer satisfaction and the bottom line.

7. Define Employee Involvement?

Employee involvement is a means to better meet the organization’s goals for quality and productivity at all levels of an organization.

8. State Maslow’s Hierarchy of Needs?

Level 1 : Survival

Level 2 : Security

Level 3 : Social

Level 4 : Esteem

Level 5 : Self-actualization

9. State Frederick Herzberg’s Two-factor theory?

Herzberg found that people were motivated by recognition, responsibility, achievement and the work itself.

10. What does an employee want?

i. Interesting work

ii. Appreciation

iii. Involvement

iv. Job security

v. Good pay

vi. Promotion/growth

vii. Good working conditions

viii. Loyalty to employees

ix. Help with personal problems

x. Tactful discipline

11. What are the concepts to achieve a motivated work force?

a. Know thyself

b. Know your employees

c. Establish a positive attitude

d. Share the goals

e. Monitor progress

f. Develop interesting work

g. Communicate effectively

h. Celebrate success

12. Define Empowerment?

Empowerment means invest people with authority. Its purpose is to tap the enormous reservoir of creativity and potential contribution that lies within every worker at all levels.

Empowerment is an environment in which people have the ability, the confidence, and the commitment to take the responsibility and ownership to improve the process and to initiate the necessary steps to satisfy customer requirements within well-defined boundaries in order to achieve organizational values an goals.

13. What are the three conditions necessary to create the empowered environment?

i. Everyone must understand the need for change.

ii. The system needs to change for the new paradigm

iii. The organization must enable its employees.

14. What are the types of teams?

i. Process improvement team

ii. Cross-functional team

iii. Natural work teams

iv. Self-directed/self-managed work teams

15. What are the characteristics of successful teams?

a. Sponsor

b. Team charter

c. Team composition

d. Training

e. Ground rules

f. Clear objectives

g. Accountability

h. Well-defined decision procedures

i. Resources

j. Trust

k. Effective problem solving

l. Open communications

m. Appropriate leadership

n. Balanced participation

o. Cohesiveness

16. What are the decision-making methods?

a) Nondecision

b) Unilateral decision

c) Handclasp decision

d) Minority-rule decision

e) Majority-rule decision

f) Consensus

17. What are the stages of team development?

i. Forming

ii. Storming

iii. Norming

iv. Performing

v. Adjourning

18. Give some common team problems?

I. Floundering

II. Overbearing participants

III. Dominating participants

IV. Reluctant participants

V. Unquestioned acceptance of opinions as facts

VI. Rush to accomplish

VII. Attribution

VIII. Discounts and “plops”

IX. Wanderlust : digression and tangents

X. Feuding team members

19. What are the common barriers to team progress?

i. Insufficient training

ii. Incompatible rewards and compensation

iii. First-line supervisor resistance

iv. Lack of planning

v. Lack of management support

vi. Access to information systems

vii. Lack of union support

20. Give the steps involved in training process?

1st. Make everyone aware of what the training is all about.

2nd. Get acceptance.

3rd. Adapt the program.

4th. Adapt to what has been agreed upon.

21. Define Recognition and Reward?

Recognition is a form of employee motivation in which the organization publicly acknowledges the positive contributions an individual or team has made to the success of the organization.

Reward is something tangible to promote desirable behavior. Recognition and reward go together to form a system for letting people know they are valuable members of the organization.

22. What are the types of appraisal formats?

i. Ranking

ii. Narrative

iii. Graphic

iv. Forced choice

23. What are the benefits of employee involvement?

Employee Involvement improves quality and increases productivity because

 Employees make better decisions using their expert knowledge of the process.

 Employees are more likely to implement and support decisions they had a part in making.

 Employees are better able to spot and pinpoint areas for improvement.

 Employees are better able to take immediate corrective action.

 Employee involvement reduces labor/management hassle by more effective communications and cooperation.

 Employee involvement increases morale by creating a feeling of belonging to the organization.

 Employees are better able to accept change because they control the work environment.

 Employees have an increased commitment to unit goals because they are involved.

24. What are the basic ways for a continuous process improvement?

 Reduce resources

 Reduce errors

 Meet or exceed expectations of downstream customers

 Make the process safer

 Make the process more satisfying to the person doing it.

25. What are the three components of the Juran Trilogy?

i. Planning

ii. Control

iii. Improvement

26. What are the steps in the PDSA cycle?

The basic Plan-Do-Study-Act is an effective improvement technique.

1st. Plan carefully what is to be done

2nd. Carry out the plan

3rd. Study the results

4th. Act on the results by identifying what worked as planned and what didn’t.

27. What are the phases of a Continuous Process Improvement Cycle?

a) Identify the opportunity

b) Analyze the process

c) Develop the optimal solutions

d) Implement

e) Study the results

f) Standardize the solution

g) Plan for the future

28. Define 5S?

5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety.

Sort – (Seiri) the first S focuses on eliminating unnecessary items from the workplace.

Set In Order (Seiton) is the second of the 5Ss and focuses on efficient and effective storage methods.

Shine: (Seiso) Once you have eliminated the clutter and junk that has been clogging your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area.

Standardize: (Seiketsu) Once the first three 5S’s have been implemented, you should concentrate on standardizing best practice in your work area.

Sustain: (Shitsuke) This is by far the most difficult S to implement and achieve.

Once fully implemented, the 5S process can increase morale, create positive impressions on customers, and increase efficiency and organization.

29. What is a Kaizen?

Kaizen is a Japanese word for the philosophy that defines management’s role in continuously encouraging and implementing small improvements involving everyone. It is the process of continuous improvement in small increments that make the process more efficient, effective, under control and adaptable.

30. What are the three key elements to a partnering relationship?

i. Long-term commitment

ii. Trust

iii. Shared vision

31. What are the three types of sourcing?

a) Sole sourcing

b) Multiple sourcing

c) Single sourcing

32. What are the ten conditions for the selection and evaluation of suppliers?

I. The supplier understands and appreciates the management philosophy of the organization.

II. The supplier has a stable management system.

III. The supplier maintains high technical standards and has the capability of dealing with future technological innovations.

IV. The supplier can supply precisely those raw materials and parts required by the purchaser, and those supplied meet the quality specifications.

V. The supplier has the capability to produce the amount of production needed or can attain that capability.

VI. There is no danger of the supplier breaching corporate secrets.

VII. The price is right and the delivery dates can be met. In addition, the supplier is easily accessible in terms of transportation and communication.

VIII. The supplier is sincere in implementing the contract provisions.

IX. The supplier has an effective quality system and improvement program such as ISO/QS 9000.

X. The supplier has a track record of customer satisfaction and organization credibility.

33. What are the four phases of inspection?

i. 100% inspection

ii. Sampling

iii. Audit

iv. Identity check

34. What are the objectives of Performance measures?

i. Establish baseline measures and reveal trends.

ii. Determine which processes need to be improved.

iii. Indicate process gains and losses.

iv. Compare goals with actual performance.

v. Provide information for individual and team evaluation.

vi. Provide information to make informed decisions.

vii. Determine the overall performance of the organization.

35. What are the characteristics used to measure the performance of a particular process?

i. Quantity

ii. Cost

iii. Time

iv. Accuracy

v. Function

vi. Service

vii. Aesthetics

36. Give the six basic techniques for presenting performance measures?

a) Time series graph

b) Control chart

c) Capability index

d) Taguchi’s Loss Function

e) Cost of poor quality

f) Malcolm Baldrige National Quality Award

Coutesy: Dr.G.Manikandan

Joined as Prof and Head / Mech from today ..

Change of Work place

Dear all, It was a great experience working at KCG. I am switching over my career with higher designation to a new place. Thanks for all your support.

UCM QB - MODEL

ME 2026 Unconventional Machining process
PART – A ( 2 marks)

1. What are functions of dielectric fluid used in EDM?
2. Write a note on electrical discharge machining?
3. Define W/T ratio?
4. What is cycle time in connection to EDM ?
5. What are the prime requirements of tool material in EDM?
6. What are the functions of adaptive control used for EDM?
7. Explain the term over cut with reference to Electric discharge machining process.
8. Explain how the current density affect the MRR in a ECM process .
9. What are the limitations of ECM?
10. Explain the term Etch Factor with reference to Electro chemical machining process.
11. Explain ‘ recast metal’.
12. What are the factors that influence oxidation in ECM?
13. What are the results when an improper selection of electrolyte in ECM is done?
14. Describe the commonly used gas mixtures in PAM and their corresponding work materials.
15. What are the limitations of ECG?
16. What is the application of ECG?
17. What are the characteristics of Laser beam?
18. Write the principle of Plasma arc machining.
19. Give a brief note about electro chemical honing process
20. What are the limitations of Laser beam machining ?
21. Compare and contrast LBM and EBM processes
22. Mention the kind of materials that can be machined by PAM.
23. What are the methods generally used to filter the electrolyte?
24. What are the characteristics of a good ECM tool?
25. What are the gases commonly used in LASER?
26. What is the effect of capacitance in EDM?
27. What are the advantages of Laser drilling?
28. Write a note about the recent advancements in Laser machining ?





PART B

1. Briefly discuss about the effect of high temperature and pressure of electrolyte on the ECM process. Also discuss about the economics of ECM.
2. Explain the principle of LBM with neat sketch ,list out the advantages and limitations of LBM process.
3. Explain the principle of PAM with sketch , list out the advantages and limitations of PAM process.
4. What is non transferred and transferred mode of plasma arc ? Explain the mechanism of material removal in PAM
5. Discuss the factors that influence the quality of the cut in PAM.
6. What is laser? Explain how it is used to machine the materials. Discuss in detail the thermal features and analysis of laser beam machining.
7. Explain the classification of various spark erosion generators. With help of neat sketch describe the mechanism of material removal in EDM.
8. Mention the specific advantages of using chemical machining over electro chemical machining giving some of the practical applications of chemical machining process.
9. Describe the process of electrochemical machining.
10. Discuss about the electrochemical honing and electrochemical grinding.
11. Explain the principles and elements of EBM, also how the worktable is protected from getting damaged by electron beam.
12. Discuss how the process variables influence MRR, HAZ and pattern generation in PAM.
13. Explain the process capabilities of EBM and PAM

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