5S – Questions and Answers.

1) The basic idea of the Deming Wheel came from

Ans. Dr. W. A. Shewhart

2) What is the primary objective of Quality Circle?

Ans. Self and mutual development of employees.

3) In which year Quality Circle was born in Japan?

Ans.1982.

4) Who assists the Quality Circle in conducting a meeting?

Ans. Facilitator.

5) The member who asks wild questions in the Quality Circle meeting is jocularly called as a

Ans. Fox.

6) The symbol is called

Ans. Terminal.

7) The symbol is called?

Ans. Database

8) The structured method of brainstorming is known as

Ans. Round Robin Method

9) Attribute data are in

Ans. Whole Number

10) Who divided the four steps of the PDCA Wheel into six?

Ans. Dr. K Ishikawa

11) In the XBar-R chart, for a subgroup of 5, what will be the value of LCLXBar if XBar is 35.5 grams?
The value of sigma is 1.5 and the value of A2 = 0.577

Ans. 31

12) What type of graph Pareto is?

Ans. Compound Graph.

13) Even though C&E Diagram is a verbal tool it has been recognized as a statistical tool by

Ans. JSI (

14) Which type of Control Chart is not for Attribute Data?

Ans. X-R Chart

 5S – Questions and Answers.
15) What should be the recommended number of classes for 627 observations for frequency
distribution for making a histogram?

Ans. 10

16) Which theory considers that work is as natural as play if it is associated with recognition?

Ans. McGregor’s Theory Y

17) For planning which activity chart will be better

a. Milestone Chart

b. Gantt Chart

c. Either a or b

18) In the context of Brainstorming, the ability to look into the future is known as

Ans. Awareness

19) Which one is not used for the selection of problems?

a. Priority Number

b. Ranking Method

c. Pareto Analysis

d. Gantt Chart

20) Which type of graph is more suitable for observing the trends?

Ans. Line Graph

1) Who gave the 14 points for Quality improvement to the top management?

Ans. Dr. W. E. Deming.

2) Who was the founder president of JUSE and KAI-DEN-REN?

Ans. Dr. Ichiro Ishikawa.

3) Which one of the actions is not part of the 4-step approach given by Dr. Juran to analyze the process
flow chart?

Ans. Examine each terminal symbol.

4) Out of 5 key elements identified by J P Gilford on the human ability to be creative, willingness to
contribute to achieving the end goal without the fear of failure is termed as

Ans. Drive.

5) The originator of the modern graphic method is?

Ans.Mr. T. H. Lambert
 5S – Questions and Answers.
6) What does “RUN” signify in the control chat?

Ans. Seven or more points occur continuously on one side of the control chart

7) A control chart helps us in identify deviations in a process due to?

Ans. Assignable Causes.

8) In X-R chart the value of A2R is 1.8. What will be the value of sigma?

Ans. 0.6

9) What is the Lorenz curve in the Pareto diagram?

Ans. Cumulative percentage curve

10) Cause and Effect diagram is used to identify?

Ans. Probable causes

11) If the coefficient of correlation of the two variables is 0.8, this shows that

Ans. There is a strong positive correlation.

12) In a scatter diagram, the closeness of the points to a central line indicates

Ans. Higher Correlation

13) In the “Finding Out the Root Cause” step in problem-solving, Quality Circle follow

Ans. Validation of causes.

14) An appropriate tool to study the problem of process variation is.

Ans. Histogram

15) If the least count of a balance is 2 grams and the minimum weight out of 289 packets checked is 98
grams. What should be the lower limit of the first-class interval?

Ans. 97

16) In the 5S System “Place for everything and everything on its place” belongs to

Ans. SEITON

17) Which one is not true for Lean Quality Circle?

Ans. Only A Type Problem is selected.

18) Meaning of GEMBA is

Ans. Shop floor

19) MURA stands for

Ans. Unevenness
 5S – Questions and Answers.
20) Which element is not a constituent of Juran’s Trilogy

Ans. Checking.

1) In Quality Circle after which step, the QC team can select the next problem?

Ans. Step No. 10

2) A graphical presentation of the relationship between two variables is known as

Ans. Scatter Diagram
3) In the “Root Cause Analysis” step in the problem-solving, Quality Circle follows:

Ans. Validation of causes

4) As per Shewhart, the variation in the process is due to

Ans. Both Chance and Assignable cause
5) Calculate the value of Sigma of a process, if the value of A2R = 3.3, the value of A2 = 0.577, and X =
75.2.
Ans. 1.1

6) Which one of the following charts is not an Attribute Control Chart?

Ans. X-R Chart

b. Number of Defective np Chart

c. Percentage Defective p Chart

d. Number of Defects c Chart

7) In Brainstorming

Ans. Quantity is more important than Quality

8) The decision symbol in a Flow Diagram is shown by

Ans. Diamond

9) QC Register is maintained by

Ans. Leader

10) Most preferably Quality Circle should meet

Ans. Once a week

11) Expand the following abbreviation - CWQC

Ans. Company Wide Quality Control

12) Which one is not the characteristic of an effective meeting?

Ans. Pressure on all members

 5S – Questions and Answers.
13) Who introduced the Poka-Yoke technique of Error Proofing

Ans. Dr. Shigeo Shingo

14) What is the most appropriate team size for Quality Circle

Ans. None of them

15) The Histogram is not used for

Ans. Showing the relationship between two variables

16) In 5S System “Sorting Out” belongs to

Ans. SEIRI

17) The meaning of GEMBUTSU is

Ans. Real Thing

18) MUDA stands for

Ans. Waste

19) Which one belongs to elementary statistical methods (7 QC Tools)?

Ans. Scatter Diagram

20) In Why-Why analysis how many times we should ask Why?

Ans. None of them

1) How many minimum problems a QC Team is expected to identify?

Ans. 50

2) In brainstorming “Hitch-Hiking” is

Ans. Making ideas from other’s ideas

3) In which type of Cause & Effect Diagram we use pre-decided headers for capturing the causes of the
problem?

Ans. Dispersion Analysis Type

4) In Cause & Effect Diagram we list

Ans. All Possible Causes

5) Pareto Diagram is used to for

Ans. Identifying Vital Few Causes, Useful Many Causes and Prioritization.

6) What is the contribution of x to y, where x is an independent variable, y is dependent of x and the

value of the coefficient of correlation r is 0.7?
 5S – Questions and Answers.
Ans. 49 %

7) Calculate the width of class intervals where the range is 15, the least count is 1 gram and the
number of classes is 8

Ans. 2

8) Double Peaked Histogram occurs when

Ans. Data is a mixture of two different conditions

9) During which period Prof. Mahalanobis was a member of the planning commission of the
Government of India?

Ans. 1955 ~ 67

10) Which is not true for Quality Circle?

Ans. Have members from anywhere in the workshop

11) In XBar-R chart, for the subgroup of 5, what will be the value of LCLXBar if XBar is 35.5 grams? The
value of sigma is 1.5 and the value of A2 = 0.577

Ans. 31

12) Who popularized Pareto Diagram?

Ans. Dr. J. M. Juran

13) For better continuity and performance of Quality Circles, which one is the best frequency and
duration

Ans. Once a week for an hour

14) To show the presence of team members in the QC register

Ans. Members put signature

15) During the identification of problems in a Quality Circle meeting, which type of brainstorming is
more useful?

Ans. Round Robin method

16) In X-R Chart the Moving Range ‘R’ is

a. Largest value b. Average of all values c. Smallest Value d. None of the above

17) Validation of the most probable causes to identify the root causes is done through

a. Observation b. Data Analysis c. Experiment d. All above

18) In 4W & 1H, 4W represents

Ans. What, Where When & Who

 5S – Questions and Answers.
19) To make the Pareto Diagram Date is organized in

Ans. Descending order

20) The meaning of “GENRI” is

Ans. Principle
 5S – Questions and Answers.
1S SERI Sort Reorganization
2S SEITON Set in order Neatness
3S SEISO Shine, clean Cleanliness
4S SEITKESU Standardize Standardization
5S SHITSUKE Sustain Discipline

* 1S + 2S + 3S = House Keeping

RED Unwanted and Unnecessary

YELLOW Unused material to be returned to a store

 LLFS – Look, Listen, Feel & Smell

 PEEP – Seiton
 Full form of PEEP – Place for everything, Everything at its place.

1. Which step of 5S is useful for maintenance of machine?

Ans. Seiso

2. In 5S which step can be developed through Kaizen?

Ans. Seiketsu

3. The benefit of 4th S

Ans. Improve employee work efficiency.

4. What standard practices to be followed for working table in office?

Ans. No paper to be placed below glass top.

5. Materials in 2nd drawer of your working table in the office, should contain

Ans. Reference table, File of pending job and urgent job, Action to be taken papers.

6. What is the 5S standard for number of icons?

Ans. Less than 5 Icons.

7. What is the frequency of seiri.

Ans. Periodically as per management.

8. What is the correct meaning of Seiton.

Ans. Neatness

9. Does Seiton helps in controlling store inventory.

 5S – Questions and Answers.
Ans. Always.

10. Which W is not used for keeping items/ things as per Seiton.

Ans. When

11. Is red area, similar to dumping area

Ans. Never

12. What is visual management in 5S

Ans. 5S Score board, Sheild for achieving the target and group identification.

13. Why labelling in items is important in 5S.

Ans. To identify quickly, To Retrieve quickly and T know the kinds of items.

14. 5S concept is the Gateway of?

Ans. TQM (Total Quality Management)

15. When to do 5S

Ans. Always.

16. Is safety an integral part of 5S?

Ans. Always.

17. In 5S concept, which color of tag is used for unused to be returned to store.

Ans. Yellow.

18. Is visual display of calibration of instrument part of 5S

Ans. Yes

19. If frequency of self-audit is weekly, Audit is done on 14th of the month, when the auditor for the
next audit to be informed.

Ans. On 14th
 5S – Questions and Answers.

 Data is two types

1. Measurable / Variable/ Continuous data.
2. Attribute / Discrete / Discontinuous data

DATA

Measurable Attribute

X-Bar – R Chart IX-MR Chart Defective Defect

X-Bar – S Chart Variable Sample Size

p - Chart

Fixed Sample Size

np- Chart

Fixed Sample Size Variable Sample Size

C - Chart U- Chart

 If (n=1) then use IX- MR Chart (Individual – Moving Range Chart)

 If n > 1 and < 10, then use X̅ - R Chart (Average and Range Chart)
 If n ≥ 10, then use X̅ - s Chart (Average and Standard deviation Chart)
 5S – Questions and Answers.
 The control chart is one such device which uses the property that 99.73% lies with in ± 3σ limits
when the parameters are under statistical control.
 The +3σ limit line is called the upper control limit (UCL).
 The -3σ limit line is called the lower control limit (LCL).
 If 7 or more consecutive points lie on one side of the center line (either below or above the
central line) also indicates some abnormality. This is known as “run of points”.
 If chart shows a tendency to clutter at the central line, it also could indicate some abnormality in
the sampling of Sub-group.

UCLx = X̅̅ + A2 R
X̅ - R Chart  σ = 1.5
LCLx = X̅̅ - A2 R
(Average and Range  A2 R̅ = 3σ
UCLr = D 4 R̅
Chart)  D3 = 0
LCLr = D 3R̅
R̅
R̅  3 = 3σ
UCLx = X̅ + 3 d2
d2
X – R Chart R̅
R̅  =σ
(Individual and Moving LCLx = X̅ - 3 d2
d2
Measurable Range Chart)
UCLr = D 4 R̅
LCLr = D 3R̅

√ [ ]
2
1 2 (X ) Calculate the standard
s= ∑X − deviation of each subgroup
n−1 n
X̅ – S Chart
(Average and Standard
A
UCLx̅ = X̅̅ + 3 S̅ ∑ X̅
 X̅̅ =
Deviation Chart) LCLx̅ = X̅̅ - A3 S̅ K
UCLs = B4 S̅ ∑S
 S̅ =
LCLs = B3 S̅ K

Standard Table

Size of R̅
sub A2 D3 D4 d2 3
d2
group
2 1.880 0 3.267 1.128 2.659
3 1.023 0 2.575 1.693 1.772
4 0.729 0 2.282 2.059 1.457
5 0.577 0 2.115 2.326 1.290
6 0.483 0 2.004 2.534 1.184
7 0.419 0.076 1.924 2.704 1.109
8 0.373 0.136 1.864 2.847 1.054
9 0.332 0.184 1.816 2.970 1.010
Factors for X̅ – S Chart

n A3 B3 B4
10 0.975 0.284 1.716
 5S – Questions and Answers.
11 0.927 0.321 1.679
12 0.886 0.354 1.646
13 0.850 0.382 1.618
14 0.817 0.406 1.594
15 0.789 0.428 1.572
16 0.783 0.448 1.552
17 0.739 0.446 1.531
18 0.718 0.482 1.518
19 0.698 0.497 1.503
20 0.680 0.510 1.490

3
√n √
UCLp = P̅ + p̅ (1− p)
P - Chart
(Variable Sample Size) 3  σ = √ p̅ (1− p̅ )/n
√n √
LCLp = P̅ - p̅ (1− p) 3
√n √
 3σ = p̅ (1− p̅ )
np - Chart UCLnp = n̅p + 3σ
(Fixed Sample Size LCLnp = n̅p - 3σ
Attribute

U - Chart
UCLu = U̅ + 3
√ U̅
n
 σ=
√ U̅

√
(Variable Sample Size) U̅ n
LCLu = U̅ - 3
n
U - Chart UCLu = C̅ + 3√ C̅
 σ = √c
(Fixed Sample Size) LCLu = C̅ - 3√ C̅

Cp= Process capability index,

Allowable spread
Cp=
Total Process spread
(USL−LSL)
Cp=
6σ
Process performance index
Cpk =
Process Capability Index

Cpk = Minimum of {( USL−X̅ ) X̅ −LSL

3σ
,
3σ }
Cpk In trance
≥ 2.0 Very Capable Process
1.67 Within 63% of the tolerance
1.33 Within 75% of the tolerance
1.00 Within 100% of the tolerance
< 1.00 Incapable
 5S – Questions and Answers.
6σ 10,00,000 production of bags 3.4 defects PPM
5σ 10,00,000 production of bags 230 defects PPM
4σ 10,00,000 production of bags 6200 defects PPM
3σ 10,00,000 production of bags 6680 defects PPM
2σ 10,00,000 production of bags 308500 defects PPM
1σ 10,00,000 production of bags 691500 defects PPM

No of No of class
Observations boundaries
≤ 50 6
51 - 100 7
101 – 200 8
201 - 500 9
501 ------- 10

Six Sigma (DMAIC)

1st step Define
2nd step Measure
3rd step Analyze
4th step Improve
5th step Control

Years
1931 The most crucial breakthrough came in the modern quality movement.
1962 Quality circle concept started in Japan
1981 Quality circle concept started in India
Prof.Mahalanobis was a member of the planning commission of
1955 - 67
government of India.
April 1962 Dr.Ishikawa renamed the study group as Quality Control Circle
When was the revised definition of the concepts of QCC introduced by
1995
JUSE
1986 KAIZEN popularized Year
1880 Suggestion Box introduced year
Years and 1989 – New Delhi
Places of 2002 - Lucknow
ICQCC hosted October 2010 - Hyderabad
by QCFI in
November 2021 - Hyderabad
INDIA

Juran’s “Projected by Project Method”

First Step Proof of the need
 5S – Questions and Answers.
Last Step (10th) Control at the new level

Juran advocated a ten-step process for quality improvement programs.

1. Build awareness of need and opportunity for improvement

 Survey the employees / personnel, find why errors / mistakes / deviations are made

 After a week, select the top ten reasons

 Decide how to make sure those mistake-causing steps aren't repeated

 Keep track of the number of mistakes being made, make sure they are decreasing

2. Set goals for improvement

 Establish specific goals to be reached

 Establish plans for reaching the goals

 Assign clear responsibility for meeting the goals

 Base the rewards on results achieved

3. Organize to reach the goals

 Establish quality councils

 Identify problems

 Select projects

 Appoint teams

 Designate facilitators

4. Provide training

 Investment in education and training will fetch rewards

5. Carry out projects to solve problems

 Large, break-through improvements through interdepartmental or even cross-functional teams

 Tackle the chronic problems for break-through improvements

 Vital few problems create the breakthroughs

6. Report progress

 Progress expected and the actual progress achieved

 Act to improve the operational status to reduce variance

 Information on progress provides confidence on quality improvement projects

7. Give recognition

 Morale booster

8. Communicate results

 Lesson learnt
 5S – Questions and Answers.
 Awareness of the approach taken, possibility to learn and improve further

 Improvement outlook for people in other areas, to emulate success

9. Keep score

 Track progress

 Report achievements, short-falls

10. Maintain momentum by making annual improvement part of the regular processes

 People oriented

 Team-work

Juran’s steps for improvements in quality have been widely accepted, practiced and evolved over time to suit different
organizations and segments.

Industrial Cycle as per Dr. A V Feignbaum

First Stage New Design Control
Second Stage Incoming Material Control
Third Stage Shop Floor Control
Fourth Stage Management Control

Abbreviations
JIS
JUSE Union of Japanese Scientist & Engineering
CWQC Company Wide Quality Control
SQC Statistical Quality Control
SPC Statistical Process Control
TQM Total Quality Management
TQC Total Quality Control
QCFI Quality Circle Forum of India
QCRG Quality Control Research Group
QIT Quality Improvement Team

1. Line Graph
Commonly Used 2. Bar chart/ Graph
Graphs 3. Pie chart or Circle Graph
4. Pictorial graph
Special Purpose 1. Belt Graph
 5S – Questions and Answers.
2. Radar Chart
3. Compound Graph – bar and line
4. Strata graph
Graphs
5. Float Graph
6. Zee Graph
7. Pyramid Graph