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CORK INSTITUTE OF TECHNOLOGY
INSTITIÚID TEICNEOLAÍOCHTA CHORCAÍ
Autumn 2011/
Module Title: Quality Engineering
Module Code: MANU
School: Mechanical & Process Engineering
Programme Title: Bachelor of Engineering (Hons) in Biomedical Engineering Bachelor of Science (Hons) in Process Plant Technology Bachelor of Science (Hons) in Advanced Manufacturing Technology
Programme Code: EBIOM_8_Y3, EPPTE_8_Y4, EAMTE_8_Y4, EPPTN_8_Y4, EAMTN_8_Y
External Examiner(s): Mr K. McCarthy, Mr G. Reilly, Mr G. Clerkin, Dr L. McNamara
Internal Examiner(s): Micheal P O’Mahony, Sally Bryan
Instructions: Answer THREE questions
Duration: 2 Hours
Sitting: Autumn 2012
Requirements for this examination: None
Note to Candidates: Please check the Programme Title and the Module Title to ensure that you are attempting the correct examination. If in doubt please contact an Invigilator.
a) During the evolution of the Quality Management System (QMS) the following four activities increased in importance: i. Employee Participation ii. Quality Audits iii. Document Control iv. Vendor Policy Briefly summarise each activity and in particular explain the impact of these on employees. (16 marks) b) ISO9000 is a generic series of standards that sets down requirements and guidelines that define the way an effective QMS should operate. What are the advantages and disadvantages of ISO9000 being ‘generic’? (9 marks) c) Explain how quality awards (e.g. Deming prize, European Quality award) can be used by companies to improve their QMS. (8 marks)
Q2. a) In acceptance sampling a sample is taken at random from a batch whereas in classical SPC a sample would be taken of consecutive units. Explain why there is this difference. (8 marks) b) Describe the procedure of a double sampling plan. What are the advantages and disadvantages of using a double sampling plan compared to a single sampling plan? (8 marks) c) A large batch is to be accepted or rejected. The following acceptance plan is to be implemented: Take a sample size of 50 and reject the batch if 3 or more faulty units are found; if two or less items are found accept the batch. i. What is the significance of the batch being ‘large’? (4 marks) ii. Find the probability of accepting a batch containing 5% and 10% faulty items (8 marks) iii. Sketch the operating characteristic curve for this plan (no need to do additional calculations). (5 marks)
Pa= 0 i!
c ie
i
^
where λ=np
a) Explain why “Overproduction” is often cited as the most damaging manufacturing waste. (6 marks) b) Differentiate between the terms; value add, non-value add and necessary non-value add. Give an example of each. (6 marks) c) Measurement Systems Analysis (MSA) is a very important part of a six sigma project. The following three aspects can add variation into results. Discuss how each aspect can add variation. i. Measurement Resolution (4 marks) ii. Measurement Accuracy (6 marks) iii. Measurement Precision. (4 marks) d) Discuss the ‘Control’ phase in a Six Sigma project. Why is this phase important? What are the main tools used? (7 marks)
