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WINTER 13 EXAMINATION
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12M
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Example:
1. Yard
2. Meter (1M)
End Standards: It is defined as the distance between the end surfaces of the material
standards. (1M)
Example:
6M
(2M)
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2.Sigma Comparator:
Comparator
3.Johnsons Mikkrokator:
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b)
It is very convenient to make correct holes of fixed sizes. Since holes are produced by drilling,
reaming, etc. their size is not easily adjustable because size of such tools are standard. On the
other hand, size of shaft produced by turning and grinding can be easily varied. In shaft basis
system upper deviation of shaft is zero, and different fits are obtained by varying the limits on
the holes.
(fig.3marks+3Marks Explanation)
16M
a) Calibration : it is done by detecting and adjusting any discrepancies in the instrument s accuracy to
bring it within acceptable limits. Calibration is done over a period of time, according to the usage of the
instrument and the materials of its parts. The dimensions and tolerances of the instrument/gauge are
checked to determine whether it has departed from the previously accepted certified condition. If
departure is within limits, corrections are made.
b) Traceability
The concept of establishing a valid calibration of a measuring instrument or measurement
standard by step-by-step comparison with better standards up to an accepted or specified standard.
Traceability implies eventual reference to an appropriate national or international standard.
b)Error in gears
1. Adjacent pitch error
2. Cumulative pitch error
3. Profile error
4. The tooth to tooth composite error Single flank
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c)
(fig.3marks+1mark naming)
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d)
e)
CLA : it is a line parallel to general direction of profile for which the ares embraced by the
profile above and below the line are equal.
Ra Value:It is defined as the average value of the ordinates (y1, y2, y3.. yn) from the mean
line.
RMS: It is defined as square root of arithmetic mean values of squares of ordinates of the
surface measured from mean line.
Rz Value: it is defined as average difference between five highest peaks and five lowest valleys
within sampling length measured from a line parallel to mean line and not crossing the profile.
(1Mark each)
Q3.Attempt any four
mark
16
a) Meaning of SIX-SIGMA
Six sigma quality approaches relies upon the normal distribution. Most of the output of
the process will meet the specifications (call it X bar). But some will deviate to varying extent,
measured by the standard deviation (sigma). So, some units will have a specification of X bar 1
sigma and some X bar 3 sigma. (2 marks)
Significance
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The manufacturing process may be at 2sigma and 3sigma etc., we start our journey
towards 6sigma. In other words, we have to shrink the variability of our process to such an extent
that the value of 6sigma of the process reduces to a new local value, which can be fitted between
+- 6sigma times, even with the same specification limits. This is quality improvement, such an
improved process hardly produces any defect. Figure explains clearly the difference between
3sigma and 6sigma process.
A six sigma process should actually generate no flows at all. But since, over the long run,
every process shifts by +- 6sigma, 3.4 parts out of every million will be beyond the six-sigma
level generating a few defects. Thus, six-sigma process capability means 3.4 ppm defects are
99.9996% good. (Table is optional)
Sigma Level
Yield in %
6sigma
3.4
99.99966
5sigma
233
99.9767
4sigma
6,210
99.3790
3sigma
66,807
93.3193
2sigma
308,537
69.1462
1sigma
690,000
(2 marks)
b)
TQM: It is defined as control of all the transformation of an organization to satisfy consumer
needs in most economical manner . (1 Mark)
Importance of TQM:
1. It is important to understand that quality conformance to requirements and not goodness.
It must have strong customer focus.
2. TQM integrates people, machines and information to provide customer quality
satisfaction at reasonable cost.
3. The system must work on the basis of prevention and not appraisal.
4. It calls for organization of quality activities in conformance with stated quality policies
and objectives.
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C) Cost of Quality
The cost of carrying out the quality functions so as to meet the quality needs of
consumers is called as cost of quality.
It includes,
1. Market research costs of discovering needs of customers.
2. Product research and developments cost of creating product concepts.
3. Design cost of translating product concepts into specifications.
4. Cost of manufacturing planning in order to meet quality specifications.
5. Cost of Inspection.
6. Cost of quality assurance.
7. Complaints, Field service and such other functions to improve quality. (2Mark)
Value of Quality
Direct or indirect returns gained by the company due to missions of quality control.
Depends upon,
Increase in sale.
Saving due to increased production.
Reduction in scrap and rework cost.
Indirect factors such as, Reputation of manufacturer and goodwill of customer,
psychological stability due to increased sale and security of job among workers. (2Mark)
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d) (1Mark each)
Flaw: Flaw is irregularity which occur at one place or at relatively infrequent or widely varying
intervals in surface.
Waviness:It results from the factors such as machine or work deflections, vibrations, chatter,
heat treatment. It is the component of surface roughness upon which roughness is superimposed.
Lay: - It is the direction of the predominant surface pattern ordinarily determined by the method
of production used.
Roughness:It is caused due to the irregularities in the surface roughness which results from the
inherent action of the production process. It is due to feed marks and the irregularities with in
them.
e) Types of Sampling Plan
1. Single Sampling Plan , Double Sampling Plan ,Multi Sampling Plan (1mark)
(3marks)
Q.4 A. Attempt any three:
a) Distinguish clearly between Roundness & Circularity.
[2 marks for point 1, 1 marks for point 2. & 1 mark for note.]
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Roundness
Circularity
1)Defined as a condition of a surface of
1) Defined as a two-dimensional geometric
revolution (like cylinder, cone or sphere)
tolerance that control how much a feature can
where all points of the surface intersected by
deviate form a perfect circle.
any plane perpendicular to the common axis in
case of cylinder and cone or passing through
common center in case of sphere
2) Roundness expresses a particular geometric 2) Circularity is the Characteristic form of the
form of a body of revolution in all the three
entire periphery of a plane figure i.e. two
dimensions.
dimensions.
Note: For measuring roundness it is only the circularity of the counter which is determined.
b)
Draw the sketch showing setup to test parallelism of axis to the intersection of two
planes.
Solution: The test setup is shown in the following figure.(4 marks for figure)
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Alignment test
Performance test
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[2 Marks each]
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For any sample size an acceptance number, there is a maximum value of AOQ beyond which ,
The average fraction defectives passed forwards will not rise, no matter how bad the quality of
lots, when they arrive at inspection. This is because , when incoming quality is good, AOQ must
be good.
However , when incoming quality is bad, the sampling plan will cause all the lots to be rejected,
!00% inspected and rectified. Therefore the outgoing quality will be good.
Therefore, at either extreme incoming quality very good or very bad, the outgoing quality will
tend to be very good.
Between these two lots , there will be a point, at which the percent of defectives will reach its
maximum. This point is known as average outgoing quality level (AOQL)
Q.5
a) i)
27 = 27
15 = 18-3 [2 Marks]
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ii)
Explain why sine bar is not used for angle greater than 45 if accuracy in angle measurement
is required.
[ 2 marks for derivation, 2 marks for explanation with figure]
We know that sin = h / l is the basic principle of working of sine bar,
Differentiating equation, we get
COS . d =
_
_
d = tan (
This indicates that error in is function of tan, and below 45 error is smaller , which suddenly increases
above 45.
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Q.5.b.i) suggest the suitable instruments to measure the external and internal threads.
For external thread measurement
1. Major diameter: Ordinary microscope or bench micrometer. Tool- makers microscope, profile
projector.
2. Minor diameter: Two V- pieces and a floating carriage diameter measuring machine or optical
projector or microscope
3. Effective diameter: Thread micrometer, ball-point micrometer, wires with micrometers.
4. Pitch: screw pitch, pitch measuring machine, profile gauge, micrometer,
5. Thread angle and form: Either a microscope or an optical projector
For internal thread measurement:
1. Major diameter: cast of the thread, microscope and optical profile projector
2. Minor diameter: Taper parallels, rollers, thread measuring machine
3. Effective diameter: screw thread micrometer, measuring machine, comparator, cast of thread.
4. Pitch: screw pitch, pitch measuring machine, profile gauge, micrometer
5. Thread angle and form: cast of the thread, Either a microscope or an optical projector
Q.5.b.ii) Explain with neat sketch working principle of floating carriage dial micrometer.
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Floating carriage micrometer is also called screw thread measuring machine or bench
micrometer.
Principle of floating carriage: it works on Principle of Nut & Bolt /Screw threads. As drum of
micrometer rotates by one revolution, it will move forward by one pitch of interval thread.
The movement will be measured using number of division on drum and main scale i.e.
Micrometer principle.
Floating carriage consist of
1)
2)
3)
4)
5)
6)
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3. ISO 14000 includes representation of core set of standards used by organizations for designing and
implementing an effective environmental management system.
4. It covers the eco-labelling, environmental aspects, life cycle assessment, environmental auditing
and environmental performance evaluation etc.
Principal elements of standards are :
(a) Environmental policy.
(b) Planning.
(c) Implementation.
(d) Operation.
(e) Checking and taking corrective action.
(f) Management review.
Q.5.c.ii)
[3 marks for any three points of advantages, 1marks for any two points of
disadvantages]
1. ISO 9000 series of standards enable to meet the requirements of an internationally uniform
quality system.
2. It enables the company to build customer confidence that it is capable of delivering the products
or services of desired quality.
3. It could enhance foreign exchange. So it is important for the industries to adopt ISO: 9000 to
compete in the international market.
4. It reduces the need for assessment by multiple buyers. It thus avoids time and money spent on
multiple inspections of the products for conformance.
5. It motivates the employees and develops pride in them for achieving excellence.
6. It ensures sound quality assurance system. This results in improvement inefficiency, and
reduction in inspection, scrap and rework.
7. Adoption of ISO 9000 helps to enhance quality image of the company.
8. ISO 9000 helps the company to :
(a) Define clearly the need of the company. .
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(b) Specify the right components, processes, tools and equipments for the job.
(c) Achieve a system of management and control.
(d) Distribute information to right people and at the right times.
(e) It provides a framework for continuous improvement in quality.
DISADVAVNTAGES of ISO 9000
1. The implementation of ISO 9000 series of standards is very much depending on resources. The
formulating and documenting of the system is time consuming and may involve considerable
clerical expenses.
2. Assessment and registration are also expensive.
3. Unless carefully interpreted and planned, the system can become burdensome and expensive,
quite often impending normal operations.
4. The need to change attitudes and accept new working practice may strain the management capability
of the company beyond its ability to cope.
Q.6. Attempt any two.
1) a) Compare attribute and variable measurement on any four parameters.
Variable inspection
Attribute inspection
1it is the method of judging the conformance or nonconformance of quality characteristic with the laid
down standard such as gauges.
4. Time consuming.
5. Higher inspection cost.
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Solution:
1.
Definition: It may be defined as the minimum spread of specific measurement variation, which
will include 99.73% of the measurement from the given process.
2.
In other words, Process capability = 6s, since 6s is taken as a measure of spread of process,
Which is also called as natural tolerance.
By this study, it becomes possible to know the % of products, which will be produced within 3s limits
on either side of mean
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(c) Suffer and sort out the defectives, if it is not economical to make any change in process.
3. When (Xmax -Xmin) = 6s
Conclusion:
Spread of process is approximately equal to difference between upper and lower specification limits.
Suggestion:
(a) It is necessary to maintain the centering process
(b) Reduce dispersion, if it is economical to do.
(c) Advisable to increase tolerance
Q.6.2. II) State the four benefits of SQC.
[4 marks for any 4 points]
Benefits of statistical quality control:
1. Efficiency and cost reduction: use of SQC ensures rapid and efficient inspection at minimum
cost.
2. Reduction of scrap: It enables to forecast the troubles before rejection occur and reduces the
amount of spoiled work.
3. More effective pressure: on quality improvement than 100% inspection.
4. Easy detection of faults: With the help of control charts, deterioration in quality can be easily
detected and corrective action can be taken.
5. Adherence to specification: specifications can be accurately predicted for future, by which it it
possible to access the capability of the process to meet the specification.
6. Easy application.
7. Better customer relations
8. Creates quality awareness in employees
9. Improves productivity and reduces wasted machine and man hours.
Q.6.3. The following are
34.0 31.6 30.8 33.0 35.0 33.2 33.0 32.6 33.8 37.8
35.8 35.4 34.0 35.0 33.8 31.6 33.0 28.2 31.8 35.6
R 4,4,2,3,5,2,5,13,19,6,4,4,14,4,7,5,5,3,9,6,
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D3=0
and N= 20,
=669
and
D4= 2.11
SR =124
Hence,
= (S
=669/20
=33.45
= (SR)/N
=124/20
=6.2
)/N
)=
+A2 x
= 33.45+0.58 x 6.2
=37.046
LCL(
)=
- A2
= 33.45-0.58 x 6.2
=29.854
Control limits for R:
UCL (R) = D4 X
= 2.11 X 6.2
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= 13.082
and
LCL(R)=D3 X
= 0 X 6.2
=0
X chart:
R chart:
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