Quality Assurance & Reliability Engineering Quiz
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Questions and Answers

What is the primary aim of Quality Assurance?

  • To maintain records for auditing purposes
  • To detect and reject defective work
  • To prevent defects from appearing (correct)
  • To ensure specifications are met

    • Which of the following is NOT a specific quality aspect in manufacturing?

  • Choice of machinery and tools
  • Selection and training of production personnel
  • Implementation of marketing strategies (correct)
  • Planning quality controls

    • What is one purpose of using trial lots in manufacturing?

  • To prove that the product will meet field performance (correct)
  • To gather customer feedback on prototypes
  • To conduct full-scale production immediately
  • To minimize production costs

    • Which aspect is crucial for Choice of tools used in manufacturing?

    <p>The ability to maintain tolerances</p> Signup and view all the answers

    What is a key method to eliminate defects according to Quality Assurance principles?

    <p>Identifying and addressing root causes</p> Signup and view all the answers

    Why is it important to maintain detailed records in Quality Assurance?

    <p>To facilitate investigations into problems or failures</p> Signup and view all the answers

    What distinguishes the pilot plant from the production shop?

    <p>Pilot plants focus on proving engineering feasibility</p> Signup and view all the answers

    What is a major risk of using an incorrect sampling plan?

    <p>Acceptance of defective lots</p> Signup and view all the answers

    What does reliability engineering primarily focus on preventing?

    <p>Defects and failures in hardware</p> Signup and view all the answers

    For which types of failures is reliability engineering most suitable?

    <p>Repetitive types of failures</p> Signup and view all the answers

    Which of the following aspects does reliability engineering NOT typically address?

    <p>Increasing employee satisfaction</p> Signup and view all the answers

    What is one of the goals of reliability engineering?

    <p>To reduce the breakdown rate of equipment</p> Signup and view all the answers

    Which process is essential in reliability engineering for identifying root causes of failures?

    <p>Failure analysis</p> Signup and view all the answers

    In reliability engineering, what type of items can the discipline be applied to?

    <p>Any type of hardware, regardless of size</p> Signup and view all the answers

    Which component of reliability engineering aims to improve operational efficiency?

    <p>Root cause analysis</p> Signup and view all the answers

    What happens when adequate sampling methods are not utilized?

    <p>Acceptance of substandard lots</p> Signup and view all the answers

    What is the primary focus of the Failure Review Group (FRG)?

    <p>Finding practical and economical solutions to problems</p> Signup and view all the answers

    Which of the following best describes reliability engineering's contribution to costs?

    <p>It helps in reducing costs by improving operational availability.</p> Signup and view all the answers

    How often should the Failure Review Group (FRG) meet to review failure reports?

    <p>Once a week</p> Signup and view all the answers

    Which of the following should NOT be the role of the FRG?

    <p>Reporting all problems to manufacturers</p> Signup and view all the answers

    What are some elements that failure report forms should include?

    <p>Failure symptoms and elapsed commission time</p> Signup and view all the answers

    Under what circumstances should an FRG be established?

    <p>Whenever new equipment is commissioned or for longstanding issues causing concern</p> Signup and view all the answers

    What does the term 'Indifference Quality Level' (SQL) represent?

    <p>A quality level with a probability of acceptance of 0.50</p> Signup and view all the answers

    How is the Average Outgoing Quality Limit (AOQL) affected when incoming quality is significantly poor?

    <p>AOQL will reach its maximum, reflecting outgoing defects</p> Signup and view all the answers

    What is essential for ensuring proper inspection between a purchaser and a supplier?

    <p>Clear specification of sampling plans</p> Signup and view all the answers

    What should an inspector do if sampling acceptance is not specified in the inspection guidelines?

    <p>Request clarification from the purchaser</p> Signup and view all the answers

    Which factor influences the sample size specified for inspection?

    <p>The method of production of items being inspected</p> Signup and view all the answers

    What is the likely outcome if both incoming quality is perfect and outgoing quality is also perfect?

    <p>There will be no rejected lots</p> Signup and view all the answers

    What is the primary concern with the consumer's risk regarding the RQL?

    <p>The actual quality received depends on inspection probability</p> Signup and view all the answers

    In the context of sampling plans, what is the significance of the inspector's role?

    <p>To follow the specified sampling plans scrupulously</p> Signup and view all the answers

    What is the relationship represented by the formula AOQ = pPa?

    <p>The link between fraction of defectives before and after inspection</p> Signup and view all the answers

    What is reliability defined as?

    <p>The probability that an item will operate correctly under specified conditions for a set time.</p> Signup and view all the answers

    What characterizes a 'misuse failure'?

    <p>Failure stemming from excessive stress beyond the item's capability.</p> Signup and view all the answers

    During which period is the failure rate considered approximately constant?

    <p>Constant failure period.</p> Signup and view all the answers

    What is indicated by a systematic failure?

    <p>Failures that provide valuable insights into underlying issues.</p> Signup and view all the answers

    What occurs during the wear out failure period?

    <p>The incidence of failures is high as components near the end of service life.</p> Signup and view all the answers

    How can failures be classified based on their cause?

    <p>As misuse failures or inherent weakness failures.</p> Signup and view all the answers

    What happens after the early failures have been removed?

    <p>A relatively long period of constant failure occurs.</p> Signup and view all the answers

    Which of the following describes 'inherent weakness failure'?

    <p>Failures arising from inherited material defects or design flaws.</p> Signup and view all the answers

    Which of the following represents a characteristic of 'random or chance failures'?

    <p>They occur at random with no identifiable cause patterns.</p> Signup and view all the answers

    What does reliability engineering primarily study?

    <p>The modes and mechanisms of failures across different hardware types.</p> Signup and view all the answers

    Which of the following is a component of maintaining quality in traction assets?

    <p>Compliance with specifications and engineering practices</p> Signup and view all the answers

    What is essential for the effective implementation of Quality Management within an organization?

    <p>Employee participation in quality circles</p> Signup and view all the answers

    Which method contributes to the improvement of service quality and equipment availability?

    <p>Application of reliability engineering concepts</p> Signup and view all the answers

    What role does sound engineering practice play in the definition of quality?

    <p>It supplements specifications even if not explicitly included</p> Signup and view all the answers

    Which guideline is emphasized for the purchase of spare parts?

    <p>Purchasing only from original or approved suppliers</p> Signup and view all the answers

    What is a significant factor in defining quality as stated in the guidelines for traction assets?

    <p>Compliance with predefined specifications and accepted designs</p> Signup and view all the answers

    What aspect is considered crucial for enhancing the quality of products and services?

    <p>Engaging all employees in quality improvement efforts</p> Signup and view all the answers

    What is the primary responsibility of the Failure Review Group (FRG)?

    <p>To provide practical and economical solutions to problems</p> Signup and view all the answers

    What should be included in a failure report form according to standard practices?

    <p>Details of the equipment type and previous modifications</p> Signup and view all the answers

    How should the FRG approach the meeting frequency regarding failure reports?

    <p>Hold meetings weekly to ensure timely reviews</p> Signup and view all the answers

    What is a key guideline for the FRG when dealing with newly commissioned equipment?

    <p>An FRG should be set up immediately upon commissioning</p> Signup and view all the answers

    What is a significant limitation of the FRG's function as outlined?

    <p>To only report problems without proposing solutions</p> Signup and view all the answers

    What is the primary focus of Quality Assurance?

    <p>To prevent defects from occurring in the work done.</p> Signup and view all the answers

    Which of the following is part of the Quality aspects in manufacturing?

    <p>Planning quality aspects of purchasing and shipping.</p> Signup and view all the answers

    What is the purpose of a trial lot in manufacturing?

    <p>To ensure the product meets desired field performance.</p> Signup and view all the answers

    Why is it essential to maintain records in Quality Assurance?

    <p>To facilitate investigations into problems or failures.</p> Signup and view all the answers

    Which of the following describes the distinction of the production shop compared to the pilot plant?

    <p>The goals and conditions can be significantly different.</p> Signup and view all the answers

    What does Quality Assurance aim to eliminate in processes?

    <p>Basic or root causes of defects.</p> Signup and view all the answers

    Which of the following is true regarding the choice of tools in manufacturing?

    <p>Tools must be capable of maintaining specified tolerances.</p> Signup and view all the answers

    What principle governs the use of acceptance sampling?

    <p>Sampling plans should facilitate efficient quality checks.</p> Signup and view all the answers

    Which statement correctly reflects the Quality Assurance objectives in terms of rework?

    <p>The aim is to eliminate basic causes of defects to minimize rework.</p> Signup and view all the answers

    What is the most accurate definition of reliability in engineering?

    <p>The probability that an item will perform as required for a stated period of time.</p> Signup and view all the answers

    Which statement accurately describes a 'misuse failure'?

    <p>Failure attributable to stress beyond the item’s stated capability.</p> Signup and view all the answers

    What is characterized by a relatively high incidence of failures due to components exceeding their service life?

    <p>Wear out failure period.</p> Signup and view all the answers

    What distinguishes systematic failures from random failures?

    <p>Systematic failures show patterns indicating specific causes.</p> Signup and view all the answers

    How is the reliability at time t calculated?

    <p>Number surviving at present divided by number at start.</p> Signup and view all the answers

    What is the purpose of defining the Indifference Quality Level (SQL) in sampling plans?

    <p>To establish a quality level with a 0.50 probability of acceptance.</p> Signup and view all the answers

    What type of failure is caused by weaknesses inherent within the item?

    <p>Inherent weakness failure.</p> Signup and view all the answers

    What can be inferred about the Average Outgoing Quality Limit (AOQL) when incoming quality is very bad?

    <p>AOQL will remain perfect due to lot rejection based on bad incoming quality.</p> Signup and view all the answers

    During which phase is the failure rate described as approximately constant?

    <p>Constant failure period.</p> Signup and view all the answers

    Why should sampling plans be specified clearly by the purchaser?

    <p>To ensure that both parties agree on the evaluation of product quality.</p> Signup and view all the answers

    What best explains the term 'random or chance failures'?

    <p>Failures that occur at irregular intervals without a specific pattern.</p> Signup and view all the answers

    How does the incoming quality influence the outgoing quality according to the AOQ formula?

    <p>The fraction of defectives in outgoing quality is directly related to the fraction in incoming quality.</p> Signup and view all the answers

    Which failure classification does NOT relate to the cause of failure?

    <p>Constant failure period.</p> Signup and view all the answers

    What action should be taken if the inspection specification does not include Acceptance by Sampling?

    <p>Refer to the purchaser before deciding on the inspection method.</p> Signup and view all the answers

    What happens to items during the early failure period?

    <p>They experience a higher incidence of failures.</p> Signup and view all the answers

    What is the implication of using smaller sample sizes in inspections of items produced by fully automatic machines?

    <p>It allows for quicker acceptance of production lots.</p> Signup and view all the answers

    In terms of sampling plans, which property might necessitate checking a larger sample size?

    <p>Properties deemed more important for quality assurance.</p> Signup and view all the answers

    What does the formula AOQ = pPa signify in the context of quality inspection?

    <p>It represents the relationship between the fraction of defectives before and after inspection.</p> Signup and view all the answers

    What is the consumer's risk associated with a specified RQL?

    <p>The chance of receiving less than one lot in ten at the RQL fraction defective.</p> Signup and view all the answers

    Study Notes

    Quality Assurance & Reliability Engineering

    • 10900 General: Every official should improve quality, productivity, and efficiency in their department. Quality Assurance involves improving, developing, and maintaining quality to meet service requirements economically.

    Definition of Quality

    • 10901 Definition: Quality spares are vital for reliable train operation. Quality is defined by:
      • Purchaser's specifications accepted by the supplier.
      • Supplier's declared design details accepted by the purchaser.
      • Sound engineering practice.

    Purchase of Spares

    • 10902 Purchase: Quality spares guidelines are outlined in Board letters (73/RS(G)/30/RLL, 30.3.87 & 17.2.89).
      • Spares sourced from original / approved suppliers.
      • Railways maintain a list of RDSO approved manufacturers.
      • Only the Chief Electrical Engineer can approve variations.

    Application of Reliability Engineering

    • 10903 Application: Using reliability engineering improves equipment availability and service quality.
      • Reliability engineering concepts for this are detailed in Annexure 9.2.

    Employees Participation

    • 10904 Participation: Employee participation in quality circles and quality improvement is essential for quality management.
    • Quality involves all levels in the company, including workers and managers.
    • Aim to build an organizational culture where improving quality is embedded in everyday work.

    Scope of Quality Assurance

    • Annexure 9.1: Quality Assurance ensures three conditions:
    • Purchaser specifications and supplier acceptance.
    • Supplier design details and purchaser acceptance.
    • Sound engineering practices.
    • Aim is to prevent defects, not just detect and reject defective work.
    • Maintain records for investigating problems and failures during the item's lifetime.
    • Manufacturing quality aspects include:
      • Appropriate machines, processes, and tools.
      • Accurate and controlled processes.
      • Planning of manufacturing information.
      • Planning of process quality controls.
      • Selecting and training production staff.
      • Planning quality of purchasing and shipping.

    Acceptance Sampling

    • Annexure 9.1, 1. Introduction: Acceptance sampling is a process for accepting or rejecting a shipment of items based on samples (not on a 100% inspection of every item)
    • Annexure 9.1, 1.2/1.3: Sampling plans define how many items to sample, from how many lots, and how many defects are permissible in each sample.
    • Annexure 9.1, 2 Quality Indices: Acceptable Quality Level (AQL) shows the maximum acceptable percent defective for sampling inspection. Rejectable Quality Level (RQL) specifies unacceptable quality levels. Indifference Quality Level (SQL) represents a probability of acceptance of 0.50.
    • Annexure 9.1, 2.4: Average Outgoing Quality Limit (AOQL) is the maximum percent of defective items remaining after inspection.

    Sampling Plans

    • Annexure 9.1, 3. Sampling Plans: Sampling Plans are specified by the purchaser in agreement with the supplier. Inspectors must strictly follow the plan.
    • Different sampling plans may be necessary for different quality aspects.
    • Lot size considerations may influence the sample size.

    Random Sampling

    • Annexure 9.1, 4. Random Sampling: Random, unbiased sampling from a lot is necessary for accurate conclusions about the whole lot.
    • Sample size consideration is relevant for reliable assessment; larger lots require larger samples.

    Limitations of Acceptance Sampling

    • Annexure 9.1, 6: Acceptance sampling involves risk and uncertainty.
    • Sampling may not accurately determine quality. Sampling plans must be accurately designed.

    Reliability Engineering

    • Annexure 9.2, 1. Introduction: Reliability engineering aims to prevent failures in all hardware (from simple tools to complex systems) to improve equipment availability, reduce costs, and enhance efficiency.
    • Annexure 9.2, 2 Basic Principles: Reliability is the probability that an item will perform as required, for a stated period of time.
    • Annexure 9.2, 2.2. Failures: Failure is the termination of an item's ability to perform its required function.
    • Annexure 9.2, 2.3. Failure Classifications: Failures are classified based on cause, suddenness (sudden or gradual), and degree (partial or complete).
    • Annexure 9.2, 2.4. Failure Patterns: Failures can be categorized by their rate of occurrence; early life, constant, and wear-out periods.
    • Annexure 9.2, 2.5. Failure Mechanisms: Common failure mechanisms: adhesion, arcing, backlash, bleeding, carbonisation, and more

    Mean Time Between Failures (MTBF)/ Mean Time To Failure (MTTF)

    • Annexure 9.2, 2.6/2.7: MTBF measures the average time between failures; MTTF is used when failures cannot be repaired.

    Failure Mode and Effects Criticality Analysis (FMECA)

    • Annexure 9.2, 3: FMECA assesses the impact of potential hardware failures to aid in early-stage reliability design and identify vulnerable components..
    • Use this method for a formal application to electronic systems, heavy electrical systems, or mechanical systems.

    Failure Reporting and Corrective Action System (FRACAS)

    • Annexure 9.2, 4: This is a system for reporting and investigating failures for systematic improvement in equipment reliability.
      • Failure review group (FRG) comprises of key staff to evaluate and propose solutions to equipment failures.

    Design and Manufacturing Stage

    • Annexure 9.2-5.1 & 5.2: Importance of detailed design review and adherence to drawings and processes during the design and manufacture stage. Critical inspection and testing are essential at every stage to prevent potential failure points.

    Operational and Maintenance Stage

    • Annexure 9.2, 5.4: Operation and maintenance staff have valuable input in identifying failures and initiating corrective actions. Importance of promptly addressing and analyzing failures to improve equipment reliability.

    Reliability and Cost

    • Annexure 9.2, 6: Reliability improvements may not always require significant cost increases.
    • Proper cost estimations for reliability improvements may be challenging.

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    Quality Assurance & Reliability Engineering PDF

    Description

    Test your understanding of Quality Assurance and Reliability Engineering principles as they apply to the railway sector. This quiz covers topics including the definition of quality, purchasing guidelines for spares, and the application of reliability engineering to enhance train operations. Explore the importance of quality in ensuring reliable services.

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