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ESE 2019

UPSC ENGINEERING SERVICES EXAMINATION

Preliminary Examination

General Studies and


Engineering Aptitude
Standards and Quality Practices in
Production, Construction,
Maintenance and Services

Comprehensive Theory with Practice Questions


and ESE Solved Questions

Publications

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Publications

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ESE 2019 Preliminary Examination :


Standards and Quality Practices in Production, Construction, Maintenance and Services
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Preface
The compilation of this book Standards and Quality
Practices in Production, Construction, Maintenance
and Services was motivated by the desire to provide a
concise book which can benefit students to understand
the concepts of this specific topic of General Studies and
Engineering Aptitude section.

This textbook provides all the requirements of the


students, i.e. comprehensive coverage of theory,
fundamental concepts and objective type questions articulated in a lucid language. The
concise presentation will help the readers grasp the theory of this subject with clarity and apply
them with ease to solve objective questions quickly. This book not only covers the syllabus of ESE
in a holistic manner but is also useful for many other competitive examinations. All the topics are
given the emphasis they deserve so that mere reading of the book clarifies all the concepts.

We have put in our sincere efforts to present detailed theory and MCQs without compromising the
accuracy of answers. For the interest of the readers, some notes, do you know and interesting
facts are given in the comprehensive manner. At the end of each chapter, sets of practice question
are given with their keys and detailed explanations, that will allow the readers to evaluate their
understanding of the topics and sharpen their question solving skills.

Our team has made their best efforts to remove all possible errors of any kind. Nonetheless, we would
highly appreciate and acknowledge if you find and share with us any printing and conceptual errors.

It is impossible to thank all the individuals who helped us, but we would like to sincerely thank all
the authors, editors and reviewers for putting in their efforts to publish this book.

With Best Wishes

B. Singh
CMD, MADE EASY Group
Standards and Quality Practices in Production,
Contents
Construction, Maintenance and Services

Chapter 1 Chapter 3
Quality ............................................................. 1 Quality Control Tools.......................................... 20
1.1 What is Quality?..........................................................1 3.1 Introduction.............................................................. 20
1.1.1 Definition of Quality....................................1 3.1.1 Quality Control Tools................................ 20
1.1.2 Consequences of Poor Quality................1 3.2 Application of 7QC Tool in Six-sigma............... 28
1.1.3 Evolution of Quality.....................................2 Objective Brain Teasers........................................... 28
1.1.4 Who are the Customers?............................2
Chapter 4
1.1.5 Dimensions of Quality................................3
Sampling ........................................................... 32
1.1.6 Quality Characteristics................................3 4.1 Sampling.................................................................... 32
1.2 Traditional Approach vs Modern Approach 4.2 How can we do Sampling Inspection?............ 32
Towards Quality.......................................................4 4.3 Acceptance Sampling............................................ 32
1.3 Types of Quality..........................................................4 4.3.1 Acceptance Sampling by Attributes... 33
1.4 Quality Cost..................................................................4 4.3.2 Acceptance Sampling by Variables..... 33
1.4.1 Cost of Conformance...................................5 4.3.3 Types of Sampling Plan........................... 33
1.4.2 Cost of Nonconformance or Failure Cost.....5 4.3.4 Single Sampling Plan............................... 34
1.5 Value of Quality vs Quality Cost............................5 4.3.5 Double Sampling Plan............................. 35
1.6 Quality Process ...........................................................6 4.3.6 Multiple Sampling Plan........................... 36
1.6.1 Quality Assurance vs Quality Control....6 4.4 Sampling Terms and Its Definitions.................. 36
1.7 Methods for Generating Solution to 4.5 Operating Characteristic Curve (OC Curve).......37
Improve Quality..........................................................7 4.5.1 Types of OC Curve..................................... 38
Objective Brain Teasers..............................................8 4.6 Military Standard 105E.......................................... 39
Objective Brain Teasers........................................... 40
Chapter 2
Different Approaches Regarding Quality......... 14 Chapter 5
2.1 Introduction.............................................................. 14 Quality Management......................................... 44
2.1.1 Dr. W. Edward Deming............................ 14 5.1 Introduction.............................................................. 44
2.1.2 Joseph M. Juran.......................................... 15 5.1.1 Traditional Management........................ 46
2.1.3 Philip Crosby Approach........................... 15 5.1.2 Emergence of TQM.................................... 46
2.1.4 Kaoru Ishikawa Philosophy of Quality....15 5.2 Principles of TQM..................................................... 46
2.2 JIT vs MRP................................................................... 16 5.3 Taguchi Approaches in TQM.............................. 48
2.3 Kanban........................................................................ 16 5.4 Taguchi Approach vs. Deming Approach....... 50
2.4 Kaizen
.......................................................................... 16 5.5 Quality Function Deployment (QFD)............... 50
2.5 Poka-Yoke [Poka-Mistake, Yoke-Avoid]............ 17 5.6 Other Methods Utilizes along TQM
2.6 Concurrent Engineering....................................... 17 to Increase Efficiency............................................. 52
2.7 Value Engineering vs Value Analysis................ 17 5.6.1 TQM Approach in Competitive
Objective Brain Teasers........................................... 18 Positioning................................................... 52
5.6.2 Obstacles while Implementing TQM......52 8.4.2 Constraints in Line Balancing Problem.......83
5.6.3 Quality Awards Related to TQM............ 53 8.4.3 Definition and Terminology
5.7 Benefits of TQM........................................................ 53 in Assembly Line...............................................84
Objective Brain Teasers........................................... 53 8.5 Price Elasticity of Demand................................... 86
Objective Brain Teasers........................................... 87
Chapter 6
ISO Standards..................................................... 56 Chapter 9
6.1 Introduction.............................................................. 56 Quality in Construction and Services................ 92
6.2 ISO 9000...................................................................... 56 9.1 Introduction.............................................................. 92
6.3 ISO 14000................................................................... 59 9.2 Methodology to Improve Quality in
6.4 OHSAS 18000............................................................ 61 Construction.......................................................... 95
6.5 Emission Norms....................................................... 62 9.2.1 General.......................................................... 95
Objective Brain Teasers........................................... 64 9.2.2 Design of Questionnaire......................... 95
Chapter 7 9.3 Service Quality......................................................... 95
Six Sigma ........................................................... 67 9.3.1 Dimensions of Service Quality.............. 96
7.1 Historical View.......................................................... 67 9.3.2 Approaches to Service Quality............. 97
7.1.1 What is Sigma?............................................ 67 9.3.3 Quality Service Improvement Methods....97
7.1.2 What is Six Sigma?..................................... 67 Objective Brain Teasers........................................... 98
7.1.3 Benefits of Six Sigma................................ 68
7.1.4 Six Sigma Management.......................... 69 Chapter 10
7.1.5 Defects Per Million Opportunities Reliability and Maintenance.............................. 99
(DPMO).......................................................... 69 10.1 Reliability.................................................................... 99
7.2 Six Sigma Methodology........................................ 70
10.2 The Bathtub Curve................................................100
7.3 Different Levels in Six Sigma............................... 71
10.3 System Reliability..................................................101
7.4 Lean Management Vs Six Sigma........................ 72
10.4 Maintainability.......................................................103
7.5 Design of Experiments.......................................... 72
7.6 Difference between DOE and 10.5 Availability...............................................................103
Statistical Process Control................................. 72 10.6 Maintenance...........................................................104
Objective Brain Teasers........................................... 73 10.6.1 Maintenance Scheme/Types...............104
10.6.2 Reliability Centered Maintenance
Chapter 8
(RCM)............................................................106
Inventory ........................................................... 75
8.1 Inventory.................................................................... 75 10.6.3 Total Productive Maintenance (TPM)... 107
8.1.1 Classification of Inventories................... 75 Objective Brain Teasers.........................................109
8.1.2 Inventory Cost............................................. 76 Chapter 11
8.1.3 Review System............................................ 77 Non-Destructive Examination......................... 113
8.2 Types of Models....................................................... 78
11.1 Non-Destructive Testing.....................................113
8.2.1 Deterministic Model................................. 78
11.2 Non-Destructive Examination (NDE) .............115
8.3 Selective Inventory Management..................... 81
8.3.1 Always Better Control (ABC).................. 81 11.3 PT Techniques.........................................................119
8.3.2 VED Analysis................................................ 82 11.4 RT Techniques.........................................................121
8.3.3 FNSD............................................................... 82 11.5 UT Techniques........................................................122
8.3.4 XYZ.................................................................. 82 11.6 ET Techniques.........................................................124
8.4 Line Balancing.......................................................... 83 Objective Brain Teasers.........................................125
8.4.1 Objective in Line Balancing Problem......83
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