Difficulty: Easy & Basic
Which quality chart ranks defect categories by frequency so the largest contributors are easy to see?
A P chart
B Pareto chart
C Process flow map
D Scatter plot
Answer: B. Pareto chart. A Pareto chart orders categories by their contribution and can guide improvement priorities.
One dyeing measurement exceeds its process control limit. What should the team do?
A Investigate a possible cause
B Change every batch recipe
C Replace all tolerances
D Ignore all later results
Answer: A. Investigate a possible cause. A point outside a control limit is a signal to investigate a special cause. It does not identify the cause.
Compared with a simple time plot, what feature does a control chart add?
A Only product labels
B Absence of times
C No plotted data
D Statistical control limits
Answer: D. Statistical control limits. A control chart adds limits derived from process behaviour to help detect unusual variation.
What does a process capability study compare?
A Carton count and order size
B Process spread and specifications
C Yarn twist and colour brand
D Dry heat and steam pressure
Answer: B. Process spread and specifications. Capability compares the distribution of a stable process with the relevant specification limits.
Which chart monitors changes in mean fabric weight across successive subgroups?
A c chart
B p chart
C X-bar chart
D np chart
Answer: C. X-bar chart. An X-bar chart monitors subgroup averages of a measured variable.
What does a check sheet provide during repetitive fabric inspection?
A Automatic fabric repair
B Continuous steam pressure
C Final dye bath formula
D Structured defect tally
Answer: D. Structured defect tally. A check sheet standardises how observations and counts are recorded.
Choose the chart for fraction nonconforming in samples of varying size.
A X-bar chart
B p chart
C c chart
D np chart
Answer: B. p chart. The p chart monitors the proportion of nonconforming units and can use varying sample sizes.
For a single sampling plan written as (n,c), what does c represent?
A Acceptance number
B Sample size
C Inspection area
D Process standard deviation
Answer: A. Acceptance number. The lot is accepted when the observed nonconforming count does not exceed the acceptance number c.
Why should fabric shade comparison use specified lighting?
A All colours become neutral
B Fabric structure changes instantly
C Observed shade depends on light
D Lighting sets fabric thickness
Answer: C. Observed shade depends on light. A controlled illuminant improves consistency because apparent shade depends on the light source.
Identify the quality cost category for laboratory verification before shipment.
A Warranty cost
B External failure cost
C Appraisal cost
D Internal scrap only
Answer: C. Appraisal cost. Tests and inspections assess conformance and are generally counted as appraisal activities.
During troubleshooting, a team plots drying speed against residual moisture. Which chart shows paired measurements?
A Scatter plot
B Check sheet
C Assembly tree
D Pie chart
Answer: A. Scatter plot. A scatter plot shows pairs of values and can reveal an association or pattern.
Count individual fabric defects per roll when every inspected roll has the same inspection area. Which basic attribute chart fits?
A R chart
B p chart
C X-bar chart
D c chart
Answer: D. c chart. The c chart models counts of nonconformities for a constant area or opportunity.
Quality staff sort roll inspection results by loom to see if one loom produces more defects. What technique is this?
A Stratification
B Routine calibration
C Random replacement
D Shade blending
Answer: A. Stratification. Grouping data by a meaningful source, such as loom, can reveal a pattern hidden in pooled results.
Which activity estimates variation attributable to different operators using the same measurement method?
A Rolling median calculation
B Only width grading
C Reproducibility study
D Shade recipe costing
Answer: C. Reproducibility study. Reproducibility can quantify variation when measurement conditions differ, such as when operators change.
Why should control limits and product specification limits be distinguished?
A They are always equal
B Both represent fabric width
C Neither uses measured units
D They serve different purposes
Answer: D. They serve different purposes. Control limits reflect process variation. Specification limits define product acceptance requirements.
What is the purpose of first-piece approval after switching a textile line to a new style?
A Avoid material identification
B Start packing without checks
C Confirm setup before bulk
D Average every past failure
Answer: C. Confirm setup before bulk. Checking a first piece helps catch setup or construction errors before bulk quantities are produced.
How does an R chart represent within-subgroup variation?
A Using material cost
B Using product ranks
C Using repair frequency only
D Using subgroup ranges
Answer: D. Using subgroup ranges. The range is the difference between the largest and smallest measurement within a subgroup.
To organise possible causes of shade variation by people, methods, material and machine, which tool fits?
A Packing checklist
B Histogram only
C Cause-and-effect diagram
D Run chart only
Answer: C. Cause-and-effect diagram. A cause-and-effect diagram groups candidate causes so they can be investigated systematically.
What lot-level decision is acceptance sampling designed to support?
A Accept or reject a lot
B Choose fabric fibre type
C Find every faulty unit
D Predict machine energy use
Answer: A. Accept or reject a lot. The sample result is used in a decision rule for the whole lot.
Select the plot that displays the frequency distribution of measured fabric weights.
A Cause-and-effect diagram
B Histogram
C Sewing operation diagram
D Assembly marker
Answer: B. Histogram. A histogram groups numeric measurements into intervals and shows their frequencies.
Replacing a rejected fabric roll before it leaves the mill is normally which kind of quality cost?
A Prevention cost only
B Internal failure cost
C External failure cost
D Equipment rating cost
Answer: B. Internal failure cost. Losses from faults discovered before customer delivery are internal failure costs.
With constant sample size, which chart monitors the number of nonconforming units in each sample?
A X-bar chart
B R chart
C u chart
D np chart
Answer: D. np chart. An np chart displays the number of nonconforming units when the sample size remains fixed.
Under a stated sampling plan with c = 2, three sample items are nonconforming. What is the decision?
A Raise the acceptance number
B Do not accept the lot
C Reduce sample size automatically
D Accept with no change
Answer: B. Do not accept the lot. The observed count of three exceeds the stated acceptance cutoff of two.
Before production, operators are trained to prevent recurring inspection and fabrication errors. Which quality cost category covers this training?
A Prevention cost
B Internal failure cost
C Appraisal cost
D External failure cost
Answer: A. Prevention cost. Training designed to prevent defects is part of prevention spending.
If area inspected varies across fabric rolls, which chart can track defects per unit area?
A u chart
B c chart
C R chart
D np chart
Answer: A. u chart. The u chart uses a defect rate per inspection unit and can account for unequal exposure.