The cost of a defect rises through the process because
Answer: C
A piece rejected after firing and glazing has consumed far more energy and labour than one rejected at the press. This is the argument for inspecting early and often rather than only at the end. Each inspection point is placed where it can save the most cost.
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Assertion (A): Inspection is placed as early in a ceramic process as the defect can be detected.
Reason (R): A piece rejected later has consumed more energy and labour than one rejected early.
Answer: D
Correct answer: Both A and R are true, and R is the correct explanation of A
Both are true and the reason gives the economics. A defect present in the green body but not found until after firing has consumed the drying energy, the kiln time, the kiln furniture space and the handling in between. Detecting it at forming costs the material alone. The principle sets where inspection is placed: as early as the defect can be seen, not where it is most convenient to look.
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Consider the following statements about defect management.
1. Fractography identifies the flaw that initiated a fracture.
2. Process control detects drift before defects appear.
3. Final inspection alone is sufficient for quality assurance.
Answer: A
Correct answer: 1 and 2 only
Statements 1 and 2 are correct: fractography identifies the initiating flaw, and process control catches drift before it produces defects at all. Statement 3 is the belief the other two exist to displace - final inspection finds defects after every cost of making them has been incurred, and it cannot find those it does not test for.
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State whether the following is true or false.
Inspecting the finished product is enough to assure quality.
Answer: B
Correct answer: False
Inspection sorts good from bad; it does not make anything good. By the time a piece is inspected the cost of making it has been spent, the causes are several steps upstream and no longer visible, and any test short of destruction samples only part of what could be wrong. Quality is assured by controlling the process that produces the pieces, with inspection as confirmation rather than as the mechanism.
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A sudden rise in reject rate accompanied by no change in the process is best investigated by
Answer: C
Correct answer: checking the incoming raw materials first
A step change in rejects with no change in the process points to a change in something entering the process, and the raw materials are the largest and most variable input - a new clay lot, a different consignment of feldspar, a shift in moisture. Checking them costs a morning. Altering the firing to compensate would mask the cause and leave the plant permanently mis-set once the material changed back.
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State whether the following is true or false.
Retaining samples of raw materials and finished product helps in investigating defects.
Answer: D
Comparing a problem batch against a known good one is often the quickest route to a cause. Without retained samples the investigation rests on records alone and usually stalls quickly. Retention periods are set against how long a fault might take to emerge.
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