Free ASQ Certified Quality Inspector & Reliability Engineer Questions and Answers — Questions and Answers

Question 1: Which of the following can concurrently measure size and location?

Coordinate measuring machine (Correct answer)
Micrometer
Dial bore indicator
Digital calipers

Correct answer: Coordinate measuring machine

A Coordinate Measuring Machine (CMM) is a sophisticated device capable of measuring the physical geometric characteristics of an object. It uses a probe to sense discrete points on a surface, allowing it to precisely determine both the dimensions (size) and the exact spatial positions (location) of features in three-dimensional space. Other instruments listed typically measure only single dimensions.

Question 2: Which of the following needs to be true for a process to be in a statistically controlled state?

All variation has been completely removed.
Most of the product output by the process is in specification.
Previously optimal process settings are used.
All subgroup averages and ranges are within control limits. (Correct answer)

Correct answer: All subgroup averages and ranges are within control limits.

For a process to be considered in a statistically controlled state, all data points plotted on its control charts (e.g., subgroup averages and ranges) must fall within the calculated upper and lower control limits. Additionally, there should be no non-random patterns or trends within these limits. This indicates that the process variation is stable, predictable, and only influenced by common causes.

Question 3: Which of the subsequent transfer type measuring instruments doesn't normally have a measuring scale?

Telescoping gauge, Vernier caliper, Joint caliper
Spring caliper, Telescoping gauge, Vernier caliper, Joint caliper
Spring caliper, Telescoping gauge, Joint caliper (Correct answer)
Spring caliper, Telescoping gauge, Vernier caliper

Correct answer: Spring caliper, Telescoping gauge, Joint caliper

Transfer type measuring instruments are tools that capture a dimension but do not have an integrated measuring scale; the dimension must be transferred to a separate scale for reading. Spring calipers, telescoping gauges, and joint calipers fit this description. Vernier calipers, however, have their own built-in scales for direct measurement, making them distinct from pure transfer instruments.

Question 4: What is 68 degrees Fahrenheit in centigrade?

16 C
20 C (Correct answer)
36 C
28 C

Correct answer: 20 C

To convert Fahrenheit to Celsius, the formula is C = (F - 32) * 5/9. Plugging in 68 degrees Fahrenheit: C = (68 - 32) * 5/9 = 36 * 5/9. This calculation results in 180/9, which simplifies to 20 degrees Celsius.

Question 5: Which of the following DOES NOT contribute to effective teamwork?

The team is accountable for specific measurable outcomes.
The team’s purpose is clearly understood and supported by all members.
Company management directly participates as a team member. (Correct answer)
A process exists for establishing goals and objectives.

Correct answer: Company management directly participates as a team member.

While management support is crucial for team success, direct participation by company management as a team member can sometimes hinder effective teamwork. It can create an imbalance of power, potentially stifling open communication, creativity, and the team's sense of ownership and accountability. Effective teams often thrive with autonomy, clear purpose, and measurable outcomes, supported by management rather than directly managed by them.

Question 6: You are looking at a gage block set's calibration history. They have been calibrated every six months for the past few years without any errors. They are also only utilized for non-critical measures and no more than once every week. <br> What should be done in this situation?

Maintain the current calibration cycle
Set the calibration cycle to every 12 months and continue to monitor the results of their calibration (Correct answer)
Set the calibration cycle to "indefinite"; the gage blocks don't receive enough use to warrant further calibration
Remove the gage blocks from use and place them in a secured area

Correct answer: Set the calibration cycle to every 12 months and continue to monitor the results of their calibration

Given that the gage blocks have consistently shown no errors over several years, are used infrequently, and for non-critical measurements, extending the calibration cycle is a reasonable and cost-effective approach. Changing the cycle to every 12 months reduces calibration frequency while still ensuring accuracy. It is crucial to continue monitoring calibration results to validate the extended cycle and make further adjustments if necessary.

Question 7: Which of the following hardness tests is most appropriate for use with rubber and plastic?

Brinell
Rockwell B
Durometer (Correct answer)
Rockwell C

Correct answer: Durometer

The Durometer hardness test is specifically designed and widely used for measuring the indentation hardness of elastomers (rubbers) and plastics. It measures the depth of indentation created by a specific indenter under a defined force. Other hardness tests like Brinell and Rockwell are typically employed for measuring the hardness of metals and harder materials.

Question 8: Which of the following situations allows for capability evaluation when a control chart is employed on a new process?

Before the chart is first started
When the plotted points hug the centerline
After the first ten points are plotted
After the process is shown to be in control (Correct answer)

Correct answer: After the process is shown to be in control

Process capability analysis assesses how well a process can meet its specified requirements. This analysis is only valid and meaningful when the process is stable and in statistical control, meaning that only common cause variation is present. Evaluating capability before the process is stable would yield unreliable and misleading results, as special causes of variation could skew the data.

Question 9: Which of the following factors should a reliability engineer take into account first when evaluating failures during a reliability test program?

The hazard rate is decreasing
The hazard rate is constant (Correct answer)
The hazard rate is increasing
The capability of test equipment

Correct answer: The hazard rate is constant

When evaluating failures during a reliability test program, reliability engineers often initially assume a constant hazard rate. This assumption is characteristic of the 'useful life' phase of many products, particularly electronic components, where failures occur randomly. While hazard rates can decrease (early life) or increase (wear-out), a constant rate provides a practical starting point for analysis and modeling.

Question 10: What is involved in failure modes and effects analysis?

The expected number of failures in a given time interval.
The study of the physics of failure to determine exactly how a product fails and what causes the failure. (Correct answer)
A study of the probability of success in a given time period.
The determination of the probability of failure in a specified period of time.

Correct answer: The study of the physics of failure to determine exactly how a product fails and what causes the failure.

Failure Modes and Effects Analysis (FMEA) is a systematic process used to identify potential failure modes in a system, product, or process. It involves a detailed study of the 'physics of failure' to understand exactly how a product might fail, what causes these failures, and the potential impact of such failures. This proactive approach helps in prioritizing and mitigating risks.

Question 11: A system for reporting failures and taking corrective action should make sure that all necessary actions are performed to:

Define the goals of the FRACAS team.
Record costs associated with the corrective action.
Identify, investigate and analyze failures. (Correct answer)
Determine responsibilities for failures.

Correct answer: Identify, investigate and analyze failures.

A Failure Reporting, Analysis, and Corrective Action System (FRACAS) is fundamentally designed to ensure that all failures are systematically identified, thoroughly investigated, and analyzed to determine their root causes. This comprehensive understanding of failures is critical for developing effective corrective actions. The primary goal is to prevent recurrence and continuously improve product or process reliability.

Question 12: Which of the following quantitative techniques DOESN'T applicable to evaluating the reliability of actual systems or components?

Statistical allocation of reliability goals. (Correct answer)
Analysis of result for reliability demonstration test.
Statistical analysis of field test data.
Evaluation of laboratory and acceptance test data.

Correct answer: Statistical allocation of reliability goals.

Statistical allocation of reliability goals is a planning and design technique used to distribute an overall system reliability target down to its individual components or subsystems. This is a predictive activity performed during the design phase, not a method for evaluating the reliability of actual, existing systems or components based on observed data. The other options involve analyzing real-world test or field data.

Question 13: Which of the many terms in the binomial expansion can be easily determined using Pascal's triangle?

Exponents
Combinations
Coefficients (Correct answer)
Permutations

Correct answer: Coefficients

Pascal's triangle is a triangular array of numbers where each number is the sum of the two numbers directly above it. These numbers directly correspond to the binomial coefficients in the expansion of (a+b)^n. Therefore, Pascal's triangle provides an easy method to determine the coefficients for terms in a binomial expansion.

Question 14: Which of the following is the primary justification for the adoption of Quality Function Deployment (QFD)?

To ensure concurrent engineering.
To implement the voice of the customer. (Correct answer)
To assign responsibilities for product designs.
To provide a structured product design approach.

Correct answer: To implement the voice of the customer.

Quality Function Deployment (QFD) is a structured methodology primarily adopted to translate customer requirements, often referred to as the 'voice of the customer,' into technical requirements for product design and development. Its main justification is to ensure that customer needs and expectations are thoroughly understood and systematically integrated throughout every stage of the product development process, from conception to manufacturing.

Question 15: Which type of failure is typically minimized by routine component overhaul and replacement?

Random
Catastrophic
Wear out (Correct answer)
Early life

Correct answer: Wear out

Wear-out failures occur towards the end of a product's life cycle due to degradation, fatigue, or depletion of materials from normal use. Routine component overhaul and replacement, often based on scheduled maintenance or predicted lifespan, are specifically implemented to prevent these predictable wear-out failures from occurring, thereby extending the useful life of the system.

Question 16: What is the MOST accurate way to check that a design satisfies the maintainability requirement?

By thorough design reviews.
By demonstration at the customer's facility. (Correct answer)
By analysis of the design.
By performing maintainability prediction.

Correct answer: By demonstration at the customer's facility.

While design reviews, analysis, and prediction are valuable steps, the most accurate way to confirm that a design truly satisfies maintainability requirements is through actual demonstration. Performing maintainability demonstrations, ideally in an operational environment or at the customer's facility, provides real-world evidence of the ease, speed, and safety of maintenance tasks under realistic conditions.

Free ASQ Certified Quality Inspector & Reliability Engineer Questions and Answers

Which of the following can concurrently measure size and location?