PRE-TRAINING WRITTEN EXAM QUESTIONS

FMEA
1. An FMEA should indicate/address Special Characteristics identified by :
a. Customer
b. Supplier
c. a & b
d. Special Characteristics do not have to be identified/addressed on the FMEA

2. FMEA’s should be geared towards :

a. Defect detection
b. Defect prevention
c. a and b
d. none of the above

3. A DFMEA should address :

a. How can the design fail to do what it is supposed to do
b. Failures caused by the Manufacturing process
c. a & b
d. none of the above

4. A DFMEA is required in the following circumstances :

a. New part
b. Changed part
c. Carry over part into a new application or environment
d. All of the above
e. a and b only

5. Functions which should be involved in the creation of a DFMEA are :

a. Assembly , Manufacturing & Quality
b. Materials (purchasing)
c. Service & suppliers
d. Persons responsible for the design of the next assembly process
e. All of the above
f. a, b and c only

6. Regardless of the RPN figure, special attention should be given to high ranking :
a. Severity
b. Occurrence
c. Detection

7. A DFMEA does not have to be fundamentally completed prior to release of production

drawings for tooling :
a. True
b. False

8. A DFMEA should begin with a :

a. Block diagram
b. Risk assessment
c. Control plan
d. Cause and effect diagram

9. A DFMEA provides future reference to aid in analyzing field concerns :

a. true
b. false

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 PRE-TRAINING WRITTEN EXAM QUESTIONS
FMEA
10. On a DFMEA, if the failure mode affects safe vehicle operation &/or involves
noncompliance with governmental regulation without warning, the severity rating should
be :
a. 10
b. 8
c. 6
d. 4
e. 2

11. On a DFMEA the severity & occurrence rating can be reduced by :

a. Increased design verification
b. Increased design validation
c. Design change
d. All of the above
e. a & c only
f. a & b only

12. On an FMEA the RPN is calculated by :

a. Severity + Occurrence + Detection
b. Severity x Occurrence x Detection

13. A DFMEA should be initiated before or at design concept finalisation :

a. True
b. False

14. Warranty data is not an input into a DFMEA :

a. True
b. False

15. A PFMEA should begin with a :

a. Block diagram
b. Process flow chart
c. Control plan
d. Risk assessment

16. If a process detailed on a PFMEA had a PpK of 1.00, what occurrence ranking should
be assigned ?
a. 7
b. 5
c. 3
d. 1

17. A type 1 process control is a control which :

a. Prevents the cause or failure mode from occurring or reduces the rate of occurrence
b. Detects the cause of the failure
c. Detects the failure

18. A DFMEA does not have to be updated once the product goes into production :
a. True
b. False

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 PRE-TRAINING WRITTEN EXAM QUESTIONS
FMEA
19. If corrective action is proposed on a FMEA, do responsibilities & target dates for actions
have to be detailed ?
a. Yes
b. No

20. Once corrective action is decided to address a failure mode, does the RPN have to be
re-calculated ?
a. Yes
b. No

21. Does the APQP manual detail checklists which can be utilised for assessing DFMEA’s &
PFMEA’s ?
a. Yes
b. No

22. Potential failure mode on a DFMEA :

a. is defined as the manner in which the component, sub system or system could
potentially fail to meet or deliver the intended function
b. is defined as the manner in which the process could potentially fail to meet the
process/design intent
c. should be described as physical or technical terms
d. should be described as symptoms noticeable to the customer
e. All of the above
f. a & c only

23. Severity is an assessment of the seriousness of the :

a. Occurrence of the potential failure mode
b. Detection of the potential failure mode
c. Effect of the potential failure mode
d. RPN

24. An increase in process capability would result in a reduction of the :

a. Severity Ranking
b. Occurrence Ranking
c. Detection Ranking
d. All of the above
e. None of the above

25. Can a control that reduces the detection ranking be classified as a type 1 control ?
a. Yes
b. No

26. On a PFMEA what is a valid detection control :

a. Random Quality Checks
b. Sampling on a statistical basis
c. Both of above
d. None of the above

27. If an FMEA is 2/3rds (initial study completed) completed horizontally and all the resultant
RPN’s and severity are low, is it acceptable for the last 3 rd to be left blank ?
a. Yes
b. No

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 PRE-TRAINING WRITTEN EXAM QUESTIONS
FMEA
28. The CUSTOMER for a design FMEA is defined as the END USER :
a. True
b. False

29. “Detect the cause of a failure” is what type of control / feature ?

a. type 1
b. type 2
c. type 3
d. all of the above
e. none of the above

30. If the possible failure rate on a PFMEA is 1 in 2,000 what is the ranking number ?
a. 3
b. 5
c. 7
d. 10

31. The process FMEA assumes :

a. the product as designed will meet design intent
b. design weaknesses will be part of process FMEA
c. all potential fail modes, including those due to design weaknesses will be included
d. all of the above
e. a and b only
f. none of the above

32. The time period for which the design is intended to perform its requirements is known as
:
a. design intent
b. design review
c. design life
d. design validation
e. none of the above

33. A written description of the system used for controlling the manufacturing / assembly
process is :
a. PFMEA
b. Control plan
c. Plant layout
d. DFMEA
e. None of the above

34. The likelihood that a specific cause/mechanism of failure will occur is known as :
a. detection
b. severity
c. occurrence
d. all of the above
e. none of the above

35. Potential effect of failure for a PFMEA should always be stated in terms of product or
system performance :
a. false
b. true

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