ASQ_CRE (Certified Reliability Engineer) Problems

Chapter 7. Reliability Design Tools.

■ Performance Check
1. For a critical application, which of the following statements regarding the safety and margin
of safety would be considered false?
Ⅰ. The safety factor will be less than 1.0
Ⅱ. The margin of safety will be greater than the safety factor
Ⅲ. The standard deviation of stress will be less than the standard deviation of strength
A. I only B. I and III only
C. II and III only D. I, II and III

Sol)
All of the items are false. The safety factor will be much greater than 1.0. Based on the formulas shown,
it is impossible for the margin of safety to exceed the safety factor. Note that the average stress is
subtracted in the numerator of the M.O.S. formula. Standard deviations are not considered in these two
calculations. Answer D is correct.
μx μ x- μ y
S. F = μy
M.O.S = μy

2. Which one of the following will NOT increase reliability in design?

A. Deterating techniques
B. Design redundancy
C. Designing for maintainability
D. Acceptance testing

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Sol)
Note that the key word is "NOT". Answers A, B and C will increase reliability in design. Answer D
(acceptance testing) is typically performed on a product or machine after design and manufacture. Answer
D is the correct, incorrect. choice.

3. Severity classifications are assigned to the potential consequences of a failure. If a resulting

failure could cause a minor injury to personnel, which category would best describe it ?
A. Category I - Catastrophic
B. Category II - Critical
C. Category III - Marginal
D. Category IV - Minor

Sol)
A possible minor injury to personnel belongs in Category III - marginal. Answer C is correct.

4. A failure modes and effects analysis :

A. Can best be conducted with a digital computer
B. Requires a knowledge og Boolean algebra
C. Is a qualitative technique
D. Is a quanitative technique

Sol)
FMEA is a procedure to analyze each potential failure mode in a system to determine the results, or
effects of these failures on the system. This determination allows the "fail-safing" of the process prior to
mass production, thus, FMEA is a "qualitative" technique. FMEAs require extensive time and experience,
thus answer A is incorrect. Boolean algebra is used in a fault tree analysis (FTA) or system diagram
analysis. Answer C is correct.

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 ASQ_CRE (Certified Reliability Engineer) Problems

5. Subcontractor ABC has provided a new canister design. The canisters are rated at 1000 psi,
with a standard deviation of 150 psi. The expected stress will p 　 Ü50 psi ith a standar
d deviation of 200 psi. What is the probability of failure of the canister ?

A. 0.3085 B. 0.1587
C. 0.1056 D. 0.0228

Sol)
This is a straight forward stress-strength problem. See the calculation. Answer B is correct.
μ x- μ y
Z = = 1,0002 -7502 = 250
250 = 1.00
σ 2x+ σ 2y 150 +200
P( Z ) = .1587

6. A vendor must perform tests on parts to determine which of the following ?

A. Functional capability under specified environmental conditions
B. Materials and processes C. Configuration and size
D. Cost

Sol)
The key question words are "must" and "tests". Although a vendor may control cost, materials, processes,
part configuration and size, they typically don't test for them. A vendor must perform tests on critical parts
under specified environmental conditions to assure reliability (functional capability). Answer A is correct.

7. A FMECA that analyzes how a device performs rather than the characteristics of the specific
components can be referred to as :
Ⅰ. A functional FMECA
Ⅱ. A hardware FMECA
Ⅲ. A black box FMECA
Ⅳ. A criticality analysis

A. I only B. I and III only C. II and III only D. I, II, III and IV

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Sol)
A functional FMECA (item I) can also be referred to as a "black box" FMECA (item III). A hardware
FMECA (item II) refers to identification of each hardware item. A criticality analysis (item IV) is an attempt
to prioritize the failure modes based on effects and probability. Answer B is correct.

8. In order to enhance the reliability of an extruder producing plastic film, the applied
operational and environmental stresses should be :
A. At the rated nominal ratings
B. Slightly above nominal ratings
C. Significantly below nominal ratings
D. Significantly above nominal ratings

Sol)
In general, the use of stresses below the nominal rated or design strength should enhance reliability.
Answer B is correct.

9. The rated breaking strength of a suspension bridge cable is 150,000 pounds. An example
using this cable in a derated condition is which of the following ?
A. The cable in a 75,000 pound maximum stress application
B. The cable in a 15,000 pound maximum stress application
C. The cable in a 225,000 pound maximum stress application
D. The cable as a parallel component

Sol)
Derating occurs when a rated component is used in a lower than rated stress. Parallel use does not
assure that it is being used in a lower than rated stress application. Answer A is correct.

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 ASQ_CRE (Certified Reliability Engineer) Problems

10. The two principal measures of failure during risk assessment are which of the following ?
A. Failure severity and failure probability
B. Failure analysis and failure effects
C. Failure method and failure mode
D. Failure mode and failure mechanism

Sol)
This question requires familarity with reliability risk assessment. The two key measures of risk assessment
are the severity and probability of failure. Answer C is correct.

11. Using an extreme worst-case method of variability analysis, if the indicated performance
characteristics values fall within specifications, the designer can be confident that:
A. The probability of occurrence will be unknown
B. The system has high drift reliability
C. A high parameter tolerance limit is needed
D. A low parameter tolerance limit is needed

Sol)
Answers C and D do not pertain to this question. Answer A may occur when the specification limits are
exceeded. Answer B is correct.

12. Design review should be a process to ensure and/or develop more reliable designs. Which
of the following person(s), if any, should work with the designer during the design process ?
A. Reliability engineer B. Designer only
C. Management team D. Design supervisor

Sol)
The design review requires an independent analysis that the originator, the creator, may not be able to
provide. The design supervisor may not be independent and the management team might not be
technically proficient. A competent and respected reliability engineer can do so. Answer A is correct.

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13. In a manufacturing situation, an engineer has an opportunity to design new machinery.

Automated machinery is best applied under which of the following conditions ?
Ⅰ. Those involving continuous repetitive processes
Ⅱ. Those requiring various degrees of originality
Ⅲ. Those requiring a very quick reaction to stimuli
Ⅳ. Those requiring an interpretation of collected data
A. I and II only B. II and III only
C. I and III only D. II, III and IV only

Sol)
Humans are better with originality and data interpretation. Automated machinery is better for continuous
repetitive processes and quick reactions. Answer C is correct.

14. Highly repetitive operations should be assigned to:

A. A machine
B. An operator
C. A machine and operator performing the task alternately
D. An operator assisted by a computer

Sol)
Machines are superior to humans in making precise repetitive motions. Answers B and C make sense
only in technology starved countries or on an interim basis (until a machine can be modeled). In the case
of answer D, both the operator and the computer would get bored and make mistakes (a little humor).
Answer A is correct.

15. The techniques of design control are :

A. Unique to the aerospace industry
B. Too expensive for general application
C. Applicable generally throughout industry
D. Limited to hardware - manufacturing enterprises

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 ASQ_CRE (Certified Reliability Engineer) Problems

Sol)
Answers A, B and D are obviously incorrect. Design control techniques are applicable generally throughout
industry. Answer C is correct.

16. Human factors are important considerations when designing for reliability because :
Ⅰ. Habits are sometimes difficult to change
Ⅱ. Conditions such as lighting and heating influence performance
Ⅲ. Weak parts must be easily replaceable
Ⅳ. Age and skill can limit one's ability to use equipment correctly
A. I and III only B. II and III only
C. II, III and IV only D. I, II, III and IV

Sol)
A review of the Items I - IV indicates all to be important design considerations. Answer D is correct.

17. A first step in the FMECA is to :

A. Define the system requirements
B. Compile a critical items list
C. Identify failure modes
D. Establish ground rules to which the FMECA is performed

Sol)
The key word in this question is "first". Unless the system requirements are defined, a list of critical
items, FMECA ground risks, and failure modes are meaningless. Answer A is correct.

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18. When requesting "worst case" design analysis, you expect the reliability group to :
Ⅰ. Analyze the worst rejects.
Ⅱ. Analyze only those products failing to meet specification requirements
Ⅲ. Determine whether product requirements can be met with subassemblies assumed at their
worst combination of tolerances
Ⅳ. Assume all subassembly tolerances are at their maximum limit

A. I only B. II only
C. III only D. IV only

Sol)
Answers A and B pertain to failure analysis not design analysis. Answer D may not be inclusive enough
since the maximum limit of one component may be restrictive at the minimum limit of another component.
Answer C is a broader and more encompassing choice.

19. Which of the following resources provides the best source for mechanical parts reliability
data ?
A. International Standards Organization.
B. Bellcore
C. Reliability Analysis Center
D. National Bureau of Standards

sol)
Answer A is filler. The National Bureau of Standards is now part of NIST and neither supply mechanical
parts reliability data. Bellcore is concerned with electrical and computer software. The Reliability Analysis
Center is the best choice. Answer C is correct.

20. What is the probability of failure if the stress on a component is 20,000 psi with a
standard deviation of 1000 psi and the strength is 25,000 psi with a standard deviation of 2000
psi ?
A. 2.24 % B. 1.25 %
C. 2.50 % D. 5.32 %

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 ASQ_CRE (Certified Reliability Engineer) Problems

Sol)
This question requires stress-strength analysis. The Z calculation is shown on the below. The probability
of failure is 1.25%. Answer B is correct.

μ x- μ y
Equation Z =
σ 2x+ σ 2y

Z= 25,000 -20,000 Z = 5,000 Pz

Calculation
(1,000) 2 +(2,000) 2 2236 = 2.24 , = 1.25%

21. The most important reason(s) for performing design reviews is to :

Ⅰ. Identify the anticipated field usage of the system
Ⅱ. Review referenced specifications to be used during procurement
Ⅲ. Follow up the outcome of action items discussed during prior meetings
A. I only B. II only
C. I and III only D. I, II and III

sol)
The key phrase in his question is "most important reason(s)". Clearly a design review addresses the
anticipated use of a system being designed and the specifications of components to be used in the
system. As with most committees there will be follow-up coverage of prior action items, as well. Answer D
is correct.

22. Reliability, maintainability, and product safety improvements are most often economically
accomplished during which of the following phases ?
A. Design and development
B. Prototype test
C. Production
D. Field operation

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Sol)
Answers C and D occur too late in the process to receive serious consideration. Even a prototype test,
answer B, can benefit economically from action taken in the design and development phase. Answer A is
correct.

23. "A structured qualitative analysis of a system to identify potential system failure modes,
their causes, and the effects on the system operation associated with the failure mode
occurrence" describes which of the following ?
A. FMECA
B. FMEA
C. QFD
D. FTA

Sol)
The above definition applies to a FMEA. When an evaluation of the failure criticality is made, then the
analysis becomes a failure mode, effects and criticality analysis (FMECA). Answer B is correct.

24. QFD stands for :

A. Quality Function Deployment
B. Quality Failure Determination
C. Quality Future Development
D. Quality For Development

Sol)
QFD stands for Quality Function Deployment. This is sometimes called the "house of quality". QFD is a
method of establishing a relationship between the "wants" or requirements and the "hows" or
specifications. Answer A is correct.

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25. The idea of concurrent engineering is changing the way U.S. managers think and manage.
How many of the following steps could be eliminated using concurrent engineering (and cycle
time reduction) ?
Ⅰ. Product Definition Ⅵ. Reverification
Ⅱ. Design Ⅶ. Reprototype
Ⅲ. Verification Ⅷ. Prototype testing
Ⅳ. Prototype Ⅸ. Production
Ⅴ. Redesign Ⅹ. Final testing
A. 2 B. 3
C. 4 D. 5

Sol)
The 3 steps numbered V, VI and VII could be removed with resulting cycle time reduction. Answer B is
correct.

26. A fault tree analysis (FTA) is a design analysis technique constructed from a "top event". A
basic problem with this technique in comparison to a FMECA would be which of the following
?
A. Assigning probabilities to the various events
B. Needing a different FTA for each defined top event
C. Understanding logical symbols
D. Only electronic systems can be analyzed

Sol)
A different FTA has to be constructed for each defined top event. Logical symbols can be learned. FTAs
apply to any system, not just electronics. Answer B is correct.

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27. Human factors engineering concepts introduced to an inspection area:

Ⅰ. Are not valuable until the test equipment has been set up and operating
Ⅱ. Should be incorporated during the design and planning stage of the area
Ⅲ. Are most costly when introduced during the design and planning stage of the area
Ⅳ. Will result in reduced efficiency but greater accuracy of inspection
A. I only B. II only
C. III only D. IV only

sol)
Answers A and C are not serious contenders. Answer D is incorrect because greater efficiency may also
result from human factors engineering. All human factors engineering should be incorporated during the
design and planning stage. Answer B is correct.

28. There is a subtle difference between a standard parts program and a standardization
program. A standardization program tends to emphasize :
A. Limited part numbers
B. Limited suppliers
C. Limited sizes
D. Limited part applications

Sol)
Standard parts programs emphasize limiting the number of part numbers and suppliers (answers A and
B). Answer D is also a standard part limitation. A standardization program limits the number of part sizes
used in the design. Answer C is correct.

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 ASQ_CRE (Certified Reliability Engineer) Problems

29. In general, one should select the highest component parameter ratings feasible so that :
Ⅰ. Failure rates may be minimized
Ⅱ. Probability of secondary failure is minimized
Ⅲ. Safety margins are offered against unforeseen transients
A. I only
B. I and II only
C. I and III only
D. I, II and III

Sol)
All three items are true, thus answer D is the correct answer. Decreasing the stress level of a component
will lengthen its life. This is a "derating" technique which is a ratio between applied versus rated stress
values; thus failure rates are reduced, secondary failure is minimized, and a safety margin has been
applied. Answer D is correct.

30. As a design or reliability engineer, you may recommend that various tests be performed on
a new part. Which of the following would NOT be a direct result of those tests ?
A. Data for an estimate of MTBF
B. A disclosure of part deficiencies
C. Knowledge of whether the part meets requirements
D. An improvement in reliability

Sol)
Answer D is the correct, incorrect, choice. Testing does not improve a part. The testing may provide data
that indicates where corrective action must be taken to improve reliability. The other answers are true.

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31. A design review committee has been formed to install a new computer system on the US
space shuttle. Which of the following people would normally be on the review committee ?
Ⅰ. Senior company personnel
Ⅱ. Qualified company personnel
Ⅲ. The design engineer
Ⅳ. The manufacturing engineer
Ⅴ. A financial representative
A. II, III and IV only B. II, III IV and V only
C. I, II, III and IV only D. I, II, III, IV and V

Sol)
The financial representative is not typically on a design review committee. Answer C is correct.

32. A critical items list is used to highlight items that could have an appreciable effect on the
product's reliability. It is evolved from :
A. A summary shown by other analysis to be critical
B. The judgement of a reliability engineer
C. A top management critique
D. Pareto analysis results

Sol)
Answers B and D are not adequate. They could both be considered subsets of answer A. A critical items
list is a document for top management to use, not to generate (answer C). Answer A is correct.

33. The House of Quality incorporates a correlation matrix roof. This describes the relationships
between which of the following ?
A. Hows (design features)
B. Whats (customers needs)
C. Whats and hows
D. Competitive comparisons

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Sol)
The whats relate to customer requirements. The relationship between whats and hows is the relationship
matrix. There can also be competitive comparisons based on customer and technical attributes. A
correlation matrix is used to identify interrelationships between the technical design features (hows).
Answer A is correct.

34. The reliability engineer should be concerned with the human factors of a new piece of
in-house manufacturing equipment as well as its operational effects because it :
Ⅰ. May speed the line to the point where a visual operator inspection is impossible
Ⅱ. May require the operator's undivided attention at the controls so the product cannot be
fully seen
Ⅲ. May remove an operator formerly devoting some portion of time to inspection
A. I only B. II only
C. I and III only D. I, II and III

Sol)
From a reliability engineer's prospective, Items I, II and III are all important human factor concerns.
Answer D is correct.

35. The purpose of derating parts is to :

Ⅰ. Increase part life
Ⅱ. Enhance overall system reliability
Ⅲ. Improve circuit design
A. I only B. I and II only
C. II and III only D. I, II and III

Sol)
It should be obvious, by removing stress that part life will increase, which will in turn enhance overall
system reliability, and improve circuit design. Answer D is correct.

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36. The main reason for the use of Quality Function Deployment (QFD) is which of the
following ?
A. To implement the voice of the customer
B. To ensure concurrent engineering
C. To assign responsibilities for product designs
D. To provide a structured product design approach

Sol)
QFD is a planning tool to fulfill customer expectations, i.e. "The voice of the customer". Concurrent
engineering could occur at a slightly later design stage but this is not related to QFD. Answers C and D
are possibilities but they also would not be prime expectations from QFD. Answer A is correct.

37. Derating is the technique of using a part, component, or system :

A. Under stress conditions below rated values to achieve reliability
B. Under normal conditions to achieve a reliable product design
C. Below stress conditions to achieve a reliable product design
D. Under stress conditions above rated values to achieve reliability

Sol)
A derated component is one used below rated values to enhance system reliability. Answer A is correct.

38. Human vision is necessary for many normal operations. MIL-STD-1472 requires a line of
sight angle for critical functions. What is that angle ?
A. 15 degrees
B. 20 degrees
C. 30 degrees
D. 45 degrees

Sol)
Plus or minus 15 degrees from both vertical and horizontal is considered optimum. Answer A is correct.

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 ASQ_CRE (Certified Reliability Engineer) Problems

39. FMEA stands for :

A. Federal Method Evaluation Agency
B. Final Means Estimate Analysis
C. Fines and Methods Evaluation Association
D. Failure Mode Effects Analysis

Sol)
All of the answers are fillers, except answer D. FMEA stands for "Failure Mode Effects Analysis". The
FMEA is used during the design process to determine potential ways (modes) that items might fail, and
the effects of that failure. In doing this the designer can determine how to reduce serious failure effects
by either altering the item design, using redundant components, or other avoidance methods. Answer D is
correct.

40. Which of the following considerations should a criticality analysis (CA) take into account ?
Ⅰ. Consequences of a failure
Ⅱ. Consequential damage of a failure
Ⅲ. Damage to the environment
Ⅳ. Potential increase in efficiencies
A. I only B. I and II only C. I, II and III only D. I, II, III and IV

Sol)
The consequences and consequential damages of a failure are important. The environment could also be
damaged as a result of a failure. Item IV should not be a consideration during criticality analysis. Answer
C is correct.

41. An engineer must design a product with a probability of success of 99%. Assume that both
the strength and stress are normally distributed and that the standard deviations are the same.
If the stress is known to be 3000 lbs with a standard deviation of 100 lbs, what must be the
approximate designed strength ?
A. 4020 lbs B. 3730 lbs C. 3330 lbs D. 3100 lbs

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Sol)
A stress-strength calculation must be used. The z value for a 1% probability of failure is 2.33. Answer C
is correct.
μ x- μ y μ x - 3,000
Z= , 2.33=
σ x+ σ y
2 2
( 100) 2 + ( 100) 2
μx = 2.33(141.42) + 3,000 = 3330lbs.

42. Which of the following techniques is NOT used when derating parts to enhance their overall
reliability ?
A. Derating for temperature
B. Derating for stress
C. Use of 100% rating
D. Lower power dissipation

Sol)
The key phrase is "NOT used". Derating involves using a part, component, or equipment under stress
conditions that are below its rated specification, to achieve a more reliable product design. Derating is a
ratio between applied versus rated stress values. Answer C is not true because using 100% rating implies
no derating. Derating may occur with lower temperature, stress, or power dissipation (which produces
lower temperature and stress). Answer C is the correct, incorrect, choice.

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 ASQ_CRE (Certified Reliability Engineer) Problems

43. Which of the following is NOT related in the stage of product design and development ?
A. Perform a reliability demonstration test
B. Develop an estimate for the MTBF
C. Develop a Boolean logic simulation
D. Develop a test for the failure rate

Sol)
Note that this question requires a negative answer. A Boolean logic simulation requires estimates or actual
specification data for a part before results can be obtained. The other answer options could be
undertaken. Answer C is the correct, incorrect, choice.

44. Design reviews should have sufficient information available to make their meetings
worthwhile. Formal controls (specifications, drawing controls, etc.) should begin with the first
design reivew. This approach is referred to as :
A. Configuration control
B. Documentation control
C. Quality systems documentation
D. Standards organization

Sol)
Configuration control is the process of having the design specifications; drawings, hardware, software,
tests, etc., all identified and controlled. Answer A is correct.

45. The House of Quality (QFD) can contain which of the following components ?
Ⅰ. Technical characteristics
Ⅱ. Technical interrelationships
Ⅲ. Customer/technical interfaces
Ⅳ. Customer requirements
Ⅴ. Technical assessments
A. I and II only B. III, IV and V only
C. II, III and IV only D. I, II, III, IV and V

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Sol)
All of the above can belong in a House of Quality. The House of Quality could contain all of the
following: customer requirements (whats), technical descriptors (hows), technical competitive assessments,
prioritized technical descriptors, customer competitive assessments, prioritized customer requirements,
matrix between whats and hows, and correlation matrix of hows. Answer D is correct.

46. Who should be chairperson of a design review committee ?

A. A senior member of management
B. The chief designer
C. The person best able to make decisions on a design
D. The reliability engineer

Sol)
The senior manager may not have design decision experience. The best answer is the person able to
make decisions on changing a design. Answer C is correct.

47. Derating parts in specific applications is performed in order to :

A. Establish a preferred parts list
B. Lower the stress limits to lower failure rates
C. Show which part s are inferior in design
D. Determine the stress rations

Sol)
From MIL-STD-721, the definition of derating is:
1. Using an item in such a way that supplied stresses are below rated values, or
2. The lowering of the rating of an item in one stress field to allow an increase in rating in another
stress field. From this definition, answer B is correct.

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 ASQ_CRE (Certified Reliability Engineer) Problems

48. In a software development project, which of the following elements is NOT essential to
ensure a reliable product ?
A. Specifying the software requirements in complete detail
B. Ensuring that requirements based testing is performed
C. Documenting changes made to the software during development
D. Performing a Failure Mode, Effects, and Criticality Analysis on the software

Sol)
This question requires general software development knowledge. A negative response is requested. A
FMECA doesn't fit software development to the same extent that it does for many other products. In
software development, tight requirements, testing and change documentation are key reliability components.
Answer D is the correct, incorrect, choice.

49. Which of the following is important to a parts supplier in establishing parts capabilities and
limits ?
Ⅰ. Accurate part characteristics
Ⅱ. Environmental limits
Ⅲ. Reliability data
A. I and II only
B. I and III only
C. II and III only
D. I, II and III

Sol)
Note that this question does not say "most important". In establishing capabilities and specification limits
for parts, the part characteristics, environmental conditions, and reliability data are all important. Answer
D is correct.

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50. Which of the following is required to establish a reliability specification ?

A. To usage environment
B. A robust design
C. The reliability policy
D. A mathematical model

Sol)
The usage environment is always a key component of a reliability specification. The reliability policy has
no particular impact on an individual specification. The mathematical model may or may not be known
when the specification is developed. A robust design may help achieve the specification but this question
doesn't ask for that. Answer A is correct.

51. One method of evaluating the design reliability is to analyze the design assuming the worst
case. Which of the following techniques is NOT applicable for worst case analysis ?
A. Root - sum squared
B. Extreme value
C. Eyring model
D. Monte Carlo

Sol)
Note that a negative response is requested. Answers A, B and D are all methods of determining the
worst case. The Eyring model is useful for handling more than one stress factor in accelerated life
testing. Answer C is the correct, incorrect, choice.

52. Design reviews should be held :

A. During the design phase
B. At each critical design program milestone
C. At least once a year
D. After the design in completed

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 ASQ_CRE (Certified Reliability Engineer) Problems

Sol)
Even though answer A is somewhat correct, answer B is the more specific best answer. "Once a year"
and "after the design is completed", are obvious incorrect answers. Answer B is correct.

53. Human reliability is defined as the probability that a human will :

A. Be available to perform a job under adverse conditions
B. Successfully accomplis a task within a specified time limit
C. Under ideal conditions fulfill specified human functions
D. carry out tasks that result in no damage to products

Sol)
Answer D is a virtual impossibility. The terms "adverse" and "ideal" conditions cause answers A and C to
be weak choices. Answer B addresses human success and indicates a specified time limit. Both of these
two elements are necessary. Answer B is correct.

54. Which of the following is the best description of a process FMECA ?

Ⅰ. It analyzes the functional output of a device
Ⅱ. It analyzes the specific hardware details of a device
Ⅲ. It analyzes a system design and how failure modes affect the system
Ⅳ. It analyzes the manufacturing operation and how manufacturing failures affect the product
operation

A. I only B. II only C. III only D. IV only

Sol)
Answer A is a functional FMECA. Answer B is a hardware FMECA. Answer C is a design FMECA.
Answer D is a process FMECA. Answer D is correct.

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55. A design review committee has recommended changes to a proposed design. Whose job is
it to investigate and incorporate the ideas that will aid product reliability ?
A. The design review chairman B. The senior decision maker
C. The reliability engineer D. The design engineer

Sol)
The design engineer is responsible to investigate and make changes to the design. He or she may want
to consult with one or more reliability engineers in the process. Answer D is correct.

56. If the FMECA environment consequences are difficult to quantify, which of the following
approaches is best for assigning severity to a failure mode?
A. Automatually assign the catastrophic classificaton
B. Use the critical category until more data is gathered
C. No assignment can be made due to no existing evidence
D. Use th Delphi technique

Sol)
The Delphi technique is named after the Delphic oracle. This is a method useful in generating ideas or
the best opinions from a group of "experts". It was initially used for forecasting by Rand Corp. in the
1950's. Answer D is correct.

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 ASQ_CRE (Certified Reliability Engineer) Problems

57. Once a new system is approved for design, a criticality analysis (CA) should be performed.
A proper design sequence could be as follows:
Ⅰ. Quantify the probability of failure of each risk
Ⅱ. Describe the system and draw up an inventory of parts
Ⅲ. Determine the criticality of the consequence of a failure
Ⅳ. Trace all risks associated with the system
A. IV, II, I, III
B. II, I, III, IV
C. I, II, III, IV
D. II, IV, I, III

Sol)
A review of the answer choices indicates that item II is a good starting point. Additionally, item IV should
precede item III. Answer D is correct.

58. In a FMECA, the potential failure modes are determined in order to improve system
reliability. The effort to assess the severity of failure effects is part of the :
A. Criticality analysis B. Risk analysis
C. Design potential D. Modeling determination

Sol)
A criticality analysis is performed on the failure modes to classify their severity and potential impact.
Answer A is correct.

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 Chapter 7 : Reliability Design Tools.

59. Consider the four normal stress and strength distributions described below. Which
component would have the highest reliability ?
Ⅰ. The average and standard deviation of the stress distribution are both higher than for the
strength curve
Ⅱ. The average and standard deviation of the stress and strength distributions are the same
Ⅲ. Both distributions have the same standard deviation but the strength average is higher
than the stress average
Ⅳ. Both distributions have the same variance but the stress average is slightly higher than
the strength average

A. I only B. II only
C. III only D. IV only

Sol)
Answers A and D imply that the failure rate will be greater than 50%. Answer B indicates a failure rate of
exactly 50%. Only answer C indicates a greater than 50% chance for success. Answer C is correct.

60. Failure results when the applied load exceeds the strength of the material in the design
phase. Which of the following factor(s) is most important for the designer to know ?
Ⅰ. That the load and strength figures are fixed
Ⅱ. That the load and strength figures are statistically distributed
Ⅲ. That the means and standard deviations must be defined
Ⅳ. That a safety margin must be maintained
A. I only B. II only
C. III only D. IV only

Sol)
The load and strength values must be statistically distributed. If there isn't a statistical distribution of
stress and strength values then averages and standard deviations could not be used to determine a
predictable safety margin. Answer B is correct.

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 ASQ_CRE (Certified Reliability Engineer) Problems

61. Derating a component to 50 percent of its operating value will generally decrease its failure
rate by a factor of :
A. Greater than 30 percent
B. Greater than 50 percent
C. Greater than 10 percent but less than 30 percent
D. Less than 10 percent

Sol)
One rule of thumb commonly used in electronics is that a 50% derating can decrease the failure rate
more than 30%. Answer A is correct.

62. What is the most vital information to know about a system in order to perform a hardware
FMECA ?
A. the details of the system
B. The details of the subsystem
C. The black box functions
D. Full process information

Sol)
System details are vital to the hardware FMECA approach. The subsystems may be important, but may
not provide enough information. A black box approach indicates that only the outputs are needed (answer
C). Knowledge of the process and how failures in the process can result describes a process FMECA
(answer D). Answer A is correct.

63. A company has a problem with damage to fragile assemblies during component handling
and parts storage. Which of the following is the best way to detect the cause of this problem ?
A. Perform a fault-tree analysis
B. Perform process reliability audits
C. Assign the control to area supervision
D. Train employees and supervisors on requirements

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 Chapter 7 : Reliability Design Tools.

Sol)
You are asked to detect the cause. Assigning the control to area supervision may not be a good idea.
First, the supervisors may be overworked and if the problem were simple they would have already solved
it or controlled it. Training employees and supervisors on requirements is always good form but this may
or may not be part of the cause. Process audits would help keep the process in control if a stable
in-control process existed. However, this is not the case. A fault-tree analysis could be useful in assessing
potential system failure modes. Answer A is correct.

64. Inherent reliability can be increased by :

A. Design change
B. Training in the manufacturing area
C. Inspection techniques
D. Good maintenance techniques

Sol)
Inherent defects are those most often caused by the design of the product. Design improvements which
reduce the stress, increase strength, or provide redundancy improve the inherent reliability of a product's
design. Training, inspection and maintenance can definitely impact a product's reliability as perceived by a
potential customer, but they normally do not influence the designed or inherent level of reliability. Answer
A is correct.

65. A component has a strength of 8000 psi and a standard deviation of 1200 psi. It needs to
withstand a load with a mean value of 5000 psi and a standard deviation of 500 psi. Both
strength and load are normally distributed. What is the probability of failure for the component
?
A. 0.0174 B. 0.0104
C. 0.0059 D. 0.0014

Sol)
This question requires a stress-strength calculation. Refer to the calculation on the left. From the z table
P(sub f) = 0.0104. Answer B is correct.
μ -μ 8,000 -5,000 =2.31
- Equation Z = x2 y2 - Calculation Z=
σ x+ σ y (1,200) 2 +(500) 2

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 ASQ_CRE (Certified Reliability Engineer) Problems

66. The Arrhenius model is used to predict part reliability. Which of the following are valid
Arrhenius model statements ?
Ⅰ. The rate of chemical reaction doubles for every 10℉ rise
Ⅱ. It is useful for all accelerated testing plans
Ⅲ. It is useful for significant thermal stresses
Ⅳ. It provides a relationship of failure to temperature
A. I and II only B. II and III only
C. III and IV only D. I, III and IV only

Sol)
Item I is not correct. The rate of chemical reaction almost doubles for each 10 ℃ rise. Item II is not
correct. The Arrhenius model must be shown to have a good chance of adequately modeling the true
data. Answer C is correct.

67. A resistor is advertised as being rated at one watt. Which one of the following is an
example of using the resistor in a derated condition ?
A. Using the resistor in a 1/2 watt application
B. Using the resistor in parallel with another resistor of the samewattage
C. Using the resistor as a standby unit
D. Using the resistor for a 2 watt application

Sol)
Derating involves using a part, component, or subassembly below rated conditions specified by the
manufacturer. This substantially reduces the failure rate of the item under stress conditions. Answers B
and C do not address derating. Answer D would overstress the part. Answer A is correct.

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 Chapter 7 : Reliability Design Tools.

68. The criticality analysis :

Ⅰ. Is part of the FMECA
Ⅱ. Identifies critical hardware items
Ⅲ. Identifies safety problem areas
A. I only B. I and II only
C. I and III only D. I, II and III

Sol)
FMEA is a procedure to analyze each potential failure mode in a system to determine the results, or
effects of these failures on the system. FMECA is a technique to examine a proposed design critically for
possible ways that a failure can occur. All items are correct. Answer D is correct.

69. Which of the following techniques provides a means of translating customer requirements
into appropriate technical requirements ?
A. Concurrent engineering
B. Quality function deployment
C. Benchmarking
D. Total quality management

Sol)
All answer choices are important quality and reliability techniques. But the question is a direct definition of
what quality functional deployment is trying to achieve. Answer B is correct.

70. The greatest contribution of a reliability effort is made in the :

A. Design area
B. Manufacturing area
C. Shipping area
D. Field service area

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 ASQ_CRE (Certified Reliability Engineer) Problems

Sol)
Clearly, the most significant contribution to product reliability is in the design area. Choice C is not a
serious consideration and B and D are of lesser importance than design. Answer A is correct.

71. Which of the following is the most important advantage of structured programming ?
A. It simplifies the writing of the program
B. It is compatible with a top down design
C. It is helpful in localizing an error
D. It simplifies the program management

Sol)
Structured programing is very beneficial in locating a fault. This approach may not simplify program
writing. It may actually take longer to write the program. Answers B and D are weak choices. Answer C
is correct.

72. The design phase of equipment :

Ⅰ. Is too early to make a human factors analysis of associated procedures
Ⅱ. Is the first place to analyze the operating procedure requirements
Ⅲ. Does not require an analysis of operating procedures because equipment design will
change during test and production
Ⅳ. Would not permit the design engineer and human factors specialist to develop equipment
operating procedures

A. I only B. II only C. III only D. IV only

Sol)
This question requires knowledge of human factors engineering. Answer A is incorrect; the design and
development phase is a good place to make a human factors analysis. Answer C is incorrect because
making an analysis of operating procedures early would minimize changes in equipment design later.
Answer D is incorrect because the design phase is an excellent place to analyze equipment operation
procedures. Answer B is correct.

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