DFMEA Exam Questions - Quality Partner

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Question 1 of 20

1. The focus of DFMEA defined in the AIAG-VDA FMEA handbook is:

To identify technical risks

To identify financial risks

To identify time-based risks

To identify strategy risks

Question 1 of 20

Question 2 of 20

2. If DFMEA is implemented effectively it should result in:

Reduced cost of poor quality

Reduced customer complaints

Reduced warranty issues

All the above are correct

Question 2 of 20

Question 3 of 20

3. The most significant reason to review and update an existing FMEA is:

An upcoming IATF third party audit

An upcoming customer audit

A proposed change in the design

A change in a member of the multidisciplinary team

Question 3 of 20

Question 4 of 20

4. In the AIAG VDA FMEA handbook the correct way to begin development of a DFMEA is:

Applying the 5T approach

Applying the 5 Why approach

Applying the 5W-2H approach

Applying the 4T approach

Question 4 of 20

Question 5 of 20

5. In the AIAG VDA FMEA handbook developing a DFMEA is based on:

A five-step approach

A six-step approach

A seven-step approach

An eight-step approach

Question 5 of 20

Question 6 of 20

6. In the AIAG VDA FMEA handbook Step 1 includes:

Defining the failure modes and effects

Undertaking a functional analysis

Undertaking a system analysis

Establishing a multidisciplinary team with clearly defined roles, responsibilities and authorities

Question 6 of 20

Question 7 of 20

7. In developing a DFMEA, the purpose of structure analysis is:

To identify and breakdown the design into system, subsystem and component parts for the technical risk analysis

To ensure that the intended functions/requirements of the product/process are appropriately allocated

To use a block diagram to break the product down into the system, sub-system and component level

To understand the potential failure modes and effects

Question 7 of 20

Question 8 of 20

8. In step 3 function analysis the following are considered:

The function of the next highest-level function and requirement

The function and requirement of the focus element

The function of the next lower level function and requirement

All the above are correct

Question 8 of 20

Question 9 of 20

9. In developing a DFMEA, the purpose of failure analysis is:

To ensure that the intended functions/requirements of the product/process are appropriately allocated

To estimate risk by evaluating severity, occurrence and detection, in order to prioritize the need for actions

To identify failure causes, modes and effects and show their relationship to enable risk assessment

To determine actions to mitigate risk and assess the effectiveness of those actions

Question 9 of 20

Question 10 of 20

10. Failure effects are:

Described in terms that the customer might notice or experience

An indication of why a failure mode could occur

The way in which the process could cause the product not to deliver the intended function

Only the effects of failure that would be seen by the customer

Question 10 of 20

Question 11 of 20

11. An example of a prevention control in a DFMEA is:

Undertaking dimensional checks of the product in process

Undertaking dimensional checks of the product at final inspection

Design and material standards

Undertaking patrol inspection

Question 11 of 20

Question 12 of 20

12. An example of a detection control in a DFMEA is:

Detailed work instructions

Optimised machine parameters

Endurance testing

Equipment maintenance undertaken by operators

Question 12 of 20

Question 13 of 20

13. When considering severity what should be considered:

Impact of a potential failure in the manufacturing process

Impact of a potential failure at your suppliers

Impact of the potential failure on the end user

All the above should be considered

Question 13 of 20

Question 14 of 20

14. If prevention control is the first application of new technology, where standards do not exisit, this will result in:

A high occurrence score

A high detection score

A high severity score

A high RPN

Question 14 of 20

Question 15 of 20

15. When scoring detection:

A rating is allocated according to detection method maturity and opportunity for detection

Consideration is given to the score for severity and occurrence

The occurrence of the failure cause in the process is considered

The action priority table is considered

Question 15 of 20

Question 16 of 20

16. In the AIAG VDA handbook the AP ranking:

Gives more emphasis on severity first, then occurrence, then detection

Accounts for all 1000 possible combinations between 1 and 1000

Is broken down into high, medium and low rankings

All the above are correct

Question 16 of 20

Question 17 of 20

17. The purpose of step 6 Optimisation is:

To determine actions to mitigate risk and assess the effectiveness of those actions

To address any risk priority numbers above 100

To re-score risk based on any proposed improvement actions

To ensure that the intended functions/requirements of the product/process are appropriately allocated

Question 17 of 20

Question 18 of 20

18. Which of the following is the most effective way of Optimisation?

Increasing the detection ability for the failure cause or failure mode

Design modifications to reduce the potential risk

Changing the severity by improving error proofing

Working on the low action priority rankings first

Question 18 of 20

Question 19 of 20

19. The purpose of step 7 is:

To summarise and communicate the results of the FMEA activity

To determine actions to mitigate risk and assess the effectiveness of those actions

To produce a summary report for internal purposes only

To produce a summary report for use only by the customer

Question 19 of 20

Question 20 of 20

20. Once a FMEA is developed it should be reviewed and updated

Only where required by the customer

At least once within a three-year certification cycle

When any changes are proposed to the design

Before any third-party audit

Question 20 of 20