SECTION - IX

DATA COLLECTION – TEST QUESTIONS

9.1. Weibull analysis is a way to quickly and easily analyze field data or interval test data.
The limits of the use of this technique include having a good estimate for the:

a. MTBF
b. Expected life
c. Shape parameter
d. Average quality of the production lots

References: CRE Primer, Sections III – 31/37 & IX – 22 (and logic). 1997 CRE Brochure,
Question 14.

9.2. Which of the following is NOT an objective of a data collection program?

a. To demonstrate reliability to customers

b. To produce reliability reports
c. To demonstrate internal reliability
d. To validate vendor supplied items

Reference: CRE Primer, Section IX – 7.

9.3. Which of the following information is needed on a reliability test report?

I. Test location
II. Test specification
III. Failure description

a. I and II only
b. I and III only
c. II and III only
d. I, II and III

Reference: CRE Primer, Section IX – 8.

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9.4. Which of the following is NOT true concerning computer collection and reporting of
data?

I. It is more accurate than manual collection and reporting

II. It is faster than manual collection and reporting
III. It can reduce the expenses of collection and reporting data

a. I only
b. I and III only
c. II and III only
d. I, II and III

Reference: CRE Primer, Section IX – 10.

9.5. An item was removed from testing after 25 hours without failing. This unit was:

I. Right censored
II. Suspended
III. Truncated

a. I and II only
b. I and III only
c. II and III only
d. I, II and III

Reference: CRE Primer, Section IX – 4.

9.6. Which vehicle experienced infant mortality failures?

Note: All failures are independent of each other; all vehicles are from the same
population.

a. A
b. B
c. C
d. D
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References: CRE Primer, Sections VIII -36 and IX – 38 (and logic). Omdahl, T. P.,
Reliability Availability, and Maintainability (RAM) Dictionary. General deduction. 1980
Published CRE Exam, Question 12 (slightly modified).

9.7. Which vehicle has the largest sample MTBF?

Note: All failures are independent of each other; all vehicles are from the same
population.

a. A
b. B
c. C
d. D

References: CRE Primer, Sections IV – 4 & IX – 4. 1980 Published CRE Exam, Question 13
(slightly modified).

9.8. Computerized data collection and storage is most appropriate when:

a. The principal failure modes are not apparent
b. Discrete attribute data is under review
c. A considerable amount of complex data must be processed
d. Human error is anticipated in the data collection process

Reference: CRE Primer, Section IX – 12 (and logic).

9.9. It is desirable to provide corrective action feedback to the originator of the problem
report because:
a. He/she originated the problem report
b. It is good business practice
c. It helps to prevent recurrence of the problem
d. The report must be approved and filed

References: CRE Primer, Section IX – 48/49(and logic). CQM Primer, Section VII. Juran,
J.M., Quality Control Handbook, Section 30. 1980 Published CRE Exam, Question 119.

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9.10. The failure data collection, analysis, and corrective action system:

I. Should include failures due to equipment failure and those due to human error
in designing, manufacturing, and operating the equipment
II. Should include elapsed operating time (or cycles) prior to failure
III. Should include all failures from initial development through acceptance
testing

a. I only
b. II and III only
c. I and III only
d. I, II and III

Reference: CRE Primer, Section IX (seceral locations and logic O. MIL – STD-785. 1980
Published CRE Exam, Question 122(modified).

9.11. The prediction technique has obviously not always been effective quantitatively.
There is often a wide difference between actual reliability and predicted reliability.
Nevertheless, the reliability prediction technique permits:

a. Separating out “the vital few” from the “trivial many”

b. Spotlighting what has gone wrong with the program
c. Indicating which department is to blame
d. Estimating how good the product really is

References: CRE Primer, Section IX – 24, 28/30, 33 & 39. 1976 published CRE Exam,
Question 146.

9.12. A reliability data system usually implies collecting data on:

a. Process machine downtime

b. Product failures and operation time
c. Maintenance costs
d. Repair times

References: CRE Primer, Section IX-6, 12/14, 28/33 & 48/49. 1984 Published CQE Exam,
Question 75.

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9.13. Which of the following would normally be used for continuous variable data
analysis?

a. Control charts
b. Fault-tree diagram
c. Gantt charts
d. Cause and effect diagrams

References: CRE Primer, Sections II, III and IX – 38 plus other locations (and logic). CQE
Primer, Sections II and VIII. CQM Primer, Section VII.

9.14. A Pareto analysis of field failure data indicates several failure categories are
approximately equal. The best next course of action to take in selecting a category for
improvement would be which of the following?

a. Select the category that is easiest to fix

b. Select the category that offers the highest overall cost savings
c. Take additional data until a more significant category is evident
d. Select the category that requires the least expense to fix

Reference: CRE Primer, Sections IX – 24/25, 33 & 39.

9.15. Which of the following is a basic element in the corrective action process?

a. Limit manufacturing expenses

b. Identify failures for trend analysis
c. Investigate problems to determine root causes
d. Apply Pareto analysis to failures

Reference: CRE Primer, Section IX – 28/33.

9.16. Assuming a large population exists and is in use, the best source
Of failure rate data is:

a. Test data under closely controlled conditions

b. From a variety of environmental tests
c. Manufacturing acceptance testing data
d. Real-time operational test data

References: CRE Primer, Sections VIII and IX – 6/8 (and logic). 1997 CRE Brochure,
Question 11.

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9.17. The purpose of a failure reporting, analysis and corrective action system (FRACAS)
includes which two of the following?

I. Provide a closed loop failure reporting system

II. Provide initial robust product designs
III. Provide management with derating methods and principles
IV. Provide a failure analysis and corrective action vehicle

a. I and II only
b. II and III only
c. I and IV only
d. II and IV only

Reference: CRE Primer, Section IX – 48/51.

9.18. Establishment of a data collection, processing, and reporting system is essential

for a firm so that it can:

a. Guard against product liability suits

b. Provide statistics to reliability engineering
c. Improve using pertinent and valid data
d. Collect needed information

Reference: CRE Primer, Section IX – 6/16.

9.19. Root cause failure analysis is necessary to identify and correct basic problems.
Usually a priority of failure mode is established. This classic or traditional approach to
improvement results in which of the following?

a. Zero defects
b. Defect reduction
c. Catastrophic problem reduction
d. Special cause reduction

References: CRE Primer, Section IX – 28/33 (and logic). Reliability Toolkit: Commercial
Practices Edition.

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9.20. Hazard identification approaches include:

I. Top-down and bottom-up

II. BOM and severity
III. Mission profile and object at risk

a. I and III only

b. II and III only
c. I and II only
d. I, II and III

References: CRE Primer, Section II – 105/107 and IX – 40/47 (and logic).

9.21. Feedback channels for the planning, management and assessment of product
safety should include:

I. Both official and unofficial sources

II. Phone, fax, mail, and questionnaire sources
III. Captured company process information

a. II only
b. I and III only
c. II and III only
d. I, II and III

References: CRE Primer, Section II0 85/86 & IX – 6/9. Also see IEC 706-4, Guide on
Maintainability of Equipment, Part 4: Section 8 – Maintainability and Maintenance
Support Planning.

9.22. Reliability data is rarely complete. 50 units are placed on test for 50 hours. During
the test several units fail. The remaining units are removed from testing at that point.
Which of the following type(s) of censoring has (have) occurred?

I. Right censoring
II. Single censoring
III. Time censoring
IV. Type I censoring

a. I only
b. II and III only
c. I, III and IV only
d. I, II, III and IV

Reference: CRE Primer, Sections II = 105/107 and IX – 40/47 (and logic).

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9.23. Root cause analysis provides a common sense approach to evaluating a problem.
Align the following action steps in proper sequence from start to finish.

I. Describe Problem conditions

II. Develop possible problem causes
III. Collect facts and determine relationships
IV. Validate the true problem causes
V. Define the problem statement

a. I, V, IV, II, III

b. V, I, III, II, IV
c. I, V, III, IV, II
D. V, III, I, IV, II

Reference: CRE Primer, Section IX – 28/30 and 50.

9.24. Arrange the following failure data steps into the correct sequence from start to
finish.
I. Verify the failure
II. Identify and control the failure
III. Investigate the failure
IV. Provide corrective action and follow up
V. Report the failure

a. II, V, I, III, IV
b. I, II, V, III, IV
c. III, II, V, I, IV
d. I, II, III, IV, V

References: Dodson, B. and Nolan, D. (1995) Reliability Engineering Bible, page 20. CRE
Primer, Section IX – 25 & 28/30.

9.25. The gathering of quality and reliability data is common in many companies.
Mainframes are used in some companies and networked PCs are used in others. The
most important senior management decision is to answer which of the following
questions?

a. How can we provide all key people with useful information?

b. What are the cost benefits of a mainframe system?
c. What are the cost benefits of a PC based system?
d. What is the proper database system to employ?

References: CRE Primer, Section IX – 11 & 15/16 and Coombs, C.F. (1988) Handbook of
Reliability Engineering and Management.
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9.26. What is (are) the prime purpose(s) of a failure reporting, analysis and corrective-
action system (FRACAS)?
I. To determine the root cause of the problem
II. To record the corrective action taken
III. To document the problem
IV. To assure proper product quality

a. I only
b. II and III only
c. I, II and III only
d. I, II, III and IV

Reference: CRE Primer, Section IX – 48/51.

9.27. In a corrective action system, trend analysis can be defined as:

I. Long-term movement
II. The short term status of problems
III. A cyclical component of a time series
IV. Seasonal variations

a. I only
b. II and III only
c. I, II and III only
d. I, II, III and IV

References: CRE Primer, Section IX – 18/19 (and logic). Wilson, P.F., Dell, L.D. and
Anderson, G.F. (1993) Root Cause Analysis: A Tool for Total Quality Management, Page
49.

9.28. In a corrective action system, trend analysis can be used for:

I. Defining long-term movement
II. Providing input to overall problem identification
III. Providing an overall status of problems and actions
IV. Providing input to the resolution process

a. I only
b. II and III only
c. I, II and III only
d. I, II, III and IV

References: CRE Primer, Section IX – 18/19 (and logic). Wilson, P.F., Dell, L.D. and
Anderson, G.F. (1993) Root Cause Analysis: A Tool for Total Quality Management, Page
48.
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9.29. Which of the following is a basic element in the corrective action process?

a. Limit manufacturing expenses

b. Identify failures for trend analysis
c. Investigate problems to determine root causes
d. Apply Pareto analysis to failures

Reference: CRE Primer, Section IX – 28/33.

9.30. 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

Reference: CRE Primer, Section V – 15 and IX – 43/47 (and logic).

9.31. 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

References: CRE Primer, Sections V – 8/14 and IX – 40/41. Bowles, J.B. and Bonnell, R.D.
(1994) Failure Mode, Effects and Criticality Analyses, 1995 Annual Reliability and
Maintainability Symposium Tutorial Notes, page 3.

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9.32. 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

References: CRE Primer, Sections V – 8/14 and IX – 40/42. Bowles, J.B. and Bonnell, R.D.
(1994) Failure Mode, Effects and Criticality Analyses, 1995 Annual Reliability and
Maintainability Symposium Tutorial Notes, page 3.

9.33. “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

Reference: CRE Primer, Sections V – 8/14 and IX – 40/42.

9.34. 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

References: CRE Primer, Section IX – 43. O’Connor, P.D.T. (1992) Practical Reliability
Engineering, page 152.

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9.35. If a failure is found to be caused by a more severe environment than the original
specification:
a. Eliminate the failure form the reliability calculations
b. Inform the customer that the failure was not the company’s fault
c. Evaluate other customer uses to determine if the severe environment is usual
d. Perform Pareto analysis on the failure causes

Reference: CRE Primer, Section IX - 27 (and logic).

9.36. A major contributor to reliability growth and continuous process improvement is:

a. Early elimination of failure causes or trends

b. Documentation and classification of all failures
c. A closed-loop coordinated system in the identification of failure modes
d. Identification of root causes

References: CRE Primer, Section IX – 25/37. Reliability Analysis Center, Reliability

Toolkit: Commercial Practices Edition.

9.37. The true root cause of a failure may be identified by:

a. The most likely cause of a number of possible failures

b. Determining the initial event which was the direct cause of the failure
c. Use of the fishbone diagram
d. Evaluating the cause of the most significant failure

References: CRE Primer, Section IX – 25/33. Reliability Analysis Center, Reliability

Toolkit: Commercial Practices Edition.

9.38. What is the trend of the following data?

a. Generally flat
b. Generally increasing
c. Generally decreasing
d. No indicated trend

Reference: CRE Primer, Section IX – 18/19.

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9.39. Does a Design FMEA include potential manufacturing errors?

a. Yes, manufacturing problems are as important as design use problems, etc and
should always be included
b. The Design FMEA may include potential manufacturing-caused failure modes
when their identification, effect and contrl are covered by the Process FMEA
c. No, the Design FMEA addresses the design intent and assumes the design will
be manufactured/assembled to this intent
d. No, the Design FMEA is conductd too early toconsider manufacturing failure
modes

References: CRE Primer, Section IX – 40. Potential Failrue Modeadn Effects Analysis
(FMEA) Reference Manual, Chrysler Corporation, ford Motor Company and General
Motors Corporation, Feburay, 1995 (Qs-9000 series).

9.40. Your plant manufactures safetty devices for powered outdoor vehicles. Various
units have been returned for analysis. A Weibull probability plot of returned failed units
is able to determine the beta coefficient. Preventive maintenance on the units is
recommended if beta is:

a. Less than 1
b. Equal to 1
c. Greater than 1 and less than 4
d. Greater than 4

References: CRE Primer, Section IX -22.

9.41. The data value 68 is an example of:

a. Variable data
b. Attribute data
c. Locational data
d. Variable or attribute data

Reference: CRE Primer, Section IX – 2/3 (and logic).

9.42. Pareto Analysis is sometimes used in reliability testing. The purpose of this
analysis is:
I. To aid in the collection of filure data
II. To identify the”vital few”
III. To help focus on the most critical failure modes
IV. To bring agreement among various proponents on what should be the next
improvemetn project

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 a. I and II only
b. II and III only
c. II, III, and IV only
d. III and IV only

Reference: CRE Primer, Section IX – 24; Juran, Quality Control Handbook, pg. 6.20, 4th
Edition.

9.43. Process problems were discovered in a specific process step. The Quality Manager
orders that an inspector be positioned at that process step to perform 100% inspection.
This is an example of:

a. An improper use of a quality inspector

b. An immediate corrective action to contain the problem
c. A quality system response that should never be utilized
d. Root cause correction

Reference: CRE Primer, Section IX – 25/26.

9.44. The failure mode in the FMEA is:

a. The manner by which the failure is observed

b. The midpoint in the failure data
c. The type of failure
d. Tha approach to the solution of the failure

References: CRE Primer, Section IX – 42. Dodson, Nolan, Reliability Engineering Bible,
pg. 305.

9.45. Time truncated testing produces data that is:

a. Highly suspect since not all the items may have failed
b. Useful, but only failed items may be used to calculate MTBF
c. Considered censored
d. Useable without special considerations to calculate the MTBF

Reference: CRE Primer, Section IX – 4.

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9.46. Root Cause analysis has the goal of discovering and eliminating the underlying
cuses of a failure so that:

a. The failure will not happen again

b. The failure due to this cause are reduced significantly
c. The mode of failure is well understood and controlled
d. The appropriate blame and responsibility may be assigned

Reference: CRE Primer, Section IX – 28/29.

9.47. Field failure data for electronic assemblies has been analyzed using the Weibull
analysis. The beta of the distribution is calculated to be less than 1. What intenal action
would you recommend?

a. Add 100% final inspection of the process

b. Ask for additional failure category data from the field
c. Review the production inspection data to determine the source
d. Add additional screening or burn in

Reference: CRE Primer, Section IX – 22.

9.48. Why is it necessary to validate the selection of the root cause of a failure?

a. In this case, Validation menas to document the root cause to allow better
implementation
b. In this case, validation means to re-check data to make sure it is correct
c. In this case, validation menas to implement the root cause solution, then make sure
the failure mode doesn’t return
d. In this case, validation menas to explain the root cause to the employees for their
support

Reference: CRE Primer, Section IX – 29.

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