CCQM Free Mock Exam (60 Minutes)

Free sample questions

3 questions from this set, shown in full with the correct answer and the reasoning behind it. Read them as a study resource.

1. Q1.Quality costs recorded on a completed building are listed below.
   
   $$\begin{array}{l|c} \hline \textbf{Cost element} & \textbf{Amount} \\ \hline \text{Quality planning} & \$30{,}000 \\ \text{Supplier surveillance} & \$45{,}000 \\ \text{Rework before handover} & \$150{,}000 \\ \text{Warranty repairs after handover} & \$90{,}000 \\ \text{Scrapped materials} & \$60{,}000 \\ \hline \end{array}$$
   
   What is the ratio of internal failure cost to external failure cost?

   • A.$1.7$ to $1$
   • B.$2.3$ to $1$✓ Correct answer
   • C.$0.4$ to $1$
   • D.$2.8$ to $1$

   Explanation

   Internal failure cost is what a defect costs while the work is still in the contractor's hands, and external failure cost is what it costs once the owner has it. Summing each category gives:
   
   $$C_{IF} = 150{,}000 + 60{,}000 = \$210{,}000 \qquad C_{EF} = \$90{,}000$$
   
   The ratio is then:
   
   $$\frac{C_{IF}}{C_{EF}} = \frac{210{,}000}{90{,}000} = 2.3$$
   
   The value $1.7$ is the primary foil, obtained by counting only the rework and forgetting that scrapped material is also a failure discovered before handover. The value $2.8$ adds supplier surveillance, which is appraisal cost, and $0.4$ inverts the ratio.

   Reference: CCQM BoK VIII

2. Q2.A failure mode and effects analysis for a structural base plate package is rated below, and the risk priority number is the product of severity, occurrence and detection.
   
   $$\begin{array}{l|c|c|c} \hline \textbf{Failure mode} & \textbf{S} & \textbf{O} & \textbf{D} \\ \hline \text{Anchor bolt undersized} & 9 & 3 & 4 \\ \text{Grout voids under the plate} & 7 & 6 & 5 \\ \text{Coating holiday on the flange} & 4 & 7 & 3 \\ \text{Bolt torque values not recorded} & 5 & 5 & 8 \\ \hline \end{array}$$
   
   A new grout inspection lowers the detection rating for grout voids from $5$ to $2$. Which failure mode then carries the highest risk priority number?

   • A.Grout voids under the plate
   • B.Anchor bolt undersized
   • C.Bolt torque values not recorded✓ Correct answer
   • D.Coating holiday on the flange

   Explanation

   The risk priority number multiplies the three ratings:
   
   $$RPN = S \times O \times D$$
   
   Before the change, grout voids led the table:
   
   $$RPN_{grout} = 7 \times 6 \times 5 = 210 \qquad RPN_{torque} = 5 \times 5 \times 8 = 200$$
   
   Improving detection to $2$ recalculates that row only:
   
   $$RPN_{grout} = 7 \times 6 \times 2 = 84$$
   
   So the unrecorded torque values, at $200$, now rank highest. Grout voids is the primary foil: it was the top risk on the original ratings, and the item turns on the point that a detection control changes the ranking without changing severity or occurrence. The undersized anchor bolt, at $9 \times 3 \times 4 = 108$, carries the worst consequence but not the highest RPN.

   Reference: CCQM BoK IV

3. Q3.Each installed air handling unit is started on its own local controls and its airflow, temperature control and safeties are proved, before any interlocks with the fire alarm or building management system are exercised.
   
   Which level of the five-level commissioning framework is this?

   • A.Level 4, individual system operation verification✓ Correct answer
   • B.Level 5, integrated system testing
   • C.Level 3, system construction verification
   • D.Level 2, component verification

   Explanation

   Level 4 proves that each system and major item of equipment operates correctly by itself, which is the necessary step before systems are made to talk to one another. Level 5 is the primary foil: it covers exactly the interlocked behaviour the scenario says has been deliberately deferred, and starting there would leave a single unit fault indistinguishable from an integration fault.

   Reference: CCQM BoK V

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