CQT 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.A moulding cell records surface defects on a defect location check sheet during one shift. The completed sheet is shown below.
   
   What does this check sheet show most clearly?

   

   • A.One inspector records more defects than the others
   • B.The defects concentrate at one corner of the part✓ Correct answer
   • C.The defects are spread evenly across the part surface
   • D.The defect rate climbs as the shift goes on

   Explanation

   A defect location check sheet records where on the part each defect was found, by putting a mark at that place on a picture of the part. Reading it means looking for a pattern in position. Fourteen of the twenty-two marks sit in one corner, and the rest are scattered singly, so position is clearly not random.
   
   The even spread reading is the primary foil, because it is the answer for a sheet where no cluster appears. The other two options describe patterns a check sheet can show, but only a different one: a defect rate over time needs a sheet with time intervals, and a comparison between inspectors needs a sheet with a column for each inspector. This sheet records position only.

   Reference: CQT BoK I

2. Q2.A capability study on a machined shaft diameter is summarised below. The process has been shown to be stable.
   
   $$\begin{array}{l|c} \hline \textbf{Parameter} & \textbf{Value (mm)} \\ \hline \text{Upper specification limit} & 10.40 \\ \text{Lower specification limit} & 9.60 \\ \text{Process average} & 10.10 \\ \text{Process standard deviation} & 0.10 \\ \hline \end{array}$$
   
   What is $C_{pk}$ for this process?

   • A.$0.50$
   • B.$1.00$✓ Correct answer
   • C.$1.33$
   • D.$1.67$

   Explanation

   $C_{pk}$ measures the distance from the process average to the nearer specification limit, in units of three standard deviations. Both sides must be worked out, and the smaller one is the answer:
   
   $$C_{pk} = \min\left[\frac{USL - \bar{X}}{3\sigma},\ \frac{\bar{X} - LSL}{3\sigma}\right]$$
   
   Substituting the values from the table:
   
   $$\frac{10.40 - 10.10}{3(0.10)} = \frac{0.30}{0.30} = 1.00 \qquad \frac{10.10 - 9.60}{3(0.10)} = \frac{0.50}{0.30} = 1.67$$
   
   The smaller value is $1.00$, so $C_{pk} = 1.00$.
   
   The value $1.67$ is the primary foil, and it is the far side of the specification, the side with room to spare. $1.33$ is $C_p$, which ignores where the average sits. $0.50$ divides by six standard deviations instead of three.

   Reference: CQT BoK II

3. Q3.A new operator starts on a stamping press and asks four questions about the station: which characteristic is checked there, how often it is checked, which gauge is used, and what to do when a reading falls outside the limit.
   
   Which single document answers all four?

   • A.The process flow diagram
   • B.The process FMEA
   • C.The control plan✓ Correct answer
   • D.The work instruction for the station

   Explanation

   A control plan is laid out as one row per characteristic, with columns for the characteristic, the specification, the measurement method, the sample size and frequency, the control method, and the reaction plan. Those columns answer all four of the operator's questions in one place.
   
   The process flow diagram is the primary foil. It shows the sequence of operations and where checks sit in that sequence, so it answers where but not how often, with what, or what to do next. The process FMEA explains why the characteristic matters and what could go wrong, and the work instruction tells the operator how to run the press rather than how the characteristic is controlled.

   Reference: CQT BoK VI

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