B. Geometric Dimensioning and Tolerancing (GD&T)

C. Blueprint Reading (e.g., views and details, symbols, drafting standards)

D. Measurement

1. Nondestructive inspection techniques (NDT) (e.g., definitions, common methods)
2. Accuracy and precision in measurement
3. Rounding rules (e.g., truncate, round up, round down, negative numbers)
4. Types of measurements (e.g., direct, differential, transfer)
5. CMM or surface plate techniques (e.g., layout)

E. Inspection Planning (e.g., sequence, priorities)

1. Classification of characteristics (e.g., critical, major, minor)
2. Classification of defects (e.g., critical, major, minor)
3. Inspection points (e.g., receiving, first article, in-process, final, source)
4. Inspection error (e.g., inspector bias, fatigue, flinching, distraction, environment, parallax)
5. Check sheets
6. Product and material traceability
7. Nonconforming material identification
8. Product audits (techniques applications)

F. Measurement Scales (e.g., analog, digital, Vernier, conversions: millionths, microns, micro-inches)

G. Gages

1. Calibration procedures
2. Gage care, cleaning, and checking
3. Gage selection (e.g., 10:1 rule, direct vs. transfer)

H. Language of Measurement, Definitions, and Terminology (e.g., datum, setup point, first article, tolerances)

III. Measurement Tools (34 questions)

A. Metrology

1. Handtools (e.g., calipers, micrometers, scales)
2. Gages (e.g., pins, thread, and custom gages)
3. Optical tools (e.g., comparator, profiles, microscopes)
4. Pneumatic/air gaging
5. Coordinate Measuring Machines (CMM)
6. Electronic gaging
7. Automatic gaging (definition) (e.g., in-line, programmable logic, controller (PLC), computer)
8. Weights, balances, scales
9. Hardness testing equipment
10. Surface plate methods and equipment (e.g., sine plate, height gage, indicators)
11. Surface analyzers (e.g., roughness, roundness, profile)
12. Force measurements (e.g., tension, torque, compression)
13. Gear inspection equipment
14. Transfer tools (e.g., hole gages, telescoping gages)
15. Angle measurement instruments (e.g., protractors, sine bar, angle blocks)

B. Calibration

1. Calibration procedures
2. Calibration status
3. Effect of calibration error on product acceptance
4. Gage correlation
5. Reproducibility and repeatability in measurement
6. Gage traceability
7. Reporting problems

IV. Statistical Techniques (14 questions)

A. Basic Statistics

1. Measurement of central tendency
2. Measures of dispersion
3. Data plotting (e.g., terms, applications)

B. Statistical Quality Control

1. Control limits vs. specification limits
2. Objectives of control charts
3. State of statistical control
4. Control limits
5. Pre-control
6. Variables charts
1. X and R
2. X and s
7. Attribute charts
1. p
2. c
3. u
4. np
8. Process capability
1. definition of Cp
2. definition of Cpk
9. Machine capability (e.g., terms, applications)
10. Analysis of charts
1. in control or out of control
2. rules to determine
3. pattern of data

C. Frequency Distributions

1. Mean
2. Variance
3. Proportion
4. Range
5. Normal
6. Pareto

V. Quality Improvement (9 questions)

A. Quality Concepts (e.g., control of design, purchase materials, product and process, special processes)

B. Plan-Do-Check-Act (PDCA) Cycle (definition only)

C. Team Concepts (definition)

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I. Technical Mathematics

1. How many minutes of arc are in one degree?

1. 30
2. 60
3. 90
4. 120

2. From a 12 x 24 piece of sheet metal, how many 2 x 2 pieces can be sheared?

1. 72
2. 74
3. 75
4. 76

3. If two angles are complementary, then both are

1. acute angles.
2. obtuse angles.
3. right angles.
4. All of the above

4. How many .001 inches are there in one inch?

1. 1000
2. 100
3. 10000
4. 10000.0

5. Convert 527 millimeters to inches. (1 mm = .0394 inches.)

1. 2.076
2. 207.6
3. 2076.00
4. 20.76

II. Blueprint Reading

6. Arrowheads are used on a drawing in many applications. One of the applications is

1. break lines.
2. center lines.
3. object lines.
4. cutting plane lines.

7. What is the geometric characteristic of the reference plane?

1. Hardness
2. Height
3. Squareness
4. Flatness

8. In a retangular coordinate system of tolerancing where the positional tolerance in two directions have equal tolerance

1. the resultant tolerance zone is square.
2. the resultant tolerance zone depends on the actual size of the feature.
3. the resultant tolerance zone is a circle.
4. there is no tolerance zone.

III. Inspection Tools and Equipment

9. Adjusting an instrument or device to a standard is called

1. correction.
2. angulation.
3. correlation.
4. calibration.
5. standardization.

10. The basis for establishing calibration intervals is

1. stability.
2. purpose.
3. degree of usage.
4. MIL-STD-45662 intervals must be used.
5. a, b, and c only.

11. To ensure continued accuracy, inspection devices must be periodically

1. polished.
2. corrected.
3. calibrated.
4. rust-proofed.
5. All of the above

12. Accuracy is

1. getting consistent results.
2. reading to four decimal places.
3. using the best measuring device available.
4. the difference between the average of multiple measurements and the true value.

13. Which of the following is in the class of vernier tools?

1. Caliper
2. Surface gauge
3. Pneumatic gauge
4. Sine bar

IV. Materials and Processes

14. Annealing process treats a metal

1. by leaving it soft.
2. by etching the surface.
3. by hardening it.
4. by removing scale.

15. Which of the following metals is a ferrous metal?

1. Steel
2. Aluminum
3. Copper
4. Lead

16. When checking a hardness tester for calibration, how many readings should be taken on a master and averaged for comparison to the master specification?

1. 7
2. 10
3. 2
4. 3, discarding the first reading and averaging the other two.

V. Inspection Planning

17. Sample selection of parts for inspection must be selected at random to ensure

1. a maximum sample size.
2. a minimum sample size.
3. the probability of not rejecting the lot.
4. the probability of accepting the lot.
5. finding typical characteristics of the lot.

18. Controls on raw material are maintained to prevent

1. use of wrong material in manufacturing.
2. storerooms from issuing wrong material
3. use of material failing test.
4. a, b, and c above.
5. a and c above.

19. Product characteristics should be classified (critical, major, etc.) so that

1. a more meaningful assessment of quality can be made.
2. emphasis can be placed on important characteristics.
3. action with the responsible individuals can be taken.
4. a quality audit would be more meaningful.

VI. Inspection Technology

20. The diameter at the root of a male screw thread is known by what standard term?

1. Thread groove diameter
2. Minor diameter
3. Pitch diameter
4. Addendum

21. What feature on a threaded plug gauge helps to clear threaded holes of small, loose chips?

1. Truncation
2. Crest
3. Chip groove or notch
4. Helix variation

22. A thread go plug gauge

1. checks male threads.
2. checks female threads by comparison.
3. checks ring gauges.
4. measures pitch diameter.
5. is not used to check parts.

23. The unit of measurement for surface texture is the

1. mil.
2. tenth-mil.
3. microinch.
4. nanoinch.

24. Methods of inspection and process monitoring shall be corrected

1. any time the inspector wants a change.
2. any time manufacturing wants a change.
3. any time their unsuitability is demonstrated, and then only when the approved procedure is followed.
4. any time their acceptance is demonstrated.
5. None of the above.

25. The technology for predicting human reliability in production processes is

1. inevitably correlated with monetary rewards.
2. represented by the many motivation programs in effect.
3. still in an early developmental stage.
4. based on the determination of the workmanship error rate.

VII. Statistics

26. Approximately what percentage of the area under the normal curve is included within ± 3 standard deviations about the mean?

1. 50.0%
2. 68.0%
3. 90.0%
4. 95.0%
5. 99.7%

27. Who has the initial responsibility for manufactured product quality?

1. The inspector
2. The statistician
3. The operator
4. The quality manager

VIII. Sampling and Sampling Plans

28. The maximum percent defective that, for purposes of sampling inspection, can be considered satisfactory as process average is the

1. AOQ.
2. AOQL.
3. AQL.
4. ALQ.
5. None of the above.

29. It is necessary to comply with and maintain data regarding the results of inspection to

1. accept good parts or batches.
2. reject bad parts or batches.
3. develop a quality history.
4. develop a realistic production schedule.
5. None of the above.

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