1

Core Tools
05 Tools (PPAP, APQP, FMEA, MSA, CEP)

CORE TOOLS EXAM

Production Part Approval Process

CONFIDENTIAL

Please write your name in this space Date: Place:

THESE SPACES ARE FOR OFFICIAL USE ONLY

Section Qualifier 1 Qualifier 2 Rating Maximum
Minimum

1 8 20
2 24 60

Total 56 80

Name of the Confirmed:

Qualifier

Result
Course Manager

Core Tools
 2

Information for candidates

This exam consists of four sections. Please answer all the sections.
The allowed time is two hours. There is no additional time to review the exam.
the maximum score is 80 points, the minimum passing score is 70% (56
points) and must reach at least 40% in each of the four sections.

Your answers must be provided on the provided sheets. Additional loose sheets are not allowed.
They will be accepted if they are not properly identified.

Core Tools - Automotive Industry Tools

PPAP: Production Part Approval Process PPAP: Parts Approval Process

2. APQP: Advanced Product Quality Planning for Production
3. FMEA: Failure Mode Effects Analysis 2. APQP: Advanced Quality Planning
4. MSA: Measurement Systems Analysis of the product
5. SPC: Statistical Process Control 3. FMEA: Failure Mode and Effects Analysis
4. MSA: Analysis of Measurement Systems
5. CEP: Statistical Process Control

10 points
Questions that require a detailed written response that normally the provided space is
sufficient.

Section II value 10 points

Multiple choice questions that require enclosing the letter with the correct answer.

Section III value 10 points

Multiple choice questions that require matching the column with the correct answer.

Section IV value 10 points

Multiple choice questions that require enclosing the option with the correct answer.

Section V value 10 points

Multiple choice questions that require matching the column with the correct answer.

Section VI value 30 points

Exercises on Incidents that require a solution using the AMEF and PPAP tools

Core Tools
 3

SECTION I

I briefly answer the following questions. (10 points)

1. What are the stages of advanced quality planning?

2. What is the standard deviation?

3. What is evaluated in a measurement system analysis (MSA)?

Core Tools
 4

4. What are the acceptance ranges for a Gage R&R study by variables?

5. What types of runs can be generated in a control chart?

Core Tools
 5

SECTION II

II Enclose in a circle the item with the correct answer. (10 points)

The process that involves and formalizes the successful completion of the advanced planning process of the
the quality of the product is:

a) PPAP
b) Process Sign-Off (PSO)
c) Finished product inspection
d) None of the above

2. Skill studies are applied to characteristics of:

a) Process and product

b) All those marked in the plans and standards
c) To the special ones indicated in the control plan
d) All of the above
e) None of the above

3. The technique for defect prevention and continuous improvement is:

100% Inspection
b) Advanced Product Quality Planning (APQP) process
c) Process sheets
d) Failure Mode and Effects Analysis (FMEA)
e) All of the above
f) None of the above

4. In the failure mode and effects analysis, severity applies to:

a) The effect of the failure

b) The mode of failure
c) The causes of the failure
d) All of the above
e) None of the above

5. In the FMEA, the probability that the controls used will detect the mode of failure before the
the salty part of the component is:

a) Identification and traceability

b) Detection
c) Control method
d) All of the above
e) None of the above

Core Tools
 6

SECTION III

III Relate the following columns with the corresponding number. (10 points)

The significant production run is a( ) FMEA

requirement of:

2. It is the way a part can fail ( ) Control plan

potentially in meeting the requirements.

3. Describe the steps and sequences of the processes of ( ) Occurrence

production.

4. Identify potential failure modes of processes ( ) PPAP

related to the product.

5. Flowcharts, numbered drawings, sheets of ( ) Client

process, feature matrix.

6. End user ( ) Supporting documents

7. Frequency at which a mode of failure occurs as ( ) Potential failure mode

result of a specific case.

8. Document that establishes the sequence of stages of a ( ) Flow diagrams

process and the relevant specific quality practices
of the same.

9. Actual process capacity ( ) Feature matrix

10. Preliminary index of the process ( ) Cpk

( ) Ppk

Core Tools
 7

SECTION IV

IV Enclose in a circle the inciso with the correct answer. (10 points).

1. When the customer does not specify which level of PPAP presentation is required, the default is taken as:

a) Level 1
Level 2
c) Level 3
d) Level 4
Level 5

2. From the significant production run, how many pieces are needed for evaluation?
same.

300 random
200 consecutive
300 consecutive
All that you want

3. The acceptance criteria for the initial study for a process that meets the requirements of
client is:

1.67
b) 1.00
0.50
d) 1.20
e) None

4. The way to declare the weight of the part is:

0.00
0.000
c) 0.0
d) 0.0000
e) None

5. The records of the approval of the production parts must be kept for the time required.
that the east side is more active:

3 calendar years
1 calendar year
c) 2 calendar years
5 calendar years
e) Not defined

Core Tools
 8

SECTION V

In relation to the following columns with the corresponding number. (10 points)

1. Evidence of PPAP release with signature ( ) Design documentation of the

of the client. marketable product

2. Requirements for materials designated with ( ) Documents changes of

appearance items. engineering, yes there is.

3. Requirements for bulk materials. ( ) Customer engineering approval,

if required
4. Drawings of the part, mathematical data, ) Dimensional results
product specifications.

5. How do the measuring teams behave and ( ) Results of tests of

the staff that uses these equipment in the process. material performance

6. Product sample authorized by the customer. ( ) Initial process study

It is used to verify the parts. ( ) System analysis studies of

measurement
8. Engineering documentation that has not yet been ) Documentation of laboratory
attached to the plan or drawing of the part. qualified

9. Evidence of compliance with what is requested by the ( ) Product change notification

client. Process (PPNC)

10. Evidence of engineering approval of ( ) Appearance approval report

client. (AAR)

11. Show compliance with the dimensions ( ) Checklist of requirements for

requested by the client. bulk materials

12. Demonstrate that the laboratory complies with ( ) Sample pattern

ISO/TS 16949:2002, Accredited laboratory.

13. Evidence the testing of the material ( ) Verification aids

of behavior and/or performance.

14. Determine if the production process is ( ) Compliance records with

able to produce a product that meets the requirements Requirements Specific del
client requirements. Client (CSR)

Core Tools
 9

SECTION VI

VI Resolve the following incidents in the sheets with the Formats:

AMEF and Control Plan. (30 points)

INCIDENT 1 (15 pts)

The company TEXTILES DE CALIDAD, S. A. manufactures upholstery for the seats of the TS model.
1500 in its luxury version, according to the monthly indicators report, there have been no rejections of the
customer, however internally their quarantine area registered the following entries with
certain failures:

25 Unraveled Garments
72 Dirty outfits

Operation – ASSEMBLY OF SEAT

Manufactured Pieces per Month – 10,000 pieces

Generate the FMEA of the process considering each effect as a potential failure mode, define the
function of the operation, define its requirements, assign at least two potential failure effects to
for each failure, assign a severity level, type of classification, assign the potential causes of failure,
occurrence level, assign current controls, detection level, calculate the NPR and suggest actions
recommended corrective actions.

INCIDENT 2 (15 pts)

The company SILLAS, SILLOTAS Y SILLITAS, S. A. has a process in which there is a plate of
steel which is drilled in operation 10 with dimensions of (3) 35.5 +/- 0.2 mm with
Strawberry No. 10, in the following operation, No. 20, a cut is made at (4) 65º +/- 0.5º with the
cutter No. 35 and in operation 30 the same piece is painted color (5) red in oven No. 12
which is compared against a master number A5.
Consider that in the painting process the oven temperature is a critical parameter, it must be
80.0º +/- 3.0ºC
The numbers inside the parentheses are the assigned feature numbers on the plan.

Generate your Control Plan, assuming that the part is part of the assembly of a car seat
for babies where the seatbelt is fastened.

INCIDENT 3 (14 pts)

Calculate the Cp, Cpk and create the Gaussian graph of the following values:
9.5mm

Core Tools