Boeing Quality Assurance (QA) Test Exam
Boeing Quality Assurance (QA) Test Exam
Mostly Tested Exam Coverage Areas
1. Quality Management Systems and AS9100/ISO 9001 Requirements
2. Inspection Methods, Sampling Plans, and Measurement Techniques
3. Nonconformance Management, Corrective and Preventive Action (CAPA)
4. Statistical Process Control and Quality Data Analysis
5. Supplier Quality and Receiving Inspection
6. First Article Inspection and Production Part Approval
7. Calibration and Tool Control
8. Auditing, Documentation, and Records Control
9. Root Cause Analysis and Continuous Improvement
10. Safety, Configuration Management, and Regulatory Compliance
,1. A quality engineer notices that a critical bracket dimension has drifted outside the
control limits on an X-bar chart while the R-chart remains stable. Which action is
most appropriate first?
A. Recalibrate the measurement gauge immediately
B. Stop production and initiate a nonconformance report
C. Investigate assignable causes of the process mean shift
D. Increase the sampling frequency without further analysis
Answer: C
Rationale: A stable R-chart with an out-of-control X-bar signals a mean shift;
investigating assignable causes is the correct first response.
2. During receiving inspection, a lot of fasteners arrives without the required
certificate of conformity. What is the most appropriate disposition?
A. Accept the lot under engineering delegation
B. Place the lot on hold and request the missing documentation
C. Return the lot to the supplier without notifying quality
D. Sample the lot and accept if dimensions conform
,Answer: B
Rationale: Missing required documentation mandates a hold pending resolution;
acceptance cannot proceed without conformity evidence.
3. An auditor finds that a calibration record for a torque wrench was signed but the
due date had already passed when used. This is best classified as:
A. A minor observation with no impact
B. A nonconformance involving use of out-of-calibration equipment
C. An acceptable practice if torque values were within tolerance
D. A documentation error requiring only a correction
Answer: B
Rationale: Using equipment past its calibration due date is a nonconformance because
measurement validity cannot be assured.
4. A supplier's process capability study reports Cpk of 0.85 for a key characteristic.
What does this primarily indicate?
A. The process is centered and highly capable
B. The process is not capable relative to specification limits
, C. The gauge system is inadequate
D. The sample size was too large
Answer: B
Rationale: A Cpk below 1.0 indicates the process spread relative to specifications is
inadequate for capable performance.
5. When performing a first article inspection, which of the following must be verified
against the design documentation?
A. Only the final assembly dimensions
B. All characteristics, materials, and processes specified
C. Only characteristics flagged by manufacturing
D. Only dimensions measured by CMM
Answer: B
Rationale: FAI verifies full conformance of all specified characteristics, materials, and
processes to design requirements.
6. A corrective action request is raised for a recurring defect. Which step ensures the
fix addresses the underlying problem?
Boeing Quality Assurance (QA) Test Exam
Mostly Tested Exam Coverage Areas
1. Quality Management Systems and AS9100/ISO 9001 Requirements
2. Inspection Methods, Sampling Plans, and Measurement Techniques
3. Nonconformance Management, Corrective and Preventive Action (CAPA)
4. Statistical Process Control and Quality Data Analysis
5. Supplier Quality and Receiving Inspection
6. First Article Inspection and Production Part Approval
7. Calibration and Tool Control
8. Auditing, Documentation, and Records Control
9. Root Cause Analysis and Continuous Improvement
10. Safety, Configuration Management, and Regulatory Compliance
,1. A quality engineer notices that a critical bracket dimension has drifted outside the
control limits on an X-bar chart while the R-chart remains stable. Which action is
most appropriate first?
A. Recalibrate the measurement gauge immediately
B. Stop production and initiate a nonconformance report
C. Investigate assignable causes of the process mean shift
D. Increase the sampling frequency without further analysis
Answer: C
Rationale: A stable R-chart with an out-of-control X-bar signals a mean shift;
investigating assignable causes is the correct first response.
2. During receiving inspection, a lot of fasteners arrives without the required
certificate of conformity. What is the most appropriate disposition?
A. Accept the lot under engineering delegation
B. Place the lot on hold and request the missing documentation
C. Return the lot to the supplier without notifying quality
D. Sample the lot and accept if dimensions conform
,Answer: B
Rationale: Missing required documentation mandates a hold pending resolution;
acceptance cannot proceed without conformity evidence.
3. An auditor finds that a calibration record for a torque wrench was signed but the
due date had already passed when used. This is best classified as:
A. A minor observation with no impact
B. A nonconformance involving use of out-of-calibration equipment
C. An acceptable practice if torque values were within tolerance
D. A documentation error requiring only a correction
Answer: B
Rationale: Using equipment past its calibration due date is a nonconformance because
measurement validity cannot be assured.
4. A supplier's process capability study reports Cpk of 0.85 for a key characteristic.
What does this primarily indicate?
A. The process is centered and highly capable
B. The process is not capable relative to specification limits
, C. The gauge system is inadequate
D. The sample size was too large
Answer: B
Rationale: A Cpk below 1.0 indicates the process spread relative to specifications is
inadequate for capable performance.
5. When performing a first article inspection, which of the following must be verified
against the design documentation?
A. Only the final assembly dimensions
B. All characteristics, materials, and processes specified
C. Only characteristics flagged by manufacturing
D. Only dimensions measured by CMM
Answer: B
Rationale: FAI verifies full conformance of all specified characteristics, materials, and
processes to design requirements.
6. A corrective action request is raised for a recurring defect. Which step ensures the
fix addresses the underlying problem?
