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PECB ISO-9001-Lead-Auditor Exam Syllabus Topics:
Topic
Details
Topic 1
- Fundamental audit concepts and principles: Questions about interpreting and applying the main concepts and principles related to a QMS audit appear in this topic.
Topic 2
- Managing an ISO 9001 audit program: This topic evaluates your abilities to establish and managing a QMS audit program.
Topic 3
- Closing an ISO 9001 audit: The topic focuses on concluding a QMS audit and conducting audit follow-up activities.
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PECB QMS ISO 9001:2015 Lead Auditor Exam Sample Questions (Q128-Q133):
NEW QUESTION # 128
At the end of a second-party audit, the audit team enters the meeting room to hold the closing meeting; only two people are present and waiting for them: the Health and Safety supervisor and the administrative officer. Neither has participated in the audit. However, the team had previously agreed with the auditee Quality Manager on two nonconformities identified during the audit (NC1 and NC2).
They said:
Health and Safety supervisor: "Good evening. We are sorry to inform you that the general manager was involved in a serious car accident, and the other two managers have had to leave urgently to attend to the emergency." Administration officer: "Our quality manager, before leaving, left a written message about 'NC2'. He declares that the correction and corrective action have been already implemented and has attached some documents to the message as evidence of these actions. Therefore, he expects that 'NC2' will not be included in the report." Which one of the following would be your preferred answer to the Quallty Manager's request?
- A. The scope of the audit does not allow auditors to review actions taken in response to the nonconformity.There would not be enough time for the full cycle of corrective action to take effect
- B. OK. I will record in the audit report that 'nonconformity 2' was closed during the Closing meeting
- C. Let me review the message and documents, and I will give you my answer in a few minutes
- D. OK. Let's all go to the workshop to see the supervisor. I hope he will be able to explain what they did to correct the nonconformity and prevent its recurrence
Answer: C
NEW QUESTION # 129
You, as auditor, are in dialogue with the quality lead and managing director of a small business that supplies specialist laboratory equipment and furniture.
You: "I'd like to look at how you manage change in the organisation. What changes have you made as a business, say, over the last 12 months?" Auditee: "We have made some strategic changes, the main one being that we no longer manufacture our own products in house." You: "That sounds like quite a significant change. What has been the impact of that?" Auditee: "We now mainly sell other manufacturers' products, under their brand names, and have outsourced manufacture of our own brand products to one of our suppliers. Unfortunately, we had to make six members of our staff redundant. This represents about 20% of our workforce, so this has been quite a challenging time." You: "I'm sure. What were the reasons for making the change?" Auditee: "Our manufacturing section was a small operation, and we struggled to cope with fluctuations in demand. During busy periods, we found it hard to meet lead times, and in quiet periods we had staff with little to do. This was having an impact on customer satisfaction and meant we had to charge premium prices that made our product uncompetitive." You: "How did you go about the change?" In relation to the auditor's question about how the change was managed, the auditee mentions the steps listed below. Match the ISO 9001 clauses to the steps.
To complete the table, click on the blank section you want to complete so it is highlighted in red and then click on the ISO 9001 clauses listed below. Alternatively, drag and drop each clause to show which step the requirement applies to.
Answer:
Explanation:
Explanation:
Here is the correct matching of ISO 9001:2015 clauses to the steps mentioned in the change management process:
* We identified risks and opportunities and fed these into our risk management processes.
* Clause 6.1 (Actions to address risks and opportunities)
* We found a suitable supplier.
* Clause 8.4 (Control of externally provided processes, products, and services)
* We monitored customer feedback and noticed an increase in negative feedback about lead times.
* Clause 9.1.2 (Customer satisfaction)
* We put together a plan for implementation.
* Clause 6.2.2 (Planning to achieve quality objectives)
* We monitored the performance of the new supplier.
* Clause 8.4.2 (Type and extent of control of external providers)
* We noticed that productivity targets were being missed.
* Clause 9.1.1 (Monitoring, measurement, analysis, and evaluation)
* We communicated the plan internally.
* Clause 7.4 (Communication)
* We looked at the data at the management review and decided we needed to do something different.
* Clause 9.3.2 (Management review inputs)
* We reorganised the staffing and implemented redundancies.
* Clause 7.1.2 (People)
* We set an objective to effectively implement the transition and outsource manufacturing.
* Clause 6.2.1 (Quality objectives and planning to achieve them)
This aligns the steps of the change process with relevant ISO 9001:2015 clauses related to risk, planning, communication, and monitoring.
NEW QUESTION # 130
An internal auditor of a manufacturer of polystyrene packaging products for the electronics industry raised a nonconformity against section 10.3 of ISO 9001 in Report IA202. The nonconformity (NC 3) stated:
"The reject rate of the finished product of 9.7% needs improvement as it doesn't meet the stated objective of top management of 5%." As the third-party auditor reviewing the internal audit process, you come across the nonconformity. For corrective action, the Quality Manager conducted an investigation into the reject rates. He reported that the collection baskets for products ejecting from the moulding machines were not large enough. About 6% of products fell onto the wet and dirty factory floor. Management stated that replacing the baskets was too costly and ordered the Maintenance Manager to ensure that the floor was kept clean and dry to prevent rejects. The auditor later checked the factory floor, which was wet and dirty in places.
From the following nonconformities, select three that the auditor could raise to ISO 9001.
- A. 7.1.4 - The factory environment is not suitably maintained to prevent dirty products.
- B. 7.1.1 - The organisation failed to provide the required resources to prevent nonconforming products.
- C. 10.3 - The organisation did not continuously improve. Reject rates were unchanged.
- D. 9.2.2 - Report IA202 contained a poorly worded nonconformity (NC 3).
- E. 8.5.1 - Production operations were not properly controlled to avoid reject products.
- F. 10.2.1 - Conduct of an investigation was not sufficient to understand the cause of the nonconformity.
- G. 8.6 - Dirty products were released to the customer.
- H. 7.3 - Staff were not aware that products were falling onto the factory floor.
Answer: A,B,C
Explanation:
The auditor could raise the following nonconformities to ISO 9001 based on the scenario:
*Option A: 10.3 - The organisation did not continuously improve. Reject rates were unchanged. This option is correct because ISO 9001:2015 clause 10.3 requires the organization to improve the suitability, adequacy and effectiveness of the quality management system. The organization did not demonstrate any improvement in reducing the reject rate of the finished product, which was a stated objective of top management. The corrective action taken by the organization was not effective in addressing the root cause of the problem and preventing its recurrence.
*Option B: 7.1.4 - The factory environment is not suitably maintained to prevent dirty products. This option is correct because ISO 9001:2015 clause 7.1.4 requires the organization to determine, provide and maintain the environment necessary for the operation of its processes and to achieve conformity of products and services.
The organization did not ensure that the factory floor was clean and dry, which affected the quality of the products and increased the risk of nonconformity.
*Option C: 7.1.1 - The organization failed to provide the required resources to prevent nonconforming products. This option is correct because ISO 9001:2015 clause 7.1.1 requires the organization to determine and provide the resources needed for the establishment, implementation, maintenance and continual improvement of the quality management system. The organization did not provide adequate collection baskets for the products ejecting from the moulding machines, which resulted in products falling onto the factory floor and becoming nonconforming.
The following options are not correct:
*Option D: 9.2.2 - Report IA202 contained a poorly worded nonconformity (NC 3). This option is not correct because ISO 9001:2015 clause 9.2.2 does not specify the requirements for the wording of nonconformities in internal audit reports. The nonconformity (NC 3) stated by the internal auditor was clear and relevant to the audit criteria and audit evidence. The issue is not with the report, but with the corrective action taken by the organization.
*Option E: 8.6 - Dirty products were released to the customer. This option is not correct because ISO 9001:
2015 clause 8.6 requires the organization to implement planned arrangements, at appropriate stages, to verify that the product and service requirements have been met. The scenario does not indicate that the dirty products were released to the customer, but that they were recalled and repaired then returned to the customers. The issue is not with the release, but with the production process and the environment.
*Option F: 7.3 - Staff were not aware that products were falling onto the factory floor. This option is not correct because ISO 9001:2015 clause 7.3 requires the organization to ensure that the persons doing work under its control are aware of the quality policy, relevant quality objectives, their contribution to the effectiveness of the quality management system, and the implications of not conforming with the quality management system requirements. The scenario does not indicate that the staff were not aware of these aspects, but that the management did not provide adequate resources and environment for the staff to perform their work. The issue is not with the awareness, but with the management responsibility and resource provision.
*Option G: 10.2.1 - Conduct of an investigation was not sufficient to understand the cause of the nonconformity. This option is not correct because ISO 9001:2015 clause 10.2.1 requires the organization to react to the nonconformity and, as applicable, take action to control and correct it and deal with the consequences. The scenario indicates that the Quality Manager conducted an investigation into the reject rates and identified the cause of the nonconformity. The issue is not with the investigation, but with the corrective action taken by the management.
*Option H: 8.5.1 - Production operations were not properly controlled to avoid reject products. This option is not correct because ISO 9001:2015 clause 8.5.1 requires the organization to implement production and service provision under controlled conditions. The scenario indicates that the production operations were controlled by the moulding machines, which ejected the products into the collection baskets. The issue is not with the production operations, but with the size of the collection baskets and the condition of the factory floor.
References:
*ISO 9001:2015 Quality management systems - Requirements
*ISO 9001 Lead Auditor Course Material, Module 6: Reporting Audit Findings, Slide 14: Writing Nonconformity Statements
*ISO 9001 Lead Auditor Training Course - IRCA Certified, Section 6.2: Reporting Audit Findings
*Lead Auditor Exam Preparation Guide (EPG) Template - PECB, Section 3.2: Exam Content Outline, Subsection 3.2.1: Section 1 - Audit Fundamentals, Subsection 3.2.2: Section 2 - Audit Principles, Subsection
3.2.3: Section 3 - Audit Process, Subsection 3.2.4: Section 4 - Audit Competencies
NEW QUESTION # 131
You are conducting an ISO 9001 audit of a Materials Recycling Facility (MRF). The company processes waste plastics into raw material for plastic bottle manufacturers. You reach the manual picking line where operators are removing contaminant materials from incoming products, such as plastic bags, plastic film and badly contaminated items that would compromise the recycling process.
You interview the line supervisor.
You: "Why are these plastic items being rejected at this stage?"
Auditee: "They do not meet our processing standards."
You: "What is the reason for that?"
Auditee: "These items are likely to damage the machinery down the line. They can also compromise our quality standards. We need to protect our reputation for good quality output materials." You: "What happens to the rejected items?" Auditee: "Some get melted down in another process later on and some are disposed of as waste products that cannot be recycled." You: "What happens to the waste products?" Auditee: "I'm not sure. I suppose they go to landfill." After further auditing, you have gathered additional evidence.
Answer:
Explanation:
Explanation:
A # 8.4.3.a
B # 7.2.b
C # 10.2.2
D # 10.2.1
E # 6.2
Comprehensive and Detailed Explanation From Exact Extract:
# A. There is no specification for incoming materials # 8.4.3.a
Clause 8.4.3(a) relates to the control of externally provided processes, products, and services, specifically the requirement to communicate appropriate specifications and requirements to suppliers:
"The organization shall ensure the adequacy of requirements prior to their communication to the external provider." Failure to specify requirements for incoming materials (e.g., what is acceptable waste plastic) risks compromising product quality.
# B. The picking operators have been trained # 7.2.b
Clause 7.2(b) relates to Competence and mandates:
"Ensure that these persons are competent on the basis of appropriate education, training, or experience." Training is a critical part of establishing and maintaining operator competence in quality-affecting tasks.
# C. The picked reject materials are not documented # 10.2.2
This clause focuses on the retention of documented information regarding nonconformities and actions taken:
"The organization shall retain documented information as evidence of: the nature of the nonconformities and any subsequent actions taken..." If rejects are not recorded, traceability and root cause analysis for quality failures are weakened.
# D. The rejected materials are segregated # 10.2.1
Clause 10.2.1 relates to nonconformity and corrective action, including containment activities such as:
"Deal with nonconforming outputs in one or more of the following ways: correction; segregation, containment..." Segregation ensures nonconforming material doesn't contaminate acceptable output.
# E. Management has set an objective for the level of rejects # 6.2
Clause 6.2 is about quality objectives. It requires organizations to:
"Establish quality objectives at relevant functions... The quality objectives shall be measurable..." Setting a measurable reject-level target aligns with improving process control and reducing waste.
References:
ISO 9001:2015 Clause 8.4.3.a - Information for External Providers
ISO 9001:2015 Clause 7.2.b - Competence
ISO 9001:2015 Clause 10.2.2 - Documentation of Nonconformity
ISO 9001:2015 Clause 10.2.1 - Control of Nonconforming Outputs
ISO 9001:2015 Clause 6.2 - Quality Objectives
NEW QUESTION # 132
Scenario 7: POLKA is a car manufacturing company based in Stockholm, Sweden. The company has around 14,000 employees working in different sectors which help with the design, painting, assembling, and test drives of the final product. The company is widely known for its qualitative products and affordable prices. In order to retain their reputation, POLKA implemented a quality management system (QMS) based on ISO 9001.
Before applying for certification, the company decided to conduct an internal audit to check whether there are any nonconformities in their QMS and if the requirements of ISO 9001 are being fulfilled.
The top management appointed Sean, the internal auditor, as the team leader of the internal audit team. Sean required from the top management to have unrestricted access to the employees and executives of POLKA and to the documented information. Furthermore, Sean required to establish a team with a large number of auditors, considering the size and the complexity of the organization. The top management of POLKA agreed with Sean's requirements.
The top management, in cooperation with Sean, assigned 10 more employees to the audit team.
Following that. Sean planned the audit activities and assigned the roles and responsibilities to each auditor. They began by interviewing employees of different manufacturing departments to check whether they are aware of the process of the QMS implementation. While conducting these activities, one of the auditors asked Sean for permission to audit the department in which he worked on a daily basis, as he was very familiar with the processes of the department.
Along the way, the teams findings showed that the staff were trained, documented information was updated, and the QMS fulfilled the requirements of ISO 9001. The internal audit took three weeks to complete, and on the last week the audit team held a final meeting The team shared their results and together drafted the audit report This report was submitted to the top management of the company. The report was maintained as documented information, and was available to the relevant interested parties.
Based on the scenario above, answer the following question:
According to Scenario 7, one of the auditors requested permission from Sean to audit the department in which he worked on a daily basis. Should Sean grant the auditor permission?
- A. Yes, Sean should grant the auditor permission
- B. Yes, but Sean himself must be present in every audit activity
- C. No, internal auditors should be independent of the processes being audited
Answer: C
Explanation:
Comprehensive and Detailed In-Depth Explanation:
ISO 19011:2018, Clause 5.1 (Impartiality) states that:
* Internal auditors must be independent of the processes they audit to ensure objectivity.
* Auditing one's own department introduces bias and is not permitted.
Thus, Sean must not allow the auditor to audit their own department.
Reference:
ISO 19011:2018, Clause 5.1 (Impartiality)
NEW QUESTION # 133
......
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