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NEW QUESTION # 113
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.
Answer: B,D,F
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 # 114
XYZ Corporation employs 100 people, and during a Stage 1 certification audit, certain issues are identified with the Quality Management System (QMS). Which two options describe the circumstances in which you could raise a nonconformity against Clause 6.2 of ISO 9001:2015?
Answer: A,C
Explanation:
Understanding Clause 6.2 of ISO 9001:2015:Clause 6.2 (Quality Objectives and Planning to Achieve Them) specifies that organizations must:
Establish measurable and relevant quality objectives consistent with the quality policy (Clause 6.2.1).
Include objectives applicable to product/service conformity and customer satisfaction.
Document these objectives and their planning as documented information (Clause 6.2.1 & 6.2.2).
Plan how to achieve the objectives, including defining actions, resources, responsibilities, timelines, and methods for evaluation.
Analysis of Options:
A). Quality objectives are not being implemented by the organisation's personnel:Incorrect. While implementation is critical, this relates more to operational aspects rather than the direct requirements of Clause 6.2. Implementation issues would typically raise concerns under Clause 9.1 (Performance Evaluation).
B). The consultant has not interpreted ISO 9001 correctly:Incorrect. The consultant's interpretation of ISO
9001 is irrelevant in terms of Clause 6.2 compliance. The focus is on whether the organization aligns with the requirements, not the consultant's role.
C). Establishing quality objectives did not include top management:Incorrect. While top management involvement is vital for QMS effectiveness (Clause 5.1), this is not a direct requirement of Clause 6.2. Top management alignment is implied but not explicitly mandated for establishing quality objectives.
D). Quality objectives were not established in alignment with the organisation's quality policy:Correct. Clause
6.2.1 requires that quality objectives be consistent with the organization's quality policy, ensuring they reflect its purpose, strategic direction, and commitment to continual improvement. Misalignment would constitute a nonconformity.
E). The organisation cannot afford to undertake quality objectives all at once:Incorrect. Financial constraints are not directly addressed in Clause 6.2. The clause focuses on planning to achieve objectives, which includes defining the necessary resources but does not demand achieving all objectives simultaneously.
F). Quality objectives are not maintained as documented information:Correct. Clause 6.2.1 specifically requires that quality objectives be maintained as documented information. Failure to document the objectives is a direct violation of this clause.
Why Options D and F Are Correct:
D: Misalignment between the quality objectives and the quality policy directly violates Clause 6.2.1, which mandates that objectives support the strategic direction of the organization.
F: Lack of documentation for quality objectives breaches the requirement to maintain them as documented information under Clause 6.2.1.
Relevant References:
Clause 6.2.1: Establishing quality objectives aligned with the quality policy.
Clause 6.2.2: Maintaining documented information for quality objectives and planning to achieve them.
Clause 5.1.1: Top management's responsibility to ensure alignment between the QMS and strategic direction.
NEW QUESTION # 115
An audit team of three people is conducting a Stage 2 audit to ISO 9001 of an engineering organisation which manufactures sacrificial anodes for the oil and gas industry in marine environments. These are aluminium products designed to prevent corrosion of submerged steel structures. As one of the auditors, you find that the organisation has shipped anodes for Project DK in the Gulf of Mexico before the galvanic efficiency test results for the anodes have been fully analysed and reported as required by the customer. The Quality Manager explains that the Managing Director authorised the release of the anodes to avoid late delivery as penalties would be imposed. The customer was not informed since the tests rarely fall below the required efficiency. You raise a nonconformity against clause 8.6 of ISO 9001.
During the audit team meeting in preparation for the Closing meeting, the second auditor disagreed with the clause of ISO 9001 selected for the above nonconformity. He thinks it should be clause 9.1.1.
Choose three options for how the audit team leader should best respond to the situation:
Answer: A,E,G
Explanation:
As the audit team leader, it is crucial to manage differing opinions constructively and ensure that the correct clause is selected for the nonconformity based on solid evidence. Here's how the situation should be handled:
E:Invite you and the second auditor to fully explain your point of view and then decide which clause to select: This promotes collaboration and transparency, allowing both auditors to present their rationale for choosing the specific clause.
F: Review the evidence with you and the second auditor, and then decide which clause of ISO 9001 would best apply: Reviewing the evidence in relation to the specific requirements of ISO 9001 is essential for determining which clause is most appropriate.
H: Try to obtain a consensus between you and the second auditor after a discussion of the different opinions:
Consensus-building is a crucial skill for an audit team leader. Achieving agreement ensures the nonconformity is addressed accurately and with full team support.
Options such as overruling immediately (D) or deferring the decision without full discussion (B) could undermine team dynamics and the audit process. Consulting the quality manager (A) or selecting an entirely different clause (G) is unnecessary, as the team should resolve the issue internally.
NEW QUESTION # 116
You work for an organisation which provides packaged food to the public. You are asked to lead a team (you as the leader and two other auditors) of a one-day audit of HMB, a supplier of hamburgers. It is 4 pm, and the audit is coming to an end. You are having an internal meeting with the team to decide what will be presented to the auditee during the closing meeting. The closing meeting is scheduled for 5 pm.
You, as the audit team leader, audited HMB's Top Management and the two production lines of hamburger production (PL1 and PL2).
Auditor 1 audited the laboratory.
You to Auditor 1: "What findings would you report?"
Auditor 1: "When reviewing the laboratory records, I noticed that during the whole morning, HMB's supervisors of each production line sent samples to be analysed by the laboratory. The samples from PL1 included the reference to the raw meat batch being used and the name of the sub-supplier, while the reports from PL2 referred only to the name of the sub-supplier. HMB's Procedure P-02 Rev.3 says that samples sent to the laboratory have to include reference to the raw meat batch being used, to ensure traceability of the products." You to Auditor 2: "OK, what do you think?" Auditor 2: "I think that this is a non-conformity." You to Auditor 1: "OK. How would you describe the evidence on which the non-conformity will be based?" Identify which one of the following statements best describes the identified evidence.
Answer: D
Explanation:
ISO 9001:2015 requires audit findings, including non-conformities, to be based on objective evidence and to be clearly described, stating exactly what requirement was not met and where.
A non-conformity statement must:
* Reference the specific requirement (procedure or ISO clause), and
* Describe the objective evidence observed, without assumptions, generalisations, or conclusions about causes.
In this scenario:
* The requirement is clearly stated in Procedure P-02 Rev.3, which requires samples sent to the laboratory to include reference to the raw meat batch number to ensure traceability.
* The objective evidence observed by Auditor 1 is that samples from PL2 did not include the raw meat batch reference, while samples from PL1 did.
Why option C is correct:
C). "Samples of hamburgers sent to the HMB's laboratory for analysis by PL2 did not refer to the raw meat batch number as required by P-02 Rev.3." This statement:
* Accurately reflects what was observed,
* Clearly identifies the affected process (PL2),
* Directly references the unmet requirement (P-02 Rev.3), and
* Is factual, specific, and evidence-based.
Why the other options are not the best description of evidence:
* A is a generalised conclusion and does not describe the specific evidence observed.
* B assumes a lack of awareness, which was not evidenced during the audit.
* D refers to product identification for delivery to the client, which is not what was observed (the issue was laboratory sample identification).
ISO-aligned conclusion:
The correct way to describe audit evidence is to state precisely what was observed against the requirement
, without interpretation or assumption. Therefore, the statement that best describes the identified evidence is Option C.
NEW QUESTION # 117
You are carrying out an audit at a single-site organisation seeking certification to ISO 9001 for the first time.
The organization manufactures cosmetics for major retailers.
You are interviewing the Manufacturing Manager (MM).
You: "I would like to begin by looking at the cleaning controls."
MM: "We record the cleaning of the equipment at the end of every batch. This document details the minimum cleaning frequency and the procedures to follow for all areas and each item of equipment. The person who carries out the cleaning puts their initial on the document and records the time and date alongside." Narrative: You sample production records over 3-days and note down evidence of nonconformity as per the table below.
Answer:
Explanation:
Explanation:
Nonconformity report
ISO 9001 Clause Number: 8.5.4 Nature of problem: Cleaning and sanitising records are not available for every batch. ISO 9001 requirement that has not been fulfilled: ISO 9001 - "The organization shall implement planned arrangements, at appropriate stages, to verify that the product requirements have been met." Evidence: 40 cleaning records are available for 63 batches.
NEW QUESTION # 118
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