1. When considering polyester resin, the polymer backbone is formed through a condensation polymerization reaction, and then styrene monomer is added as a crosslinking component. When the peroxide initiator is added to the system the curing reaction takes place. Which of the following best describes the reaction:

a. Free radicals attack the carbon-carbon double bonds on the polymer chain
b. Styrene monomer is bonded to the ends of the polymer chain by van der Waals forces
c. The acid group reacts with the alcohol group producing a solid network

2. What would be the term used to describe the relationship between the amount of resin and the amount of fiber reinforcement in a laminate?

a. Matrix density
b. Fiber volume fraction
c. Component weight delineation

3. When inorganic fillers are added to polyester resin the result will be:

a. Increased flowability through a modification of the rheology of the resin
b. An increase in matrix volume and a decrease in cost
c. Enhanced crosslinking within the polymer matrix

4. In safety supervision, one theory on accidents is the “Domino Theory of Accident Causation.” This theory suggests that:

a. If one domino (cause) is removed from the line an accident can be prevented
b. Proper procedures can keep the dominos from falling
c. There is always one domino responsible for an accident

5. Understanding workers is a prime function of a supervisor. Which of the following will assist in building employee confidence and morale? [Indicate all that apply]

a. Using strict controls over employee actions
b. Being very conservative when directing production actions
c. Giving workers responsibility to control certain actions
d. Allowing employees to be part of operational decision making
e. Keeping talented employees in their job positions so they can gain long term
experience.

6. A composites manufacturing operation is considered a major emissions source if it has the potential-to-emit 10-tons per year of any single listed hazardous air pollutant (HAP) – It is therefore subject to MACT compliance. Would an operation be subject to MACT if it had the potential-to-emit three different HAP’s in these quantifies:

- 9 tons/yr of styrene
- 9 tons/yr of methylmethactylate
- 9 tons/yr of listed coatings solvents

a. Yes, it would be subject to MACT compliance
b. No, at less than 10-tons per HAP it would not be subject to MACT
c. If it used non-atomized spray application it would not be subject to MACT

7. The Unified Emissions Factor (UEF) table is used to determine emissions from the open molding process. When using the table, the primary variables used to specify emissions are based on:

a. The velocity of air flow over the mold and laminate thickness
b. The process method (e.g. mechanical spray application) and styrene content
c. The specific brand of spray gun used and distance from the mold

8. In the course of safety training, workers are instructed on the proper use of fire extinguishers. For a small electrical fire, what is the most appropriate type of fire extinguisher(s)? [Indicate all that apply]

a. Type A
b. Type B
c. Type C
d. Type ABC

9. A written hazard communication program is required by OSHA. This written program must include the following required information:

a. A list of hazardous chemicals known to be present in the workplace
b. The methods by which hazardous substance labels are derived
c. A notice of the use of hazardous chemicals use posted in the local newspaper

10. Total quality management (TQM) is an operating philosophy and a set of guiding principles for continuously improving an organization. Three of the six basic concepts of TQM include: Committed and involved management to provide organizational support; A focus on the internal and external customer; and ______________________________.

a. A focus on ever increasing manufacturing volumes
b. Effective involvement of the entire workforce
c. Competing on price with the most aggressive competitors

11. One method of addressing quality is to partner with suppliers to achieve specific goals and objectives. There are three key elements that define a manufacturer/supplier relationship aimed at improving quality. Indicate the three elements:

a. Planned incremental price adjustments
b. Long-term commitment
c. Progressive outsourcing
d. Trust
e. Shared vision

12. When estimating the cost of manufacturing a composites product, direct labor describes the man-hours required to produce the product. Considering a plant working a standard 40-hour week, if actual worker productivity is 6.5 hours per day they will most likely be paid for:

a. 6.5 hours per day
b. 8.0 hours per day
c. 42 hours per week including overtime

13. The two methods of determining the overhead burden when estimating the cost of a project are: [Indicate two that apply]

a. Use a shop-rate figure supplied by upper management
b. Calculate detailed variable and fixed operational costs
c. Use an assumed percentage of raw material costs

14. When manufacturing a new product, taking the learning curve cost into account during the cost estimating procedure is more important when:

a. A long production run is expected
b. The production volume is expected to amortize the tooling cost
c. A short production run is expected

If you have questions about the CCM Exam, procedures, or administration of the program:

Call ACMA Headquarters – 703-525-0511 or log on the ACMA website: www.acmanet.org.

Answers to sample test questions:

1. a 2. b 3. b 4. a 5. c,d 6. a 7. b 8. c,d 9. a 10. b 11. b,e 12. b 13. a,b 14. c