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These 10 free AMAI40 questions are organized by exam domain, so you can see how each part of the Festo Industry Certification Program - Applied Industry 4.0 (Level 2) blueprint is tested. Reveal the answer and explanation under each question.
An integration team must automate dispatch of released work orders, verify predecessor operations, and record component consumption against finished serial numbers. ERP already manages demand and purchasing, while the PLC controls each machine's sequence. Which capability should own the new responsibilities?
Correct answer: B - An MES that manages operation execution and as-built genealogy
An MES receives test-result messages through MQTT QoS 1. Its arrival log contains E401: serial S82, test attempt 1, FAIL; a second E401 with identical content; and E437: serial S82, test attempt 2, PASS after rework. E401 and E437 are identifiers assigned to the production events, not MQTT packet numbers. Which duplicate-detection rule preserves the full production history?
Correct answer: A - Record each production-event ID once, retaining both E401 and E437.
A 4-20 mA pressure transmitter is ranged from 0 to 10 bar. At steady load, a calibrated gauge reads 5.0 bar and the measured loop current is 12.0 mA. The PLC's engineering-value tag and the HMI both show 6.0 bar; the HMI displays that tag without additional scaling. Where should the error be corrected?
Correct answer: A - Correct the PLC's scaling: 12.0 mA should represent 5.0 bar.
An automated transfer cell has stopped with a fixture raised on a pneumatic lift. The HMI shows Stopped, but the air circuit remains pressurized. An authorized technician must reach beneath the fixture to remove a jam; the work requires hazardous-energy isolation under the site's procedure. What must be established before the technician enters?
Correct answer: B - Lock out energy sources, secure the raised load, control trapped pressure, and verify isolation under the equipment's procedure.
An OPC UA connection uses valid, trusted certificates and a read-only service account. Its MessageSecurityMode is Sign. During an authorized security check, recipe contents are readable in captured traffic. Both endpoints support SignAndEncrypt, and no separate encrypted tunnel protects the connection. How should the connection be changed to protect the recipe contents?
Correct answer: C - Use SignAndEncrypt while retaining the account's read-only permissions.
A CAD design specifies a guide opening of 80.0 ± 0.3 mm and a carrier width of 79.1 ± 0.2 mm. The design requirement is at least 0.5 mm of total width clearance, not 0.5 mm per side. All combinations of dimensions within those tolerances must fit. Does this design guarantee the required clearance?
Correct answer: D - No; the minimum total clearance is 0.4 mm, so the fit needs revision.
A UHF RFID reader at an assembly station reports two valid EPCs whenever a loaded pallet waits beside the pallet being processed. Both tags have unique identities, and anti-collision communication is working. The station has one pallet-presence sensor, but reader data are not tied to its trigger interval. Which modification would make the product-to-station association dependable?
Correct answer: B - Constrain the read zone and correlate valid reads with station presence.
A technician copies a working RFID reader's configuration into a replacement reader and connects both devices to the same VLAN. Communication with the original reader then becomes intermittent. The ARP entry for its IPv4 address alternates between the two readers' distinct MAC addresses; removing the replacement restores stable communication. What single configuration fault best explains that combination?
Correct answer: D - Both readers have been assigned the same IPv4 address.
A motor's archived vibration trend is velocity in mm/s RMS. After a sensor replacement, the dashboard receives peak acceleration in m/s² but retains the old trend label. It compares the earlier value of 2.8 with the new value of 5.1 and announces an 82% increase. Sensor location and operating load are unchanged; independent machine protections indicate no abnormal condition. How should maintenance interpret the reported increase?
Correct answer: A - The comparison is invalid; obtain matching vibration quantities and amplitude conventions before judging the trend.
During a sustained production run, a drilling station repeatedly waits because its output buffer is full. The leak tester immediately downstream is almost continuously processing, while the final packing station repeatedly waits for incoming units. Raw material and customer demand are ample, and there are no equipment faults or rejects. Where should the team focus its first throughput improvement?
Correct answer: C - Reduce the leak tester's cycle time without compromising the required test.
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