CLL Risk Assessment & Management 2

Question 1

In FMEA, the Risk Priority Number (RPN) is calculated by multiplying which three factors?

Accepted Answer

Severity, Occurrence, Detection

Answer

RPN = Severity × Occurrence × Detection, where each factor is rated on a scale (typically 1–10).

Question 2

A Lean team identifies a high-severity failure mode with a very low occurrence rating. Which action is most appropriate?

Accepted Answer

Apply poka-yoke to prevent its occurrence entirely

Answer

Even low-occurrence, high-severity risks warrant mistake-proofing because the consequences of a single failure can be catastrophic.

Question 3

Which Lean tool is most directly used to prevent a known risk from occurring in a process?

Accepted Answer

Poka-yoke (error-proofing)

Answer

Poka-yoke devices physically or digitally prevent errors from occurring or immediately detect them, directly mitigating identified risks.

Question 4

What is the primary difference between a Process FMEA (PFMEA) and a Design FMEA (DFMEA)?

Accepted Answer

PFMEA focuses on manufacturing process failures; DFMEA focuses on product design failures

Answer

PFMEA analyzes risks within the manufacturing or assembly process, while DFMEA analyzes risks inherent in the product design itself.

Question 5

During a Lean transformation, a control plan is best described as:

Accepted Answer

A document specifying what to monitor, how, and how often to sustain process controls

Answer

A control plan details the monitoring methods, frequency, and responsible parties needed to sustain process improvements and prevent recurrence of risks.

(CLL) Certified Lean Leader Practice Test

(CLL) Certified Lean Leader Practice Test

CLL Risk Assessment & Management 2