Design for Six Sigma (DFSS) Flashcards
7 cards from real Lean Six Sigma Black Belt Certification practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 7 Design for Six Sigma (DFSS) flashcards as text
In Design FMEA (DFMEA), the Risk Priority Number (RPN) is calculated as:
Answer: Severity × Occurrence × Detection
RPN = Severity × Occurrence × Detection (each rated 1–10), providing a relative risk score to prioritize which design failure modes require immediate corrective action.
A Transfer Function expressed as Y = f(X) in DFSS is used to:
Answer: Mathematically describe how input variables influence the critical output response
The transfer function models the relationship between controllable input variables (Xs) and the critical quality output (Y), enabling designers to predict and optimize performance before physical prototypes are built.
Monte Carlo simulation is used in DFSS primarily to:
Answer: Propagate input variation through a design model to predict the output distribution
Monte Carlo simulation runs thousands of randomized trials using probability distributions for input variables to predict how variation in those inputs will affect the critical output, revealing design risk before prototyping.
Tolerance design in DFSS is best described as:
Answer: Determining the acceptable variation ranges for key design parameters to keep CTQ outputs within specification
Tolerance design determines how much variation is allowable in each design input parameter so that the critical output (CTQ) remains within its specification limits, balancing quality performance against manufacturing cost.
Which DFSS reliability tool uses a top-down, deductive approach to identify combinations of component failures that can cause a system-level failure?
Answer: Fault Tree Analysis (FTA)
Fault Tree Analysis (FTA) starts with an undesired top-level system failure and works downward through logical gates to identify combinations of component-level failures and events that could cause it.
In the DMADV roadmap, the Verify phase primarily involves:
Answer: Piloting the design, validating performance against CTQs, and transitioning to full-scale production
The Verify phase confirms the new design meets all CTQ requirements through prototype testing or pilot production, then ensures a smooth handoff to the process owner for sustained operation.
Robust design, based on Taguchi methods, aims to achieve which of the following?
Answer: Make product or process performance insensitive to uncontrollable noise factors and variation
Robust design optimizes design parameter settings so that CTQ performance remains consistent despite uncontrollable noise factors such as environmental variation, manufacturing variation, and product wear.