Lean Six Sigma Black Belt Certification Design for Six Sigma (DFSS) 2

Question 1

In Design FMEA (DFMEA), the Risk Priority Number (RPN) is calculated as:

Accepted Answer

Severity × Occurrence × Detection

Answer

Severity + Occurrence + Detection

Answer

Severity × Occurrence / Detection

Answer

Probability of Failure × Cost of Failure

Question 2

A Transfer Function expressed as Y = f(X) in DFSS is used to:

Accepted Answer

Mathematically describe how input variables influence the critical output response

Answer

Transfer lessons learned from one Six Sigma project to the next

Answer

Map the flow of value through a process to identify waste

Answer

Calculate the cost of poor quality attributed to design failures

Question 3

Monte Carlo simulation is used in DFSS primarily to:

Accepted Answer

Propagate input variation through a design model to predict the output distribution

Answer

Generate random test scenarios to validate software functionality

Answer

Create randomized experiment designs for a DOE study

Answer

Randomly sample production lots for outgoing quality inspection

Question 4

Tolerance design in DFSS is best described as:

Accepted Answer

Determining the acceptable variation ranges for key design parameters to keep CTQ outputs within specification

Answer

Setting acceptable defect levels for final inspection of finished goods

Answer

Designing products to be tolerant of customer misuse or abuse

Answer

Establishing time limits for completing each phase of the DFSS roadmap

Question 5

Which DFSS reliability tool uses a top-down, deductive approach to identify combinations of component failures that can cause a system-level failure?

Accepted Answer

Fault Tree Analysis (FTA)

Answer

Control Chart

Answer

Process Capability Study

Answer

Value Stream Map

Question 6

In the DMADV roadmap, the Verify phase primarily involves:

Accepted Answer

Piloting the design, validating performance against CTQs, and transitioning to full-scale production

Answer

Verifying that root causes of defects have been correctly identified in the Analyze phase

Answer

Verifying that the project charter is aligned with the company's strategic objectives

Answer

Conducting hypothesis tests on historical data to confirm baseline performance

Question 7

Robust design, based on Taguchi methods, aims to achieve which of the following?

Accepted Answer

Make product or process performance insensitive to uncontrollable noise factors and variation

Answer

Ensure all design specifications are met under ideal laboratory conditions only

Answer

Reduce the number of design iterations required before product launch

Answer

Eliminate all sources of defects through comprehensive 100% final inspection