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

RPN = Severity × Occurrence × Detection (each rated 1–10), providing a relative risk score to prioritize which design failure modes require immediate corrective action.

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

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.

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

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.

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

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.

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

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.

Lean Six Sigma Black Belt Certification Practice Test

Lean Six Sigma Black Belt Certification Practice Test

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