Six Sigma Lean & DFSS Questions with
Answers (100% Correct Answers)
The risk priority number (RPN) is the measure of risk related to a particular failure
mode. The ratings for each category (severity,occurrence, and detection) are on a 1to 10
scale. If a FMEA has 10failure modes with RPN numbers ranging from 50 to 300, an
Improvement team's recommended actions should focus on which of the following?
a. Work on those failure modes with RPNs greater than 50
b. Use the Pareto principle to prioritize the
highest RPNs
c. Identify failure modes with high severity rankings, followed by high RPN numbers
d. Use the Pareto principle and start with the
top 20% of the failure modes
Ans:
The production of product in large lots has what advantage?
a. Maximization of machine efficiencies
b. Longer customer delivery lead times
c. Additional product transportation expenses
d. Potential product damage or deterioration costs
Ans:
A process FMEA is generally performed:
© 2025 All rights reserved
,a. Just after the design FMEA is completed
b. Just before the production tooling is authorized
c. Just after the design drawings are finalized
d. As soon as a manufacturing defect is
uncovered
Ans:
Why is DFSS called the future of six sigma?
a. There are few remaining DMAIC projects available in most companies
b. DFSS roadmaps are more attractive than DMAIC tools
c. DFSS better serves the current innovation initiatives of many companies
d. DMAJC projects do not achieve six sigma levels without DFSS
Ans:
3.5. Which of the following forms of muda affects people more than product quality?
a. Overproduction
b. Excess Inventory
c. Waiting
d. Transport
Ans:
3.6. Which IDOV phase defines overall product requirements, quantifies marketing
information and customer feedback, and creates the first set of CTQ (critical to quality)
features.
a. Identify
© 2025 All rights reserved
, b. Design
c. Optimize
d. Validate
Ans:
Which of the following is a goal of TOC?
a. Increase throughput
b. Increased inventory
c. Increased operating expenses
d. Flow greater than demand
Ans:
What Is the best definition of takt time?
a. It is a calculated time element that equals customer demand
b. It is the speed at which parts must be
manufactured in order to satisfy demand
c. It is the heartbeat of any lean system
d. It is the application of Kaizen to continuous flow manufacturing
Ans:
Upon completion of a FMEA, what critical event should be established next?
a. Ensure that a process owner is in charge of the FMEA
b. Designate an engineer to follow-up on the recommended actions
c. Review the documents at regularly scheduled Intervals
d. Have cross functJonal teams assigned to each FMEA for review activities
© 2025 All rights reserved
Answers (100% Correct Answers)
The risk priority number (RPN) is the measure of risk related to a particular failure
mode. The ratings for each category (severity,occurrence, and detection) are on a 1to 10
scale. If a FMEA has 10failure modes with RPN numbers ranging from 50 to 300, an
Improvement team's recommended actions should focus on which of the following?
a. Work on those failure modes with RPNs greater than 50
b. Use the Pareto principle to prioritize the
highest RPNs
c. Identify failure modes with high severity rankings, followed by high RPN numbers
d. Use the Pareto principle and start with the
top 20% of the failure modes
Ans:
The production of product in large lots has what advantage?
a. Maximization of machine efficiencies
b. Longer customer delivery lead times
c. Additional product transportation expenses
d. Potential product damage or deterioration costs
Ans:
A process FMEA is generally performed:
© 2025 All rights reserved
,a. Just after the design FMEA is completed
b. Just before the production tooling is authorized
c. Just after the design drawings are finalized
d. As soon as a manufacturing defect is
uncovered
Ans:
Why is DFSS called the future of six sigma?
a. There are few remaining DMAIC projects available in most companies
b. DFSS roadmaps are more attractive than DMAIC tools
c. DFSS better serves the current innovation initiatives of many companies
d. DMAJC projects do not achieve six sigma levels without DFSS
Ans:
3.5. Which of the following forms of muda affects people more than product quality?
a. Overproduction
b. Excess Inventory
c. Waiting
d. Transport
Ans:
3.6. Which IDOV phase defines overall product requirements, quantifies marketing
information and customer feedback, and creates the first set of CTQ (critical to quality)
features.
a. Identify
© 2025 All rights reserved
, b. Design
c. Optimize
d. Validate
Ans:
Which of the following is a goal of TOC?
a. Increase throughput
b. Increased inventory
c. Increased operating expenses
d. Flow greater than demand
Ans:
What Is the best definition of takt time?
a. It is a calculated time element that equals customer demand
b. It is the speed at which parts must be
manufactured in order to satisfy demand
c. It is the heartbeat of any lean system
d. It is the application of Kaizen to continuous flow manufacturing
Ans:
Upon completion of a FMEA, what critical event should be established next?
a. Ensure that a process owner is in charge of the FMEA
b. Designate an engineer to follow-up on the recommended actions
c. Review the documents at regularly scheduled Intervals
d. Have cross functJonal teams assigned to each FMEA for review activities
© 2025 All rights reserved
