Lean Six Sigma Exam
FMEA & Risk Analysis Practice Questions
100 practice questions with detailed explanations — aligned to the Lean Six Sigma Exam.
Master FMEA & Risk Analysis to boost your score on the Lean Six Sigma Exam. Each question below mirrors the style and difficulty of real exam questions, complete with detailed explanations so you understand the why behind every answer. Work through all 100 questions, review any that trip you up, and use the related topics below to round out your preparation.
Q1.In an FMEA, the Risk Priority Number (RPN) is calculated as:
A.Severity + Occurrence + DetectionB.Severity × Occurrence × DetectionC.Severity × Occurrence ÷ DetectionD.(Severity + Detection) × OccurrenceB. Severity × Occurrence × DetectionExplanation: RPN = Severity (S) × Occurrence (O) × Detection (D), each rated 1–10. High RPN scores indicate the highest-priority failure modes requiring corrective action. Note: a high Severity score alone (e.g., S = 10) should also trigger action regardless of RPN, because even rare, detectable failures with catastrophic consequences must be addressed.
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Q2.An FMEA is best used during which phase of DMAIC?
A.DefineB.MeasureC.AnalyseD.ControlC. AnalyseExplanation: FMEA is primarily an Analyse-phase tool for systematically identifying potential failure modes and their causes. It can also be used in the Improve phase to evaluate risks of proposed solutions before implementation, or in the Control phase to build the control plan. It is most commonly associated with the Analyse phase in Six Sigma DMAIC projects.
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Q3.What does the 'Detection' score in an FMEA measure?
A.How often the failure mode occursB.The severity of the effect on the customerC.The likelihood that the failure will be caught before reaching the customerD.The number of controls currently in placeC. The likelihood that the failure will be caught before reaching the customerExplanation: Detection (D) rates the effectiveness of current controls at catching the failure mode before it escapes to the customer — a score of 1 means the failure is almost certainly detected; a score of 10 means detection is almost impossible. Lower detection scores are better. Improving detection (adding inspection, testing, or poka-yokes) reduces RPN.
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