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A

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A Component-oriented Process Failure Risk Analysis Method by Profess

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ICAutomachinery

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Product Name and Appearance Before Process

Machinery Work

Name of Organization Responsible for the Process

IC Automachinery Inc

Other Organizations Involved in the Process

MDDI, Converting, OPEX, Muratec

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Subcontractors, process Plants Effected

N/A

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12

Product Serial Number and Optional Image Map

N/A

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14

Describe the Process for Each Process Step and


Optionally Illustrate the State of the Device/ Part/
Process ID
Subassembly/ Object AFTER the Process is
Complete

Specify the Tool(s) Used in Each Process


Step

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16
17

Raw Material Inspection

Eye, Hand, Harness

Inspection of Bearings

Eye, Hand, Harness

Dimensions of all parts

Eye, Hand, Harness

Inspection of sockets

Eye, Hand, Harness

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19
20
21
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23
24
25
26

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B

Inspection of sockets

Inspection of Machinery parts

Eye, Hand, Harness

Tolerance of shafts used

Eye, Hand, Harness

Tensile strength testing

Eye, Hand, Harness

Wiring

Eye, Hand, Harness

Quality Control

Eye, Hand, Harness

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Quality Assurence

Eye, Hand, Harness

Eye, Hand,
D Harness

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80

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A
83

B
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84
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86

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87
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89

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90
91
92

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93
94
95

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96
97
98

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99
100
101

29

102
103
104

30

105
106
107

31

108
109
110

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B

111
112
113

33

114
115
116

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117
118
119
120
121

35

1
2

re Risk Analysis Method by Professor Paul G. Ranky, PhD, NJIT/MERC


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ICAutomachinery
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ICAutomachinery 101

PFRA Study ID Number


Date of This Study (mm/dd/yy)

Orignal Date of This Study

11/1/2015

Process Code
Engineering Release Date of Process
Methodology
Type of Product Processed

Product Group Classifier

10 Revision Number

11/1/2015

11 Comments
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13

Specify the Fixtures / Clamps Used in Each


Process Step

Engineering Release Date of the Product

List / Identify the Parts / Components


Retrieved in Each Process Step

Process
Time

14

Accumulated
Process Cost

250.00

15
16

Process
Cost

[sec]

[USD]

[USD]

Raw materials required for assembly

500

34.72

34.72

Required Bearings

400

27.78

62.50

All the parts used like shafts, blocks , etc

100

6.94

69.44

Elements used for socketing

700

48.61

118.06

Human Hand, Workbench

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18
19

Human Hand, Workbench

20
21
22

Human Hand, Workbench

23
24
25
26

Human Hand, Workbench

Elements used
F for socketing

700
G

48.61
H

118.06
I

Parts

800

55.56

173.61

Shafts

900

62.50

236.11

All the material used

3000

208.33

444.44

Wires

1500

104.17

548.61

Screws

800

55.56

604.17

Finished Assembly

150

10.42

614.58

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28

Human Hand, Workbench

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30
31

Human Hand, Workbench

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34

Human Hand, Workbench

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37

Human Hand, Workbench

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40

Human Hand, Workbench

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Human Hand, Workbench

E
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82

E
83
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90
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99
100
101
102
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E
111
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120
121

1
2

Copyright by Paul G. Ranky, 1992-2002

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Date of Process
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N/A

This PFRA Study was Prepared By

Ye Chen

N/A

PFRA Team

N/A

essed

N/A

Responsible Organization/ Department ICAutomachinery

ifier

10

N/A

Comments

11
Date of the Product
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13
14

N/A

The PFRA Team Describes / Illustrates the Potential Process Failure


RPN (Risk
Mode and the Effect; the Risk of Failure
Severity RatingDetection Rating
Occurrence Rating
Priority
Number)
Proc.ID
Failure Mode(s) and Effect(s)

15

(1-10)

(1-10)

(1-10)

16 ID 1.1

Receing Material on time

126

17 ID 1.2

Material Size Error

120

18 ID 1.3

54

19 ID 2.1

Damaged Materials
Faulty Material

64

20 ID 2.2

Insufficient quantity

162

21 ID 2.3

Products not satisfy specification

28

22 ID 3.1

Oversize parts

23 ID 3.2

Rough Finishing

252
80

24 ID 3.3

160

25 ID 4.1

Unwanted dimensions
Improper alignment

112

26 ID 4.2

Not in specified tollerances

16

Max. RPN

126

162

252
112

J
27 ID 4.3

O
0

Damaged Parts
Over or undersized parts

64

144

31 ID 6.1

Low error tolerance

96

32 ID 6.2

Parts damaged

40

28 ID 5.1
29 ID 5.2

112
P

144

30 ID 5.3

33 ID 6.3

96

34 ID 7.1

Low tensile strength

252

35 ID 7.2

Bending failure

315

36 ID 7.3

320
168

320

37 ID 8.1

Low stress point


Wrong connections

38 ID 8.2

Wrong type of wires

180

180

40 ID 9.1

Improper wiring

41 ID 9.2

Incorrect screw location

72

39 ID 8.3

42 ID 9.3

43 ID 10.1

Bad surface quality

160

44 ID 10.2

Improper finish

54

45 ID 10.3
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50
51
52
53
54

72

160

J
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J
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J
111
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120
121

Risk
Associated

The Effect of Each Process Step Failure


Risk on Other Processes

1
2
3
4
5
6

Ye Chen

N/A

ICAutomachinery

9
10
11
12
13

Tooling
Factor

14
15

Clamping/
Lack of
Accumulated
Fixturing Skill Factor
Experience
RPN
Factor

0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100%

16
17

Process stopped or delayed


1.10

1.00

1.20

1.30

18

Process stopped or delayed


216.22

HIGH

19
20

Process delayed
1.00

1.00

1.30

1.20

21

Process delayed
252.72

HIGH

22
23

Process delayed
Increased Cost/Production Schedule

1.00

1.00

1.00

1.00

24

Increased Cost/Production Schedule


252.00

HIGH

25
26

Process stopped or delayed

Increased Cost/Production Schedule


Increased Cost/Production Schedule

1.20

1.30

1.30

1.20

Increased Cost/Production Schedule


272.56

HIGH

1.20
Q

1.30
R

1.30
S

1.20
T

27

272.56

HIGH

28
29

Increased cost
1.10

1.20

1.40

1.20

30

Product might not work/increased cost


319.33

HIGH

31
32

Control Panel doesn't work/Process Delay


1.20

1.00

1.30

1.20

179.71

Low

Control Panel doesn't work/Process Delay

33
34
35

Cost and time impact


1.10

1.10

1.20

1.10

36

Cost and time impact


511.10

HIGH

37
38

Cost impact
1.40

1.20

1.30

1.30

39

Cost impact
511.06

HIGH

40
41

Cost and time impact

Cost Impact and delay


1.10

1.10

1.20

1.10

115.00

Low

1.00

1.00

1.00

1.00

160.00

Low

Cost Impact and delay

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Cost impact
Cost impact/customer satisfation impact

Q
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Q
83
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100
101
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108
109
110

Q
111
112
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114
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117
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120
121

The Effect of Each Process Step Failure


Risk on Other Parts (I.e. components/
objects)

Detection Mode

Recommended Corrective Action(s)

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3
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11
12
13
14
15
16 Direct measurable effect: loss!
17 Direct measurable effect: loss!

Shipping and Receiving Department

Re-check order, confirm delivery

Shipping and Receiving Department

Re-check order, confirm delivery

18 Direct measurable effect: loss!


19 Direct measurable effect: loss!

Shipping and Receiving Department

Re-check order, confirm delivery

Shipping and Receiving Department

Re-order

20 Direct measurable effect: loss!


21 Direct measurable effect: loss!

Shipping and Receiving Department

Re-order

Shipping and Receiving Department

Re-order

22 Direct measurable effect: loss!


23 Direct measurable effect: loss!

Manufacturing Depertment

Machining

Manufacturing Depertment

Grinding

24 Direct measurable effect: loss!


25 Direct measurable effect: loss!

Manufacturing Depertment

Machining

Manufacturing Depertment

Machining

26 Direct measurable effect: loss!

Manufacturing Depertment

Machining

27
28 Direct measurable effect: loss!
29 Direct measurable effect: loss!

Manufacturing Depertment

Machining

Manufacturing Depertment

New product

Manufacturing Depertment

Machining to adjust tolerance

Manufacturing Depertment

Grinding

34 Direct measurable effect: loss!


35 Direct measurable effect: loss!

Quality Control Department

Change in design

Quality Control Department

Change in design

36 Direct measurable effect: loss!


37 Direct measurable effect: loss!

Quality Control Department

Change in design

Quality Control Department

Change in connections

38 Direct measurable effect: loss!


39

Quality Control Department

Correct type of wires

40 Direct measurable effect: loss!


41 Direct measurable effect: loss!

Quality Control Department

Testing of screws

Quality Control Department

Replacement of screws

Quality Control Department

Anti-rust solutions

Quality Control Department

Anti-rust solutions

30
31 Direct measurable effect: loss!
32 Direct measurable effect: loss!
33

42
43 Direct measurable effect: loss!
44 Direct measurable effect: loss!
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54

X
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X
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90
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97
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99
100
101
102
103
104
105
106
107
108
109
110

X
111
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114
115
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119
120
121

AA

AB

AC

1
2
3
4
5
6
7
8
9
10
11
12
13

Corrective Action(s) Taken and Date


(mm/dd/yr)

RPN for Each Failure Mode

14

15

50

100

150

200

250

ID 1.1

16 Replace
17 Replace

ID 1.2
ID 1.3

18 Replace
19 Replace

ID 2.1
ID 2.2

20 Replace
21 Replace

ID 2.3
ID 3.1

22 Replace
23 Replace

ID 3.2
ID 3.3

24 Replace
25 Replace

ID 4.1
ID 4.2

26 Replace
ID 4.3

ID 5.1
ID 5.2
ID 6.1

300

350

ID 2.3
ID 3.1
ID 3.2
ID 3.3
ID 4.1
ID 4.2

AA
27

AB

AC

ID 4.3
ID 5.1

28 Recall
29 Audit

ID 5.2

30
ID 6.1

31 Lathe Machine
32 Grinding Machine
33

ID 6.2
ID 6.3
ID 7.1

34 New material
35 New material
36 New material

ID 7.2
ID 7.3
ID 8.1

37 Inspection
38 Inspection
39

ID 8.2
ID 8.3
ID 9.1

40 Inspection
41 Phone call
42

ID 9.2
ID 9.3
ID 10.1

43 Inspection
44 Inspection
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48
49
50
51
52
53
54

ID 10.2
ID 10.3

AA

AB

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#N/A

AC

AA
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109
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AB

AC

AA
111
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114
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118
119
120
121

AB

AC

AD

AE

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3
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Accumulated RPN for Each Failure Mode


0

100

200

300

400

16
17
18

19
20
21

22
23
24

25
26

500

600

4
AD

AE

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10

AD
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AE

AD
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100
101
102
103
104
105
106
107
108
109
110

AE

AD
111
112
113
114
115
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120
121

AE