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A Component-oriented Process Failure Risk Analysis Method (Ver. 5) by Professor Paul G. Ranky, PhD, NJIT/MERC

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Product Name and Appearance Before Process

Pins (Female and Male)

PFRA Study ID Number

Pin-1224

Name of Organization Responsible for the Process

A&P Eco-Automated Guided Vehicles

Date of This Study (mm/dd/yy)

10-27-2012

Other Organizations Involved in the Process

QCT, Sunnen

Orignal Date of This Study

10-27-2012

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

10

Subcontractors, process Plants Effected

N/A

Revision Number

Rev#02

Product Group Classifier

11
12

Product Serial Number and Optional Image Map

PIN F/M

Comments

Possible High Failure Process

Engineering Release Date of the Product

13

Process ID

14

Describe the Process for Each Process Step and


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

Specify the Tool(s) Used in Each Process


Step

Specify the Fixtures / Clamps


Used in Each Process Step

List / Identify the Parts /


Components Retrieved in Each
Process Step

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16
Human eye, Visual Inspector , diamond stylus
profilometer

Fixtures and clamps

Examine Pin length

Competent person's hand and eye; vernier


caliper

Human hand

Examine Pin diameter

Human eye, Visual Inspector, Vernier caliper

human hand

Examine Pin for Surface Roughness

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Process
Time

Process
Cost

Accumulated
Process Cost

20.00
[sec]

[USD]

[USD]

Pin male or female Surface


Roughness with Ra value between
1.6-0.4m

75

0.42

0.42

Pin with Length of 120mm

60

0.33

0.75

60

0.33

1.08

18
19
20
21
22
23

pin with diameter 40 0.01 mm

24
25
26

Examine Internal threading in female pin/external


threading on male

Human hand,Visual Inspector, thread pitch


gauge

Human Hand

pin with appropriate thread pitch

60

0.33

1.42

Pairing: Engage the male and female pins

Visual Inspector

Human hand

Pair of pins

60

0.33

1.75

RFID technology for product information & tracking

RFID tagged product information

250

1.39

3.14

0.00

3.14

0.00

3.14

27

28
29
30
31
32

RFID tags and tracking tools

RFID tags

33
34
35
36
37

A
38

B
8

G
0

H
0.00

I
3.14

0.00

3.14

10

0.00

3.14

11

0.00

3.14

12

0.00

3.14

13

0.00

3.14

14

0.00

3.14

15

0.00

3.14

16

0.00

3.14

17

0.00

3.14

18

0.00

3.14

19

0.00

3.14

20

0.00

3.14

21

0.00

3.14

22

0.00

3.14

23

0.00

3.14

24

0.00

3.14

39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85

A
86

B
24

G
0

H
0.00

I
3.14

25

0.00

3.14

26

0.00

3.14

27

0.00

3.14

28

0.00

3.14

29

0.00

3.14

30

0.00

3.14

31

0.00

3.14

32

0.00

3.14

33

0.00

3.14

34

0.00

3.14

35

0.00

3.14

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89
90
91
92
93
94
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96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
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118
119
120
121

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2

Accumulated
RPN

Risk
Associated

Copyright by Paul G. Ranky, 1992-to date

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rocess Code
ngineering Release Date of Process
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Methodology
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ype of Product Processed

roduct Group Classifier

10

ngineering Release Date of the11


Product
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Pin-CHCK 1224

This PFRA Study was Prepared By

4/21/2010

PFRA Team

Mecanum wheel part PIN F/M

Responsible Organization/ Department MME Quality Control

4321

Comments

Early Identification & Correction

7/6/2009

The PFRA Team Describes / Illustrates the Potential Process


Failure Mode and the Effect; the Risk of Failure
Proc.ID

Abhishek Patil

Failure Mode(s) and Effect(s)

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RPN (Risk
Severity Rating Detection Rating
Occurrence Rating
Priority
Number)
(1-10)

(1-10)

(1-10)

96

Max. RPN

Tooling
Factor

Clamping/
Any Other
Fixturing Skill Factor Factor You
Factor
Define

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

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ID 1.1

Pin does not have a surface roughness Ra value between


1.6-0.4m, would result the rubber roller to consume at
higher rate.

17

ID 1.2

The pin has visible defects (cracks, pits, etc), pin is at risk of
fail under load.

150

18

ID 1.3

19

ID 2.1

Pin length requirement of 120 mm is not met, does not fit


inside the roller along the length.

45

20

ID 2.2

21

ID 2.3

22

ID 3.1

23

ID 3.2

24

ID 3.3

25

ID 4.1

Thread pitch requirement of 3.5 mm is not met , the pin may


fail due to shearing.

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ID 4.2

The male and female parts would not engage properly.

27

ID 4.3

28

ID 5.1

29

ID 5.2

30

ID 5.3

31

ID 6.1

32

ID 6.2

33

ID 6.3

34

ID 7.1

35

ID 7.2

36

ID 7.3

37

ID 8.1

150

1.00

1.00

1.00

1.00

150.00

Low

45

1.00

1.00

1.00

1.00

45.00

Low

60

1.00

1.00

1.00

1.00

60.00

Low

210

1.00

1.00

1.00

1.00

210.00

HIGH

1.00

1.00

1.00

1.00

8.00

Low

54

1.00

1.00

1.00

1.00

54.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

Bit diameter requirement of 40 0.01 mm is not met, the pin


may fail and will not fit inside the roller with clearance fit.

60
0
0

10

210
0
0

If not paired would cause rupture of the threads during


handling.

8
0

RFID tag failure would lead error in assembling wrong pin to


a specific wheel.

0
9

54
0

38

J
ID 8.2

O
0

39

ID 8.3

40

ID 9.1

41

ID 9.2

42

ID 9.3

43

ID 10.1

44

ID 10.2

45

ID 10.3

46

ID 11.1

47

ID 11.2

48

ID 11.3

49

ID 12.1

50

ID 12.2

51

ID 12.3

52

ID 13.1

53

ID 13.2

54

ID 13.3

55

ID 14.1

56

ID 14.2

57

ID 14.3

58

ID 15.1

59

ID 15.2

60

ID 15.3

61

ID 16.1

62

ID 16.2

63

ID 16.3

64

ID 17.1

65

ID 17.2

66

ID 17.3

67

ID 18.1

68

ID 18.2

69

ID 18.3

70

ID 19.1

71

ID 19.2

72

ID 19.3

73

ID 20.1

74

ID 20.2

75

ID 20.3

76

ID 21.1

77

ID 21.2

78

ID 21.3

79

ID 22.1

80

ID 22.2

81

ID 22.3

82

ID 23.1

83

ID 23.2

84

ID 23.3

85

ID 24.1

P
0

Q
1.00

R
1.00

S
1.00

T
1.00

U
0.00

V
Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.60

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

86

J
ID 24.2

87

ID 24.3

88

ID 25.1

89

ID 25.2

90

ID 25.3

91

ID 26.1

92

ID 26.2

93

ID 26.3

94

ID 27.1

95

ID 27.2

96

ID 27.3

97

ID 28.1

98

ID 28.2

99

ID 28.3

100 ID 29.1

101 ID 29.2

102 ID 29.3

103 ID 30.1

104 ID 30.2

105 ID 30.3

106 ID 31.1

107 ID 31.2

108 ID 31.3

109 ID 32.1

110 ID 32.2

111 ID 32.3

112 ID 33.1

113 ID 33.2

114 ID 33.3

115 ID 34.1

116 ID 34.2

117 ID 34.3

118 ID 35.1

119 ID 35.2

120 ID 35.3

121

O
0

P
0

Q
1.00

R
1.00

S
1.00

T
1.00

U
0.00

V
Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

1.00

1.00

1.00

1.00

0.00

Low

AA

The Effect of Each Process Step Failure


Risk on Other Processes

The Effect of Each Process Step Failure


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

Detection Mode

Recommended Corrective Action(s)

Corrective Action(s) Taken and Date


(mm/dd/yr)

Rubber Roller

human and measuring instrument

training for machining of pin, maintain


machinery and tools

4/20/2012

Remachining required
Increase the waiting time for further
operations

Safety Hazard

human and measuring instrument

training for machining of pin, maintain


machinery

4/20/2012

Will affect the assembly of the wheel

Pin size critical

human and measuring instrument

training for machining of bit, maintain


machinery

4/20/2012

During assembly the pin will not fit into the


roller with required type of fit.

human and measuring instrument

training for machining of pin, maintain


machinery

4/20/2012

Pin diameter critical

mating process

May rupture the roller while in operation.

human and measuring instrument

training for machining of pin, maintain


machinery

human

Training the workers

develoment department

proper maintainance of the RFID tags

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7
8
9
10
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13
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15
16

17
18
19
20
21
22
23
24
25
26

4/20/2012

Will affect the assembly of the wheel

27

28

Wil increase the assembly time of the


wheel.

Process is delayed

4/20/2012

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30
31
32
33
34
35
36
37

this will lead to improper tracking of material delay in shipping

5/1/2012

W
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85

AA

W
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121

AA

AB

AC

AD

AE

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

Accumulated RPN for Each Failure Mode

RPN for Each Failure Mode


14
15

50

100

200

250

0.00

50.00

ID 2.3

20

ID 3.2

ID 3.1
ID 3.3

ID 4.1

22

ID 4.2
ID 4.3

24

ID 5.1

25

ID 5.2

26

ID 5.3

27

ID 6.2

ID 6.1
ID 6.3

29
30
31
32
33

250.00

ID 2.1

19

28

200.00

1
ID 1.2

ID 2.2

23

150.00

ID 1.3

18

21

100.00

ID 1.1

16

17

150

ID 7.1

ID 7.2
ID 7.3
ID 8.1

ID 8.2
ID 8.3

34

ID 9.1

35

ID 9.2

36

ID 9.3

37 ID 10.1

10

ID 10.2
ID 10.3
ID 11.1

11

ID 11.2
ID 11.3
ID 12.1
ID 12.2

12

ID 7.3

ID 8.1
ID 8.2
ID 8.3

ID 9.1
ID 9.2
ID 9.3
ID 10.1

AB

AC

10

38 ID 10.2
39 ID 10.3
40 ID 11.1
41 ID 11.2
42
ID 11.3
43
ID 12.1
44
ID 12.2
45
ID 12.3
46
ID 13.1
47
48 ID 13.2
49 ID 13.3
50 ID 14.1

11

12

13

14

51 ID 14.2
52 ID 14.3
53 ID 15.1
54 ID 15.2
55
ID 15.3
56
ID 16.1
57
ID 16.2
58
ID 16.3
59
ID 17.1
60
61 ID 17.2
62 ID 17.3
63 ID 18.1

15

16

17

18

64 ID 18.2
65 ID 18.3
66 ID 19.1
67 ID 19.2
68
ID 19.3
69
ID 20.1
70
ID 20.2
71
ID 20.3
72
ID 21.1
73
74 ID 21.2
75 ID 21.3
76 ID 22.1

19

20

21

22

77 ID 22.2
78 ID 22.3
79 ID 23.1
80 ID 23.2
81
ID 23.3
82
ID 24.1
83
ID 24.2
84
ID 24.3
85
ID 25.1

23

24

25

ID 25.2
ID 25.3
ID 26.1

26

ID 26.2
ID 26.3
ID 27.1
ID 27.2

27

AD

AE

ID 20.3

21

ID 21.1
ID 21.2
ID 21.3

22

ID 22.1
ID 22.2
ID 22.3

23

ID 23.1
ID 23.2
ID 23.3

24

ID 24.1
ID 24.2
ID 24.3
86

ID 25.1

AB

AC

25

87 ID 25.2
88 ID 25.3
89 ID 26.1

26

90 ID 26.2
91 ID 26.3
92 ID 27.1

27

93 ID 27.2
94 ID 27.3
95
96
97
98

ID 28.1

28

ID 28.2
ID 28.3

ID 29.1
99
100 ID 29.2
101 ID 29.3

29

102 ID 30.1

30

103 ID 30.2
104 ID 30.3
105 ID 31.1

31

106 ID 31.2
107 ID 31.3
108
109
110
111
112

ID 32.1

32

ID 32.2
ID 32.3
ID 33.1

33

113 ID 33.2
114 ID 33.3
115 ID 34.1

34

116 ID 34.2
117 ID 34.3
118 ID 35.1
119 ID 35.2
120 ID 35.3
121

35

AD

AE