Ye Chen Pfra

A
1
2
A Component-oriented Process Failure Risk Analysis Method by Profess
3
4
ICAutomachinery
5
6
7
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
10
Subcontractors, process Plants Effected
N/A
11
12
Product Serial Number and Optional Image Map
N/A
13
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
15
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
18
19
20
21
22
23
24
25
26
4
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
10
Quality Assurence
Eye, Hand, Harness
Eye, Hand,
D Harness
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
11
48
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50
12
51
52
53
54
13
55
56
14
57
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59
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60
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62
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63
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66
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68
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69
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72
73
74
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78
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80
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81
82
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A
83
B
23
84
85
86
24
87
88
89
25
90
91
92
26
93
94
95
27
96
97
98
28
99
100
101
29
102
103
104
30
105
106
107
31
108
109
110
32
32
B
111
112
113
33
114
115
116
34
117
118
119
120
121
35
1
2
re Risk Analysis Method by Professor Paul G. Ranky, PhD, NJIT/MERC

3
4
5
ICAutomachinery
6
7
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
12
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
17
18
19
20
21
22
23
24
25
26
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
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
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51
52
53
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E
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61
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63
64
65
66
67
68
69
70
71
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73
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77
78
79
80
81
82
E
83
84
85
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
E
111
112
113
114
115
116
117
118
119
120
121
1
2
Copyright by Paul G. Ranky, 1992-2002
3
4
5
6
7
Date of Process
8
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
12
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
46
47
48
49
50
51
52
53
54
72
160
J
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
J
83
84
85
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
J
111
112
113
114
115
116
117
118
119
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

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

252.00
HIGH
25
26

1.20
1.30
1.30
1.20

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

511.10
HIGH
37
38
Cost impact
1.40
1.20
1.30
1.30
39
Cost impact
511.06
HIGH
40
41
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
42
43
44
45
46
47
48
49
50
51
52
53
54
Cost impact
Cost impact/customer satisfation impact
Q
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
Q
83
84
85
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
Q
111
112
113
114
115
116
117
118
119
120
121
The Effect of Each Process Step Failure

Risk on Other Parts (I.e. components/
objects)
Detection Mode
Recommended Corrective Action(s)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16 Direct measurable effect: loss!
Shipping and Receiving Department
Re-check order, confirm delivery

Re-order

Re-order
Re-order

Manufacturing Depertment
Machining
Grinding

Machining
Machining
Machining
27
Machining
New product
Machining to adjust tolerance
Grinding

Quality Control Department
Change in design
Change in design

Change in design
Change in connections

39
Correct type of wires

Testing of screws
Replacement of screws
Anti-rust solutions
Anti-rust solutions
30
33
42
45
46
47
48
49
50
51
52
53
54
X
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
X
83
84
85
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
X
111
112
113
114
115
116
117
118
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
45
46
47
48
49
50
51
52
53
54
ID 10.2
ID 10.3
AA
AB
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
#N/A
AC
AA
83
84
85
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
AB
AC
AA
111
112
113
114
115
116
117
118
119
120
121
AB
AC
AD
AE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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
27
5
28
29
30
6
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
10
AD
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
AE
AD
83
84
85
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
AE
AD
111
112
113
114
115
116
117
118
119
120
121
AE

Ye Chen Pfra

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A

A Component-oriented Process Failure Risk Analysis Method by Profess

Product Name and Appearance Before Process

Name of Organization Responsible for the Process

Other Organizations Involved in the Process

MDDI, Converting, OPEX, Muratec

Subcontractors, process Plants Effected

Product Serial Number and Optional Image Map

Describe the Process for Each Process Step and

Specify the Tool(s) Used in Each Process

Raw Material Inspection

Eye, Hand, Harness

Eye, Hand, Harness

Dimensions of all parts

Eye, Hand, Harness

Eye, Hand, Harness

Inspection of Machinery parts

Eye, Hand, Harness

Tolerance of shafts used

Eye, Hand, Harness

Tensile strength testing

Eye, Hand, Harness

Eye, Hand, Harness

Eye, Hand, Harness

Eye, Hand, Harness

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

PFRA Study ID Number

Orignal Date of This Study

Product Group Classifier

Specify the Fixtures / Clamps Used in Each

Engineering Release Date of the Product

List / Identify the Parts / Components

Raw materials required for assembly

All the parts used like shafts, blocks , etc

Elements used for socketing

Human Hand, Workbench

Human Hand, Workbench

Human Hand, Workbench

Human Hand, Workbench

All the material used

Human Hand, Workbench

Human Hand, Workbench

Human Hand, Workbench

Human Hand, Workbench

Human Hand, Workbench

Human Hand, Workbench

Copyright by Paul G. Ranky, 1992-2002

This PFRA Study was Prepared By

Responsible Organization/ Department ICAutomachinery

The PFRA Team Describes / Illustrates the Potential Process Failure

Receing Material on time

Material Size Error

Products not satisfy specification

Not in specified tollerances

Low error tolerance

Low tensile strength

Low stress point

Wrong type of wires

Incorrect screw location

Bad surface quality

The Effect of Each Process Step Failure

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