Assignment 3 IE 655 Concurrent Engineering

Process Failure Mode and Effects / Failure Risk Analysis in the

CE Context

Full Name: Pavan Patel

Student ID: 31321594
Student e-mail: pp488@njit.edu
eLearning Pack ID: IE655-Fall 201633-15
My Company: AquaDrive, Inc.
4 Collaborating Companies: Land
Rover Discovery , BMW Group (Mini),
California Motors, LLC, Cognex
Statement of Work
The following work was completed by Pavan Patel. The material used
was that from the eLearning pack, which has various resources such as
the 3D eBook.
Contents
I.
II.
III.
IV.

V.
VI.
VII.

Introduction
Objectives
Methodologies
Main Body of the Project
a. Developing the FMEA/DFRA Model
b. Main Process Failure Modes & Solution Processes
c. Engineering Management Decisions based on PFRA
d. Image Analysis (Potential Failure Modes)
e. Utilizing the Ranky-Weibull Calculator & Spreadsheet
f. Collaborative approach with 4 Companies
g. Understanding the FMEA/DFRA results
h. Social Networking Content
Summary
Future Work Proposed
References

I.

Introduction

The AquaDrive organization is the future

air, we strive to move towards a cleaner, safer
transportation. By utilizing what we consider a
leave an enormous & effective global footprint
generations to come.

of tomorrow. From land, sea or

and efficient world of
vast resource, water, we can
for our generation and

At AquaDrive, we manufacture high quality modes of transportation

that run on clean and pure H2O. We also Research and Develop ways to
replace or reduce the use of natural gas to power transportation. Through
our persistent and economic approach, weve been able to build a foundation
that upholds and administers the ISO standards: 9001, 14001, 50001
amongst others.
In this report we define and implement various risk analysis methods.
These include taking the PFRA approach (process failure risk analysis).
II.

Objectives

The objective of this assignment is for AquaDrive as briefly described

above, is to develop the PFRA spreadsheet. These tool help us make
management decisions and eliminate or at the very least eliminate all quality
defect and/or rework. We also utilized the Ranky-Weibull calculator to aide in
the companys overall quality objectives.
III.

Methodologies

The methodologies in this project that were applied are as follows:

1. FMEA (Failure Methods Effects Analysis)
2. PFRA (Process Failure Risk Analysis)
3. DFRA
4. Ranky-Weibull Calculator
5. TQM (Total Quality Management)
6. Lean Six Sigma
7. ISO 9001, 14001, 50001
8. GMP & cGMP
9. PLM (Product Lifecycle Management)
10. Overall Cost Analysis (Production & Reduction)
11. Customer Input & Feedback

Combined, these are the main methods that we apply to our process so that
we can become the worlds number one suppliers of sustainable and
environment friendly transportation.
IV.

Main Body of the Project:

a. Developing the FMEA/DFRA Model
It is vital to our company to develop a method and processes
that will reduce our risk in the design of our product.
Analyzing and managing risk will greatly reduce the need for
reworked products and/or quality damaged products. For
complete spreadsheet analysis refer to the attached
document at the top of the link for HW Assignment # 3
b. Main Process Failure Modes & Solution Processes
RPN for Each Failure Mode
0

100

200

300

400

500

600

700

AD-P-1.1
AD-P-1.2
AD-P-1.3
AD-P-2.1
AD-P-2.2
AD-P-2.3
AD-P-3.1
AD-P-3.2
AD-P-3.3
AD-P-4.1
AD-P-4.2
AD-P-4.3
AD-P-4.4

From the above visual representation of AquaDrives PFRA

spreadsheet, the following are areas of interest:
1) Incorrect paperwork received for incoming materials
2) Damaged product received for incoming materials
3) Misshipped product received for incoming materials
4) Limited Storage capacity of materials
5) Incorrect paperwork for storage of materials
6) Improper storing of materials
7) Material shortage
8) Material breakage
9) Mismanaged quality checks

10)
11)
12)

Reduced or no human quality checks

Reduced or no testing equipment
Inexperienced testers

c. Engineering Management Decisions based on PFRA

Based on the graphs product in the PFRA spreadsheet,
AquaDrive has discovered that there are two potential
failures, with a subsection of 2-3 failure modes/effects:
1. Assembly of base model
2. Inspecting finished model
These two processes have to deal with both the
manufacturing of the product but also the inspection process.
These can both greatly cause a disaster but if well
maintained, can produce prime products. The type of
engineering management decisions that can be made will be
based on the type of risk it is, potential modes of failure as
well as the severity/detection/occurrence ratings.
d. Image Analysis (Potential Failure Modes)

IMG_1684: This picture shows a product that is for use in underwater

photo/video. Poor quality standards or requirements are reflected by
the screw and nuts. They are beginning to rust and as a customer
appearance is key. This company should look into long term or rust
resistant type of screws.

IMG_1685: This particular picture is of the housing for an underwater

camera. The housing is somewhat flawed and a quality review of the
material should be conducted to either fix defective or easily damaged
material. Poor material selection in combination with customer neglect
has driven this product to quality defect.

IMG_1688: The damage here is the scratching of the housing as well

as some imperfections in the plastic housing. In this instance, the
company should look into a housing that is more durable. The housing
is also slightly bulky, therefore space utilization is an important
discussion to be had during a review.

IMG_1689: Upon closer inspection of this picture, it seems that the

question of durability and water resistance is again taken into question.
A product should and will be able to withstand extreme pressure and
aquatic conditions.

IMG_1692: Upon closer inspection, the inside housing of this device

seems a bit bulk and too much space inside. Product quality inspection
should be done before producing more. The manufacturer should also
consider making the housing more compact and water/scratch
resistant

IMG_1693: As seen in the first picture, the screws seem to have built
up some rust. The manufacturer of this product should consider this
when doing a quality change assure customer satisfaction.

IMG_1695: This part shown is of the light/flashlight source of the

camera housing unit. While it may look fine now it could get exposed
to difficult conditions under water that can end up damaging the part.
This product should have some type of high rated material housing so
that it can stay safe and run normally under harsh conditions.

IMG_1696 & IMG_1697: The product shown here is some sort of knob,
such as something to tighten or loosen when used. The two pictures
shown do not look uniform in style nor are they aesthetically pleasing
to the customers liking. They can be a one off situation where some
quality defected material passed through inspection, but in that case
the quality checking system of the manufacturer has failed.

IMG_1698: The product shown here seems to be some type of

connector cable/socket. If this is an entry way for a product to interact
with the housing, it is vital that the outside area is of high quality to
protect what is on the inside. From the look of this product, it seems to
be prone to rust.

IMG_1699, IMG_1701 & IMG_1703, IMG_1704: These groups of pictures

are interrelated by interacting with each. They seem to form some type
of pin and electrical connector. The quality defects can be clearly seen
in these photos, under some type of harsh conditions, the quality of
the product took a negative turn and caused the breaks in the pin
housing. It seems as if the black material surrounding the copper pin
broke off, quite possibly can be from extreme force/pressure.

IMG_1702: The product shown here is a somewhat important piece of

material. This is the cover for which the battery, basically the life of the
product, is housed. If poor quality material is used in this instance, the
battery could get damaged or corroded and would render the product
unusable.
e. Utilizing the Ranky-Weibull Calculator & Spreadsheet
Log
3.000
2.000
1.000
0.000
-1.000
-4.000 -3.000 -2.000 -1.000
0.000 1.000 2.000 3.000
i
-2.000
-3.000
-4.000
-5.000
-6.000
x

Standard
2.000
1.500
1.000
i

0.500
0.000
-4.000 -3.000 -2.000 -1.000
0.000 1.000 2.000 3.000
-0.500
-1.000
-1.500
x

The
spreadsheet that AquaDrive used to analyze their data is
located above in a separate attachment labelled AquaDrive
utilized by Ranky-Weibull Calculator. The document is
intended for top level management to see how perfect or
imperfect the quality production process is and whether the
product conforms to standard or not.

Inverse
12.000
10.000
8.000
i

6.000
4.000
2.000
0.000
-3.000 -2.000 -1.000
0.000
-2.000

1.000

2.000

3.000

4.000

f. AquaDrive will work with the following companies in a

collaborative approach to achieve technological
advancements:
Land Rover Discovery: This company will help AquaDrive build
superior machines that can withstand different terrains using
high grade material
BMW Group (Mini): This company will help AquaDrive with the
durability of the end product.
California Motors: The technology developed at CM will help
AquaDrive build supreme products. Since it is of customer
requirement to have high powered equipment, California
Motor will help develop and implement well run and powerful
equipment.

Cognex Corporation: This corporation is of the most significant

when the question of defect free systems arises. They
specialize in this field where a production/manufacturing plant
should be up to a six sigma level. With the use of their
detection systems, AquaDrive will be closer to a 6 sigma level.
g. Understanding the FMEA/DFRA results
The graphs produced in the Ranky-Weibull spreadsheet show
that there are 3 types of models that can be created through
the FMEA/DFRA results. The only one that is at the level of a
straight & linear line is the log distribution of the Weibull
calculator.
h. Social Networking Content:
Link 1: http://www.manufacturing.net/news/2016/08/delphimobileye-join-forces-autonomous-car-platform-0?
et_cid=5484830&et_rid=576098541&location=top&et_cid=5
484830&et_rid=576098541&linkid=http%3a%2f
%2fwww.manufacturing.net%2fnews
%2f2016%2f08%2fdelphi-mobileye-join-forces-autonomouscar-platform-0%3fet_cid%3d5484830%26et_rid%3d%
%subscriberid%%%26location%3dtop
Discussion Link:
http://njit2.mrooms.net/mod/forum/discuss.php?d=160388
My comments: What's interesting about this article is that it
shows how far we have progressed in the transportation
world. It seems as if it were yesterday when the idea of
autonomous technology was of something in the future. The
idea of having a car drive you without human input is both
exciting yet can be dangerous. It is safe to implement human
backups but as with any technology, glitches can cause
damages.
Link 2: http://www.aviationtoday.com/av/embeddedsystems/88487.html?
hq_e=el&hq_m=3277843&hq_l=1&hq_v=dc7084f768
Discussion Link:
http://njit2.mrooms.net/mod/forum/discuss.php?d=163610

My comments: At the moment, normal air transportation

seems to be limited to an altitude of about 30,000 ft. It would
be amazing to see how high in the sky we can use manned
machines to fly to and from across the world. These
opportunities to fly above the norm can open up various
possibilities such as an increased amount of flights flying at
the same time.
Link 3: http://www.manufacturing.net/news/2016/08/tugboats-help-refloat-oil-rig-ran-aground-scottish-coast?
et_cid=5484830&et_rid=576098541&location=top&et_cid=5
484830&et_rid=576098541&linkid=http%3a%2f
%2fwww.manufacturing.net%2fnews%2f2016%2f08%2ftugboats-help-refloat-oil-rig-ran-aground-scottish-coast%3fet_cid
%3d5484830%26et_rid%3d%%subscriberid%%%26location
%3dtop
Discussion Link:
http://njit2.mrooms.net/mod/forum/discuss.php?d=162822
My comments: The shipping and transportation of highly
valuable yet dangerous goods can be a nuisance. In this
article we are told that an oil rig was able to detach from the
vessel it was latched to and wandered off track. Luckily the rig
did not get damaged to a point where its contents, the diesel,
spilled into the ocean causing an ecological disaster. At this
point, the shipping/transporting company should do a review
of their processes and account for any type of risks.
V.

Summary
This report will help AquaDrive develop a strong understanding of
PFRA, FMEA and the Ranky-Weibull Calculator. Developing a risk
analysis plan, from discovery to execution can help AquaDrive
reduce or eliminate the need for reworking or replacing damaged
product. Instead what we will achieve is a goal towards a Six
Sigma verified company.

VI.

Future Work Proposed

As products, processes and people change, so does the various
methodologies we applied today will. Todays rate, for example,
for inspecting product may take 5 minutes but future
investments/continuous improvement plans will reduce that

number to 2 minutes. Therefore, continuously monitoring and

improving all the spreadsheets learned to day will help
AquaDrive become a sustainable business.
VII.

References
1. Paul G Ranky Concurrent Engineering 3D eBook
2. http://www.cimwareukandusa.com/All_IE655/IE655Fall2016.html#
Anchor-26625