A B C D

2
A Component-oriented Process Failure Risk Analysis Method (Ver. 5) by Prof
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7 Product Name and Appearance Before Process Eco-Runner (Lawnmower)
8 Name of Organization Responsible for the Process Eco-Runner Company
9 Other Organizations Involved in the Process RAFI GmbH & Co. KG, BOHLER, ZCC.CT Co., LT
10 Subcontractors, process Plants Effected N/A
11 Product Serial Number and Optional Image Map N/A
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Describe the Process for Each Process Step and
13 Optionally Illustrate the State of the Device/ Part/ Specify the Tool(s) Used in Each Process
Process ID
Subassembly/ Object AFTER the Process is Step
14 Complete
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Overheat handle, proper handling techniques are
17 1 Automated thermal material is used
used
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Hazardous mateiral transfer to final Human hand, fork lift, pallet jacks,
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mitigation/reclaimation/storage facility transportation
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23 3 Analysing and inspection process statistical process control/mistake-proofing
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26 4 Spare equipment/parts formation drills and nuts
 A 4
B Spare equipment/parts formation
C drills and
D nuts
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29 5 Routine Check performance by monitoring
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32 6 Test analysis/Final inspection motors and clamps
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35 7 Blade installation mechanical cutting tools
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38 8 RFID product finish scanners, barcodes
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41 9 Power Battery check electrical battery voltage test
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44 10 Power button check electrical clamps
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47 11 Examination of assembled parts rotators and clamps
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50 12 waste accumulation Rotating collectors
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 E F G H I
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Risk Analysis Method (Ver. 5) by Professor Paul G. Ranky, PhD, NJIT/MERC
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7 PFRA Study ID Number Lawn Mower - 07302019 Process Code
Engineering Release Date of Process
8 Date of This Study (mm/dd/yy) 7/30/2019
Methodology
9 Orignal Date of This Study 6/12/2019 Type of Product Processed
10 Revision Number Rev. 1 Product Group Classifier
11 Comments N/A Engineering Release Date of the Product
12

Process
13 Specify the Fixtures / Clamps Used in List / Identify the Parts / Components Process Accumulated
Cost
Each Process Step Retrieved in Each Process Step Time Process Cost
14 32.00
15 [sec] [USD] [USD]
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17 Human hand physical functional, human safety 20000 500.00 500.00
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20 Pallets, tie downs Blades, Ropes 4600 40.89 540.89
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23 Proper examination 1200 500.00 1040.89
24 safety report
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26 Machines N/A 600 200.00 1240.89
 Machines
E N/A F 600
G 200.00
H 1240.89
I
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29 Human eye N/A 200 800.00 2040.89
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32 Machines, Human hand N/A 700 1000.00 3040.89
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35 Machines sharp steel 4600 5000.00 8040.89
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38 RFID tags RFID tag 550 3000.00 11040.89
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41 Human hand Battery 500 5000.00 16040.89
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44 Human hand switches 500 2000.00 18040.89
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47 Machines, Human hand Recycled material 700 900.00 18940.89
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50 machine recycled material 1000 8.89 18949.78
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 E F G H I
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 E F G H I
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 J K L M N O P
1

2 © Copyright by Paul G. Ranky, 1992-2002

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7 A This PFRA Study was Prepared By Avni Patel with the help of Dr. Ranky
e Date of Process
8 7/30/2019 PFRA Team Avni Patel with the help of Dr. Ranky
ocessed 9 Lawn Mower Responsible Organization/ Department Eco-Runner Company
sifier 10 N/A Comments Safety and Risk Based Eco-friendly Pr
11
e Date of the Product 8/6/2019
12

The PFRA Team Describes / Illustrates the Potential Process RPN (Risk
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Failure Mode and the Effect; the Risk of Failure Severity RatingDetection Rating
Occurrence Rating
Priority Max. RPN
Number)
14 Proc.ID Failure Mode(s) and Effect(s)
15 (1-10) (1-10) (1-10)
16 ID 1.1 Incorrectly handled 10 3 4 120
17 ID 1.2 Material melt 8 5 5 200 200
18 ID 1.3 Material burnt 8 3 8 192
19 ID 2.1 EPA ausit and facility closure 9 6 3 162
20 ID 2.2 damaged product 10 6 4 240 315
21 ID 2.3 environmen contamination 9 7 5 315
22 ID 3.1 pings not transmitted 8 2 3 48
23 ID 3.2 pings not received 8 3 3 72 72
24 ID 3.3 0
25 ID 4.1 GPS reciever obstructed view of the sky 4 3 4 48
26 ID 4.2 Cable not straight 3 5 5 75 75
 J K L M N O 75
P
27 ID 4.3 0
28 ID 5.1 rain water or snow might come in enclosure 5 4 4 80
29 ID 5.2 0 80
30 ID 5.3 0
31 ID 6.1 Pings not received 4 3 3 36
32 ID 6.2 0 36
33 ID 6.3 0
34 ID 7.1 Algorithm has bug 8 8 6 384
35 ID 7.2 server containing software fails 5 3 2 30 384
36 ID 7.3 0
37 ID 8.1 pings not received 8 3 3 72
38 ID 8.2 algorithm has bug 8 7 4 224 224
39 ID 8.3 server containing software fails 5 3 2 30
40 ID 9.1 pings not received 8 3 3 72
41 ID 9.2 Algorithm has bug 8 8 4 256 256
42 ID 9.3 server containing software fails 5 3 2 30
43 ID 10.1 Trackplot fails to receive signals 8 4 3 96
44 ID 10.2 Algorithm has bug 8 9 4 288 288
45 ID 10.3 server containing software fails 5 3 2 30
46 ID 11.1 measurement errors 8 8 4 256
47 ID 11.2 server containing software fails 5 3 2 30 256
48 ID 11.3 0
49 ID 12.1 Algorithm has bug 8 7 4 224
50 ID 12.2 server containing software fails 5 3 2 30 224
51 ID 12.3 0
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 J K L M N O P
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 Q R S T U V W
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7 of Dr. Ranky
Avni Patel with the help
8 of Dr. Ranky
Avni Patel with the help
Eco-Runner Company9
10 Eco-friendly Process
Safety and Risk Based
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13 Clamping/ Any Other

Tooling Accumulated Risk The Effect of Each Process Step Failure
Fixturing Skill Factor Factor You
Factor RPN Associated Risk on Other Processes
Factor Define
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15 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100%
16 Safety, Major cost
17 1.00 1.00 1.00 1.00 200.00 Low Safety issues
18 Air pollution
19 Schedule, time
20 1.00 1.00 1.00 1.00 315.00 HIGH major cost
21 Schedule, time
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23 1.00 1.00 1.00 1.00 72.00 Low inspection process
24 delayed production
25 inspection process
26 1.00 1.00 1.00 1.00 75.00 Low
 1.00
Q 1.00
R 1.00
S 1.00
T 75.00
U Low
V W
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28 inspection process
29 1.00 1.00 1.00 1.00 80.00 Low delayed production
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32 1.00 1.00 1.00 1.00 36.00 Low
33 Inspection process
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35 1.00 1.00 1.00 1.00 384.00 HIGH Work with other servers
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37 rfID tag failure
38 1.00 1.00 1.00 1.00 224.00 HIGH RFID tag failure
39 improper assembled item
40 improper assembled item
41 1.00 1.00 1.00 1.00 256.00 HIGH bad and poor quality
42 improper assembled item
43 bad and poor quality
44 1.00 1.00 1.00 1.00 288.00 HIGH improper assembled item
45 damaged parts
46 bad and poor quality
47 1.00 1.00 1.00 1.00 256.00 HIGH break parts
48 improper assembled item
49 none
50 1.00 1.00 1.00 1.00 224.00 HIGH
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 Q R S T U V W
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 X Y Z
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13 The Effect of Each Process Step Failure

Risk on Other Parts (I.e. components/ Detection Mode Recommended Corrective Action(s)
objects)
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16 System failure, loss of time Testing & Equipment Calibration Perform Periodic audit
17 System failure, loss of time training
18 System failure, loss of time Testing & Equipment Calibration training
19 System failure testing & Equipment Calibration training
20 System failure, loss of time manufacturing engineering training
21 loss of time testing & Equipment Calibration training
22 Find whether the battery failed
23 loss of time
24 cost
25 loss of time Low signal send technician to correct the obstruction
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 X Y Z
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28 loss of time inspection process
29 loss of time
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31 on time action
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33 loss of time tesing
34 Fix
35 loss of time testing Fails, you can automatically switch to
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37 loss of time RFID team
38 System failure RFID team Fix
39 money waste RFID team Quality product
40 money waste Quality assurance
41 System failure Project Engineering Fix
42 delayed Manufacturing engineering constant evaluation
43 cost manufacturing engineering
44 System failure manufacturing engineering fix
45 cost manufacturing engineering constant evaluation
46 System failure manufacturing engineering Fix
47 cost quality assurance Fails, you can automatically switch to
48 cost manufacturing engineering
49 System failure quality assurance fix
50 constatnt evaluation
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 X Y Z
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 AA AB AC
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13 Corrective Action(s) Taken and Date

(mm/dd/yr) RPN for Each Failure Mode
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0 50 100 150 200 250 300 350 400 450
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16 Proper mounting ID 1.1

17 material is tested ID 1.2

18 Heat testing ID 1.3

19 ID 2.1

20 Immediate action needed ID 2.2

21 Immediate action needed ID 2.3

22 ID 3.1

23 ID 3.2

24 ID 3.3

25 obstruction corrected ID 4.1

26 ID 4.2
ID 4.3
ID 5.1
ID 5.2
ID 5.3
ID 6.1
 ID 2.3
ID 3.1
ID 3.2
ID 3.3
ID 4.1
ID 4.2
AA AB AC
27 ID 4.3

28 Immediate action needed ID 5.1

29 ID 5.2

30 ID 5.3

31 ID 6.1

32 ID 6.2

33 ID 6.3

34 Immediate action needed ID 7.1

35 install new blades ID 7.2

36 ID 7.3

37 ID 8.1

38 Immediate action needed ID 8.2

39 automatic switchover created ID 8.3

40 ID 9.1

41 Immediate action needed ID 9.2

42 install new batteries ID 9.3

43 ID 10.1

44 Immediate action needed ID 10.2

45 install new push buttons ID 10.3

46 Immediate action needed ID 11.1

47 automatic switchover created ID 11.2

48 ID 11.3
49 Immediate action needed ID 12.1
50 automatic switchover created ID 12.2
51 ID 12.3
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 ID 12.1
ID 12.2
ID 12.3

AA AB AC
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 AD AE
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Accumulated RPN for Each Failure Mode
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 3

AD AE
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 12

AD AE
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