Scuba Modern Pfra Method With Rfid

1
Max. RPN
Tooling
Factor
AA
Risk
Associated
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)
AB
AC
AD
AE
Copyright by Paul G. Ranky, 1992-2002
A Component-oriented Process Failure Risk Analysis Method (Ver. 1) by Matthew Negron
Copyright by Paul G. Ranky, 2002 to date
4
5
6
7
Product Name and Appearance Before Process

Name of Organization Responsible for the Process
8
9
10
11
12
13
14
Other Organizations Involved in the Process

Subcontractors, process Plants Effected
Product Serial Number and Optional Image Map
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
Cell Phone Case

Scuba Modern
Sunnen, Super Mill
N/A
N/A
Specify the Tool(s) Used in Each Process

Step
PFRA Study ID Number
Date of This Study (mm/dd/yy)
11/23/2014
Orignal Date of This Study

Revision Number
Comments
2/12/2012
Rev. 01
none
Specify the Fixtures / Clamps Used in Each

Process Step
List / Identify the Parts / Components

Retrieved (if any) in Each Process Step
Process Code
Engineering Release Date of Process
Methodology
Type of Product Processed
Product Group Classifier
Engineering Release Date of the Product
Process
Time
[sec]
15
Process
Cost
18.00
[USD]
Accumulated
Process Cost
19
20
21
22
23
Product Ideation & Development
Human Hand, Sketching, & Computer
Human hand
Potential Parts for Sourcing
432000
2160.00
2160.00
Choosing Materials & Components
Working Prototype Test
Human Research
3D Printing
Human hand
Human hand
Suppliers and Vendors with Contractual

Agreements
Sample Order of Parts
86400
28800
432.00
144.00
2592.00
2736.00
Market Survey & Testing
Adult Human Hand & Eye
Human hand
None
7200
36.00
2772.00
32
33
34
35
Product Revisions
Human Hand
Human hand
Final Order of Parts
144000
720.00
3492.00
Product CTL (Consumer Testing Laboratory)

Compliance
Custom Mold Design
Machine Testing, Adult Human Hand & Eye
3D Modeling
Human hand & Testing Laboratory
Human hand & Computer Analysis
None
14400
Metal Mold
36000
72.00
180.00
3564.00
3744.00
40
41
42
Proc.ID
Failure Mode(s) and Effect(s)
ID 1.2
designers overlooks user need

engineers do not review correct manufacturability
Severity
Rating
Detection
Rating
Occurrence
Rating
(1-10)
(1-10)
(1-10)
ID 2.1
suppliers do not agree to our contract
Tooling for Mold
Product Branding/Logo (Screen Printing)
Machinery
Human hand & Machinery
Human hand
Tools for Mold Making
Screen Print Die for Logo
26000
8000
130.00
40.00
3874.00
3914.00
28
42
ID 3.1
product does not have proper quality
28
ID 3.2
product fails under testing
24
ID 4.1
survey sampling is incorrect
10
30
ID 4.2
ID 4.3
product does not meet market needs
10
120
0
revisions chosen incorrectly
4
6
2
1
64
48
ID 6.1
fails CTL testing
56
ID 6.2
ID 6.3
incorrect information sent for testing
56
0
ID 7.1
mold designer is wrong type for proper release
80
ID 7.2
mold design exceed budget
80
mold is the wrong quality
ID 8.2
ID 8.3
mold does not have proper lifecycle

mold has wrong materials which causes warping
ID 9.1
logo does not adhere to product

die has the incorrect lifecycle
6
5
8
10
ID 11.1
ID 11.2
11
Palletizing
Adult Human Hand & Eye & Forklift
Human Hand
Biodegradable Packaging
Rapid Renewable Wood for Pallets
20000
6000
100.00
30.00
4014.00
4044.00
9
8
6
6
2
3
1
1
Delivery
Truck and/or Ship
Human Hand, Trucks & Ships
None
50000
250.00
4294.00
13
T ags & Antenna
Human Hand & Eye
Assemnly Lines to Attach RFID Tags

"Will Trace Info about Product"
120
0.01
4294.01
1.00
1.00
1.80
201.60
HIGH
42
28
1.00
1.00
1.00
1.00
1.00
1.00
1.80
1.80
75.60
50.40
Low
Low
120
0
120
1.00
1.00
1.00
1.80
216.00
HIGH
Faulty end product: phone case
compsition of phone case relationship

critical


64
1.00
1.00
1.00
1.00
64.00
Low

56
80
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
56.00
80.00
Low
Low
120
1.00
1.00
1.00
1.00
120.00
60
1.00
1.00
1.00
1.00
60.00

Low
Low

28
pallets breaks
54
no properly stacked for container
24
54
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
40.00
54.00
Human inspection
critical
critical
multi-point review
Immediate Action Need
proper audintg
28
ID 12.2
devlivery causes damage or loss of product
30
Low
Low
1.00
1.00
1.00
1.00
30.00
Low
28
ID 12.2
Tags become detacched
42
ID 12.3
Implementation not complete with all distributors
60
ID 3.1
ID 3.2
ID 3.3
Human inspection
quality testing and inspection

proper inspection from trained employee
ID 4.1
ID 4.2

critical
Human inspection
user results properly anaylzed

information cataloged and sorted

ID 4.3
ID 5.1

critical
Human inspection
ID 5.2
ID 5.3
Revisions tracked and dated

ID 6.1

critical
ID 6.2
Human inspection
pre-testing to ensure compliance

create testing checklist

critical

critical

critical
Human inspection
computer analysis
contact collaborators for assistance
ID 7.1
ID 7.2
ID 7.3
ID 8.1
Human inspection
contact multiple tool makers

check quality of tools
ID 8.2
ID 8.3
ID 9.1
Human inspection
employee knowledge and trainingp

performance

critical
ID 6.3
ID 9.2
ID 9.3
10
ID 10.1
Human inspection

performance
ID 10.2
ID 10.3

critical
Human inspection
11
ID 11.1
ID 11.2
train employee on proper storage method

ID 11.3
30
60
1.00
1.00
1.00
1.00
60.00
250
ID 2.2
quality testing and inspection

critical
Human inspection
Low

ID 12.1
train employee on proper storage method
ID 12.2
0
Tags are damaged by supplier
Accumulated
50
RPN
100 for Each150
Failure Mode
200
ID 2.1
communicate with suppliers
0
4
ID 2.3
40
140
ID 1.3
Human inspection
120
ID 1.1
40
product delivered with wrong lead time
for Each
Failure
60
80 Mode100
48
60
RPN
40
20
performance
108
ID 12.1
ID 12.1
1.00
18
ID 12.3
RFID Tags added to each Cell Phone Case and
Pallets for Shipping

critical
critical

112
ID 1.2
ID 11.3
12
0.12,1=100%
46
Human Hand
0.12,1=100%
excess packaging for less units per delivery
0.12,1=100%
Other
Accumulated
Factor:
RPN
Design
Experience
36
8
8
ID 10.3
54
product revisions tooled wrong

materiality can not have changes necessary
45
52
53
ID 5.2
ID 5.3
Packaging Product
12
2
3
does not protect product
50
51
2
2
ID 10.2
49
ID 9.3
10
30
7
7
ID 9.2
Clamping/
Fixturing Skill Factor
Factor
112
raw materials received does not meet quality standards

suppliers materials do not meet the required quality
ID 8.1
8
0.12,1=100%
ID 2.2
ID 2.3
packaging is not biodegrabable
47
48
RPN (Risk
Priority
Number)
ID 10.1
43
44
ID 7.3
36
37
38
39
The PFRA Team Describes / Illustrates the Potential Process Failure

Mode and the Effect; the Risk of Failure
ID 5.1
30
31
N/A
ID 3.3
27
28
29
Responsible Organization/ Department

Comments
ID 1.3
24
25
26
Cell phone case to protect phone
ID 1.1
1
Matthew Negron
PFRA Team
[USD]
16
17
18
This PFRA Study was Prepared By

critical
ID 12.3
Human inspection
check quality of tools

performance
12

Scuba Modern Pfra Method With Rfid

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1

The Effect of Each Process Step Failure

The Effect of Each Process Step Failure

Recommended Corrective Action(s)

Corrective Action(s) Taken and Date

Copyright by Paul G. Ranky, 1992-2002

A Component-oriented Process Failure Risk Analysis Method (Ver. 1) by Matthew Negron

Copyright by Paul G. Ranky, 2002 to date

Product Name and Appearance Before Process

Other Organizations Involved in the Process

Cell Phone Case

Specify the Tool(s) Used in Each Process

PFRA Study ID Number

Date of This Study (mm/dd/yy)

Orignal Date of This Study

Specify the Fixtures / Clamps Used in Each

List / Identify the Parts / Components

Product Ideation & Development

Human Hand, Sketching, & Computer

Potential Parts for Sourcing

Choosing Materials & Components

Working Prototype Test

Suppliers and Vendors with Contractual

Sample Order of Parts

Market Survey & Testing

Adult Human Hand & Eye

Final Order of Parts

Product CTL (Consumer Testing Laboratory)

Custom Mold Design

Machine Testing, Adult Human Hand & Eye

Human hand & Testing Laboratory

Human hand & Computer Analysis

Failure Mode(s) and Effect(s)

designers overlooks user need

suppliers do not agree to our contract

Tooling for Mold

Product Branding/Logo (Screen Printing)

Adult Human Hand & Eye

Human hand & Machinery

Tools for Mold Making

Screen Print Die for Logo

product does not have proper quality

product fails under testing

survey sampling is incorrect

product does not meet market needs

revisions chosen incorrectly

fails CTL testing

incorrect information sent for testing

mold designer is wrong type for proper release

mold design exceed budget

mold is the wrong quality

mold does not have proper lifecycle

logo does not adhere to product

Adult Human Hand & Eye & Forklift

Rapid Renewable Wood for Pallets

Truck and/or Ship

Human Hand, Trucks & Ships

T ags & Antenna

Human Hand & Eye

Assemnly Lines to Attach RFID Tags

Faulty end product: phone case

compsition of phone case relationship

Faulty end product: phone case