A P Pfra 1

A
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A Component-oriented Process Failure Risk Analysis Method (Ver. 5) by Professor Paul G. Ranky, PhD, NJIT/MERC
3
4
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6
7
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
15
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
17
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
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
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2
Accumulated
RPN
Risk
Associated
Copyright by Paul G. Ranky, 1992-to date
3
4
5
6
7
rocess Code
ngineering Release Date of Process
8
Methodology
9
ype of Product Processed
roduct Group Classifier
10
ngineering Release Date of the11

Product
12
13
14
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
S K S RAJ KUMAR MADA
Failure Mode(s) and Effect(s)
15
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%
16
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.
26
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
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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

machinery
4/20/2012
Will affect the assembly of the wheel
Pin size critical
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.

machinery
4/20/2012
Pin diameter critical
mating process
May rupture the roller while in operation.

machinery
human
Training the workers
develoment department
proper maintainance of the RFID tags
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
29
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
1
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

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A

Product Name and Appearance Before Process

Pins (Female and Male)

PFRA Study ID Number

Name of Organization Responsible for the Process

A&P Eco-Automated Guided Vehicles

Date of This Study (mm/dd/yy)

Other Organizations Involved in the Process

Orignal Date of This Study

Subcontractors, process Plants Effected

Product Group Classifier

Product Serial Number and Optional Image Map

Possible High Failure Process

Engineering Release Date of the Product

Describe the Process for Each Process Step and

Specify the Tool(s) Used in Each Process

Specify the Fixtures / Clamps

List / Identify the Parts /

Fixtures and clamps

Examine Pin length

Competent person's hand and eye; vernier

Examine Pin diameter

Human eye, Visual Inspector, Vernier caliper

Examine Pin for Surface Roughness

Pin male or female Surface

Pin with Length of 120mm

pin with diameter 40 0.01 mm

Examine Internal threading in female pin/external

Human hand,Visual Inspector, thread pitch

pin with appropriate thread pitch

Pairing: Engage the male and female pins

RFID technology for product information & tracking

RFID tagged product information

RFID tags and tracking tools

Copyright by Paul G. Ranky, 1992-to date

roduct Group Classifier

ngineering Release Date of the11

This PFRA Study was Prepared By

Mecanum wheel part PIN F/M

Responsible Organization/ Department MME Quality Control

Early Identification & Correction

The PFRA Team Describes / Illustrates the Potential Process

S K S RAJ KUMAR MADA

Failure Mode(s) and Effect(s)

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

Pin does not have a surface roughness Ra value between

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

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

The male and female parts would not engage properly.

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

If not paired would cause rupture of the threads during

RFID tag failure would lead error in assembling wrong pin to

The Effect of Each Process Step Failure

The Effect of Each Process Step Failure

Recommended Corrective Action(s)

Corrective Action(s) Taken and Date

human and measuring instrument

training for machining of pin, maintain

human and measuring instrument

training for machining of pin, maintain

Will affect the assembly of the wheel

Pin size critical

human and measuring instrument