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A B C D E
Product Name and Appearance Before Process Recycling and Waste Management PFRA Study ID Number
Name of Organization Responsible for the Process GollaTech Date of This Study (mm/dd/yy)
Other Organizations Involved in the Process Collaborative Companies Orignal Date of This Study
Subcontractors, process Plants Effected Ranky Assoc. , USA Revision Number
Product Serial Number and Optional Image Map PT-RWM-1000 Comments
A Component-oriented Process Failure Risk Analysis Method of Recycling and Waste Management Process (Ver. 5) by Anjaneya Ravi Teja Golla and Professor Paul G. Ranky, PhD,
NJIT/MERC
hot/cold rolling machine, folding machine rollers, guide rails, folding machine
Eddy current devices, RFID tags
large shredders
Delacquering device, adult human hand, protective
clothing, safety glasses, delacquering chemicals
bailing device, melting furnace, adult human hand
chemical bath, human hand
human hand, Conveyor belt, side rails,
RFID readers
shredder
human hand, chemical bath
bailing device, human hand, moulds
Cast Iron rolling into roles of thin sheet for packaging
For Plastic: Cleaning of plastic: Make sure no toxicity remains
Bailing and melting of Cast Iron shreads to make Cast Iron plates
Sorting of metal recyclates into Cast Iron and other metals
For Cast Iron: Shreading of Cast Iron into tiny pieces
Chemical Delacquering process after shredding to remove any paint or other materials:
Make sure to remove all contaminants
Adult human hand and eye, hand gloves, safety
glasses, cleaning chemicals
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4
5
6
7
8
Spreading of commingled recylates on the moving conveyor belt/ Conveyor belt populated
with single layer recyclate
1
2 Sorting of recyclates into different major components like plastic, paper, Cast Iron
Adult human hand and eye, hand gloves, safety
glasses, helmet, RFID tags
human hand, Conveyor belt, side rails
human hand, Conveyor belt, side rails,
RFID readers
Adult human hand and eye, hand gloves, safety
glasses, helmet
Process
ID
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 Fixtures / Clamps Used in
Each Process Step
Specify the Tool(s) Used in Each Process Step
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63
64
A B C D E
automatic paper cutters,
rollers, guide rails
paper trays
bleach vat, adult human hand, hand gloves, safety
glasses
felt-covered press rollers,
hot air dryers, temperature controllers
human hand, bleach vat
rollers, guide rails
plastic grinder, plastic feeder
rollers, extruder
Bleaching of paper cellulose
Rolling of cellulose into paper
Drying of rolled paper
Cutting of dry paper roles into sheets
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14
15
16
Chemical bath, chemicals, adult human hand, hand
gloves, safety glasses, spinner
water bath, flotation vat, surfactants, soap, adult
human hand, hand gloves, safety glasses
De-inking of paper cellulose
human hand, spinner
human hand, storage tank
For paper: Breakdown of paper into cellulose in the chemical bath
Grinding of plastic to small pieces
Pelletizing and extruding of plastic into thin sheet for packaging pelletizing furnace, extruder,
plastic grinder, plastic feeder
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11
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F G H I J K L M N O P Q
Copyright by Paul G. Ranky, 1992-to date
GT-QA-102105 GT-RWM-1231240PWR
04-19-2014 04-16-2014
04-17-2014 Plant Site
Rev. 01 RW-01-1310
Based on on floor process study 04-14-2014
Process
Cost
15.00 Proc.ID Failure Mode(s) and Effect(s)
sec/100
kg
[USD] [USD] (1-10) (1-10) (1-10)
0.1-
2,1=100%
ID 1.1
Large pieces like corrugated fireboards can cause machinery
jam
6 2 4 48
ID 1.2 Multiple layers sometimes that lower the sorting quality 4 4 6 96
ID 1.3 0
ID 2.1
Some non-recyclable plastic also gets sorted into recyclable
plastic
4 4 5 80
ID 2.2 0
ID 2.3 0
ID 3.1
Eddy current machine not providing enough current for
sorting
6 3 3 54
ID 3.2
Large Cast Iron pieces not getting sorted
3 3 4 36
ID 3.3 0
ID 4.1 Thick Cast Iron pieces not getting properly shreadded 3 5 4 60
ID 4.2
Shreadder jammed due to access feeding
7 1 3 21
ID 4.3 0
ID 5.1 chemical bath leak: hazardous chemical spill and wastage 6 1 2 12
ID 5.2 Inadequate chemical mixing: inadequate delacquering 5 4 4 80
ID 5.3 0
ID 6.1
Furnace cooling while molten Cast Iron inside: furnace
electrodes ruined
8 3 1 24
ID 6.2
Improper venting of volatile gases: hazardous gas build up
6 3 2 36
ID 6.3
Some Cast Iron plate moulds leaking: Improper plates hard to
role
4 3 4 48
ID 7.1
Gap between rollers is higher than tolerence: Improper
uneven thickness of Cast Iron sheet
8 5 5 200
ID 7.2
Rollers have loosened with contiunous use: improper surface
finish and uneven thickness and high noise
6 4 4 96
ID 7.3 0
ID 8.1 chemical bath leak: hazardous chemical spill and wastage 9 3 2 54
ID 8.2
Inadequate chemical mixing: inadequate cleaning, affect
downstream processes
5 4 4 80
ID 8.3 0
A Component-oriented Process Failure Risk Analysis Method of Recycling and Waste Management Process (Ver. 5) by Anjaneya Ravi Teja Golla and Professor Paul G. Ranky, PhD,
NJIT/MERC
Anjaneya Ravi Teja Golla
Anjaneya Ravi Teja Golla and Prof. Ranky
GollaTech
Updates needed every 6 months
Process Code
Engineering Release Date of Process
Type of Product Processed
Product Group Classifier
This PFRA Study was
PFRA Team
Responsible Organization/
Comments
Engineering Release Date of the Product
heated Cast Iron plates, rolling machine, folding
machine
plastic received from sorting, chemical storage
tank
conveyor belt, storage container
Cast Iron to be shredded, storage container
Shredded painted Cast Iron, chemical storage
tanks
moulds, bailing device, delacqured Cast Iron
8.00
conveyor belt, storage container 9900
115.50
60
0.90
81.75
22.50 104.25
11.25
1920
45.00 171.25
10.75 126.25
conveyor belt
List / Identify the Parts / Components
Retrieved in Each Process Step
Process
Time
Severity
Rating
Detection
Rating
Occurrence
Rating
RPN (Risk
Priority Number)
600
80
200
48
80
54
7200
10800
2580
2700
5400
The PFRA Team Describes / Illustrates the Potential Process
Failure Mode and the Effect; the Risk of Failure
Accumulated
Process Cost
30.00 30.00
Max. RPN
80 41.25 71.25
96
2.50 73.75
1.00
Tooling
Factor
1.00
0.70
0.80
1.20
1.00
1.00
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F G H I J K L M N O P Q
ID 9.1 Plastic dust: hazardous for human 6 4 2 48
ID 9.2
Grinder Jam due to large plastic pieces: Grinding cannot
proceed
6 1 2 12
ID 9.3 0
ID 10.1
Uneven cooling of plastic pallet in the extruder: Uneven
extrusion, strain in plastic
5 6 4 120
ID 10.2
Uneven heating of plastic pallet in furnace: Uneven extrusion
7 5 4 140
ID 10.3 0
ID 11.1 chemical bath leak: hazardous chemical spill and wastage 6 1 2 12
ID 11.2
Inadequate chemical mixing: not complete breakdown to
cellulose, affect downstream processes
5 4 4 80
ID 11.3 0
ID 12.1 Volatile gases and vapour: Hazardous work environment 5 4 2 40
ID 12.2
Improper safety valves in case of piping leaks: Hazardous
chemical spill,
6 5 3 90
ID 12.3 0
ID 13.1
Improper handeling of used chemicals: Hazardous work
environment
6 3 2 36
ID 13.2
Worn out lining of the chemical bath: Leak of bleach can
happen
7 4 4 112
ID 13.3
Low bleaching agent conc: Improper bleaching, paper is
yellowish
4 5 5 100
ID 14.1 High friction at roller bearings: Breaking in paper sheet 6 5 4 120
ID 14.2 0
ID 14.3 0
ID 15.1
Inadequate air temp monitoring: Not fully dried paper or
buring of paper
7 6 4 168
ID 15.2 0
ID 15.3 0
ID 16.1
Play in the paper cutter cutting blade: Rough edges of cut
paper
5 4 3 60
ID 16.2 0
ID 16.3 0
1.00
1.20
1.30
1.20
112
120
168
60
256.25
286.25
346.25
358.75
5400
7200
14400
3000
de-inked cellulose mix, bleach vat, human hand
bleached cellulose mix, rollers,
rolled wet paper, air dryer
dried paper roles, paper cutter, paper trays
22.50
1.00
30.00
60.00
12.50
cellulose mix, flotation vat, human hand
small plastic pieces, extruder
sorted waste paper, chemical storage tank,
3600
2400
7200
1800
90
80
140
48 7.50
15.00 233.75
30.00 208.75
10.00 218.75
178.75
0.96
1.00
cleaned plastic, plastic grinder, plastic feeder,
storage container
0.85
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R S T U V W X Y
0.1-2,1=100%
0.1-
2,1=100%
0.1-2,1=100%
Machinery jam and damage down the line, Delay in recycling
Maintenance cost increased Human Inspection
Improper sorting; Metal and plastic can get mixed Measurable effect on quality of final product Human Inspection
Plastic recycling processes affected;
Maintenace cost increased; measurable effect on
plastic quality Human Inspection
Low Cast Iron recycling efficiency; Less feed rate to
downstream
Measurable effect on output quantity
Control charts; Human Inspection
Low Cast Iron recycling efficiency; Increased production cost
Maintenance cost increased Human Inspection
Improper delaquering and bailing of thicker pieces; Higher
melting time in furnace
Maintenance cost increased; Minor effect on
quality Human Inspection
Feed to downstream processes interrupted; Reduced
shredder efficiency; Higher maintenance cost; Maintenance cost increased Automatic detection as process stopped
Other process in nearby workspace stopped due to chemical
leak; feed to downstream processes interrupted Maintenance cost increased Human Inspection
Higher waste content in Cast Iron furnace; lower quality Cast
Iron sheets Measurable effect on quality Sampling; Process simulation
Feed to downstream process interrupted; Cast Iron prod
delayed Maintenance cost increased Automatic detection as process stopped
Other process in nearby workspace stopped due to gas build
up; feed to downstream processes interrupted
Safety risk for employees; Maintenance cost
increased Automatic gas detectors
Lower quality feed downstream Maintenance cost increased Human Inspection
Affects packaging process due to uneven thickness of Cast
Iron;
Maintenance cost increased; Direct measurable
effect Human Inspection
Affects packaing process due to bad surface finish;
Direct measurable effect Human Inspection
Other process in nearby workspace stopped due to chemical
leak; feed to downstream processes interrupted Maintenance cost increased; Human Inspection
Higher waste content found in palletizing and extrusion; lower
quality plastic sheets Direct measurable effect Sampling; Process simulation
Anjaneya Ravi Teja Golla
Anjaneya Ravi Teja Golla and Prof. Ranky
GollaTech
Updates needed every 6 months
Low 1.00
Low
Low
Low
HIGH
Risk
Associated
Low
Low
Low
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
Clamping/
Fixturing Factor
Skill
Factor
0.95 1.00
1.00 1.00
1.00 1.10
1.00 0.90
1.30
1.00 0.90
1.00 1.10
1.00
1.00
1.00
1.00
1.00
Accumulated
RPN
91.20
80.00
41.58
43.20
93.60
Any Other Factor
You Define
43.20
1.00
1.00
264.00
80.00
1.00
1.00
1.00
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R S T U V W X Y
affects work environment of other process; dust problem in
other processes Direct measurable effect Dust level detectors
Feed to downstream processes interrupted; Reduced grinder
efficiency; Higher maintenance cost;
Maintenance cost increased; Direct measurable
effect Automatic detection as process stopped
Uneven plastic sheet affects packaging process; Higher reject
rate Direct measurable effect Temp Sensors
Uneven plastic sheet affects packaging process; Higher reject
rate Direct measurable effect Temp Sensors
Feed to downstream processes interrupted; Other process in
nearby workspace stopped due to chemical leak
Maintenance cost increased; Direct measurable
effect Human Inspection
Low efficiency of paper recycling; Inadequate cellulose feed
for downstream processes; Direct measurable effect Sampling; Process simulation
Makes the whole recycling process less green;
Direct measurable effect Automatic gas detectors
Other process in nearby workspace stopped due to chemical
leak; feed to downstream processes interrupted
Maintenance cost increased; Direct measurable
effect Human Inspection
Makes the whole recycling process less green;
Direct measurable effect Human Inspection
Leaked bleach affects other machinery; Feed to downstream
processes interrupted
Maintenance cost increased; Direct measurable
effect Human Inspection
Lower quality paper for labeling; Labeling process affected Direct measurable effect Human Inspection
Bad paper quality; Labeling process affected; Cutting process
also affected Direct measurable effect Human Inspection
Poor paper quality; Bad labeling; increased production cost Direct measurable effect Human Inspection
Bad paper quality; Labeling process affected; Increased waste Direct measurable effect Human Inspection
Low
Low
HIGH
Low
145.60
136.80
218.40
64.80
1.00
1.00 0.90 1.00
1.00 1.30 1.00
0.95 1.00 1.00
1.00 1.00
Low
Low
Low
Low
1.00 1.05
0.95 1.00
1.00 1.10
1.00
95.04 1.00
147.00
38.76
1.00 80.00
1.00
1.00
1.00
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Z AA AB AC AD
Iron net with adequate size holes to filter
large recyclates Action Taken; 04-19-2014
Frequent human inspection Action planned; 04-17-2014

Frequent training about recyclable plastic


Operator training; Current meter
installation
Large pieces sorted manually

Thick pieces manually removed and
thickness reduced before shreading
Feed rate controlled by control charts;
Operator training

Frequent inspection of chemical bath
Better stirrer used; Increase stirring time

Back up power arrangement for furnace
Venting corrected as per safety guidelines
Leaking mould replacement
Repair of rollers; Gap monitoring devices Action Taken; 04-19-2014
Roller bearings replaced

Frequent inspection of chemical bath
Better stirrer used; Increase stirring time

Corrective Action(s) Taken and Date
(mm/dd/yr)
Recommended Corrective Action(s)
ID 1.1
ID 1.2
ID 1.3
ID 2.1
ID 2.2
ID 2.3
ID 3.1
ID 3.2
ID 3.3
ID 4.1
ID 4.2
ID 4.3
ID 5.1
ID 5.2
ID 5.3
ID 6.1
ID 6.2
ID 6.3
ID 7.1
ID 7.2
ID 7.3
ID 8.1
ID 8.2
ID 8.3
ID 9.1
0 50 100 150 200 250
RPN for Each Failure Mode
1
2
3
4
5
6
8
9
0 50 100 150
Accumulated RPN for Each Failure Mode
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Z AA AB AC AD
Better masks for workers; Dust trapping
mechanisms installed
Grinder jam removed; Large plastic pieces
manually removed and cut

Temp control mechanism installed
Temp control mechanism installed

Frequent inspection of chemical bath
Better stirrer used; Increase stirring time

Proper gas ventilation; Chimney used if
necessary
Valves placed as per safety guidelines

Training for proper handeling
Lining replaced; Frequent inspection
Bleaching agent conc range defined;
Frequent bearing lubrication

Air temp control mechanism installed Action Taken; 04-19-2014

Frequent inspection and repair


ID 9.1
ID 9.2
ID 9.3
ID 10.1
ID 10.2
ID 10.3
ID 11.1
ID 11.2
ID 11.3
ID 12.1
ID 12.2
ID 12.3
ID 13.1
ID 13.2
ID 13.3
ID 14.1
ID 14.2
ID 14.3
ID 15.1
ID 15.2
ID 15.3
ID 16.1
ID 16.2
ID 16.3
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16
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AE
7
150 200 250 300
Accumulated RPN for Each Failure Mode
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AE
10
13
14
15