A
1
2
A Component-oriented Process Failure Risk Analysis Method for the Unmanned Underwater Drilling Apparatus by Frank Lewis, NJIT
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Product Name and Appearance Before Process
Unmanned Underwater Drilling Apparatus
PFRA Study ID Number
Name of Organization Responsible for the Process
Frank & CO
Date of This Study (mm/dd/yy)
4/5/2015
Other Organizations Involved in the Process
Canon, Sowa, Haimer, STM
Orignal Date of This Study
4/5/2015
Process Code
Engineering Release Date of Process
Methodology
Type of Product Processed
10
Subcontractors, process Plants Effected
Canon, Sowa, Haimer, STM
Revision Number
Product Group Classifier
11
12
Product Serial Number and Optional Image Map
as345345
Comments
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
Engineering Release Date of the Product
Specify the Fixtures / Clamps Used in Each
Process Step
List / Identify the Parts / Components
Retrieved in Each Process Step
Process
Time
Process
Cost
15.00
15
[sec]
[USD]
16
17
Inspection of All Components
Parts are cleaned and put away properly
Assembly technicians bring necessary parts to their
work stations
Assembly of UUDA
Test of the UUDA
Packaging of The UUDA and placing in final storage
Hands, microscope
microscope stand
Separate parts from Partner Companies
600
2.50
hands, wash unit, cart
wash unit
Separate parts from Partner Companies
300
1.25
hands
work station
Parts located in storage location
20
0.08
hands, drill, plasma welder, screwdrivers, loctite,
work station
3600
15.00
Underwater test unit
underwater test unit
UUDA
1800
7.50
hands
packaging area
packaging boxes, UUDA
180
0.75
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
0.00
0.00
0.00
10
0.00
11
0.00
36
37
38
39
40
41
42
43
44
45
46
A
47
B
11
H
0.00
48
49
50
12
0.00
13
0.00
14
0.00
15
0.00
16
0.00
17
0.00
18
0.00
19
0.00
20
0.00
21
0.00
22
0.00
23
0.00
24
0.00
25
0.00
26
0.00
27
0.00
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
86
87
88
89
90
91
92
93
94
A
95
B
27
H
0.00
96
97
98
28
0.00
29
0.00
30
0.00
31
0.00
32
0.00
33
0.00
34
0.00
35
0.00
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
Max. RPN
Tooling
Factor
1
2
Copyright by Paul G. Ranky, 1992-2002
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Process Code
Engineering Release Date of Process
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Methodology
1 This PFRA Study was Prepared By
Frank Lewis
1/21/2015
PFRA Team
9
Type of Product Processed
main product
Responsible Organization/ Department Frank & Co
10
Product Group Classifier
n/a
11 Date of the Product
Engineering Release
12
13
Accumulated
Process Cost
14
15
17
2.50
18
19
20
3.75
21
25
18.83
27
28
29
26.33
30
31
32
27.08
33
34
35
27.09
36
37
38
27.09
39
40
41
27.10
42
43
44
(1-10)
(1-10)
(1-10)
ID 1.1
Parts Not received / unable to proceed
10
50
ID 1.2
Parts not accurately checked / bad part created
10
60
ID 1.3
damaged parts received / unable to proceed
10
20
ID 2.1
parts are not cleaned properly / may cause issues in assembly
ID 2.2
parts not put away properly / parts lost, hard to locate
12
ID 3.1
3.83
24
26
The PFRA Team Describes / Illustrates the Potential Process Failure
RPN (Risk
Mode and the Effect; the Risk of Failure
Severity RatingDetection Rating
Occurrence Rating
Priority
Number)
Proc.ID
Failure Mode(s) and Effect(s)
ID 2.3
22
23
Comments
1/21/2015
[USD]
16
Frank Lewis
27.10
45
46
27.10
Clamping/
Any Other
Fixturing Skill Factor Factor You
Factor
Define
Accumulated
RPN
0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100%
60
1.00
1.00
1.00
1.00
60.00
12
1.00
1.00
1.00
1.00
12.00
1.00
1.00
1.00
1.00
8.00
240
1.00
1.00
1.00
1.00
240.00
100
1.00
1.00
1.00
1.00
100.00
1.00
1.00
1.00
1.00
8.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
0
wrong parts retrieved / wasted time
ID 3.2
ID 3.3
ID 4.1
welding error / part ruined
10
120
ID 4.2
drilling error / part ruined
10
240
ID 4.3
gluing error / part fails testing
64
ID 5.1
part fails testing with a fixible issue / time wasted
75
ID 5.2
part fails testing and is unfixible / part ruined
90
ID 5.3
false pass test of a bad part / bad part sold to customer
10
10
100
ID 6.1
box is broken while packaging/ box wasted
ID 6.2
part damaged during packaging
ID 6.3
ID 7.1
ID 7.2
ID 7.3
ID 8.1
ID 8.2
ID 8.3
ID 9.1
ID 9.2
ID 9.3
ID 10.1
ID 10.2
ID 10.3
ID 11.1
47
I
27.10
J
ID 11.2
O
0
48
ID 11.3
49
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
ID 17.1
ID 17.2
ID 17.3
ID 18.1
ID 18.2
ID 18.3
ID 19.1
ID 19.2
ID 19.3
ID 20.1
ID 20.2
ID 20.3
ID 21.1
ID 21.2
ID 21.3
ID 22.1
ID 22.2
ID 22.3
ID 23.1
ID 23.2
ID 23.3
ID 24.1
ID 24.2
ID 24.3
ID 25.1
ID 25.2
ID 25.3
ID 26.1
ID 26.2
ID 26.3
ID 27.1
50
27.11
51
52
53
27.11
54
55
56
27.12
57
58
59
27.12
60
61
62
27.13
63
64
65
27.13
66
67
68
27.13
69
70
71
27.14
72
73
74
27.14
75
76
77
27.15
78
79
80
27.15
81
82
83
27.15
84
85
86
27.16
87
88
89
27.16
90
91
92
27.17
93
94
27.17
P
0
Q
1.00
R
1.00
S
1.00
T
1.00
U
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.60
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
95
I
27.17
J
ID 27.2
O
0
96
ID 27.3
97
ID 28.1
ID 28.2
ID 28.3
ID 29.1
ID 29.2
ID 29.3
ID 30.1
ID 30.2
ID 30.3
ID 31.1
ID 31.2
ID 31.3
ID 32.1
ID 32.2
ID 32.3
ID 33.1
ID 33.2
ID 33.3
ID 34.1
ID 34.2
ID 34.3
ID 35.1
ID 35.2
ID 35.3
98
27.18
99
100
101
27.18
102
103
104
27.18
105
106
107
27.19
108
109
110
27.19
111
112
113
27.20
114
115
116
27.20
117
118
119
120
121
27.20
P
0
Q
1.00
R
1.00
S
1.00
T
1.00
U
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
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)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
no
processprocess
can happen
untilbad
rectified
assembly
affected,
part
created
each part created individually
Receiving / Inspections
frequent contact with partner companies
each part created individually
Receiving / Inspections
proper training of workers
18
no process can happen until rectified
each part created individually
Receiving / Inspections
frequent contact with partner companies
19
process delay
each part created individually
Storage Department
proper training of workers
process delay
each part created individually
Storage Department
proper training of workers
process delay
each part created individually
Assembly technician
proper training of workers
customer not satisfied
each part created individually
Assembly technician
proper training of workers and care of tools
customer not satisfied
each part created individually
Assembly technician
proper training of workers and care of tools Immediate action needed
27
process delay, possible rework
each part created individually
Assembly technician
proper training of workers and care of tools
28
process delay, possible rework
each part created individually
Testing Department
issues avoided during assembly
customer not satisfied
each part created individually
Testing Department
issues avoided during assembly
30
customer not satisfied
each part created individually
Testing Department
proper training of workers and care of tools
31
small process delay
each part created individually
Packaging/ Shipping
proper training of workers
process delay
each part created individually
Packaging/ Shipping
proper training of workers
17
20
Low
Low
21
22
23
Low
24
25
26
29
32
HIGH
Low
Low
33
34
35
Low
36
37
38
Low
39
40
41
Low
42
43
44
Low
45
46
Low
47
V
Low
48
49
50
Low
51
52
53
Low
54
55
56
Low
57
58
59
Low
60
61
62
Low
63
64
65
Low
66
67
68
Low
69
70
71
Low
72
73
74
Low
75
76
77
Low
78
79
80
Low
81
82
83
Low
84
85
86
Low
87
88
89
Low
90
91
92
Low
93
94
Low
AA
95
V
Low
96
97
98
Low
99
100
101
Low
102
103
104
Low
105
106
107
Low
108
109
110
Low
111
112
113
Low
114
115
116
Low
117
118
119
120
121
Low
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
150
200
250
300
0.00
50.00
100.00
150.00
200.00
250.00
ID 1.1
16
ID 1.2
17
ID 1.3
18
ID 2.1
19
ID 2.2
20
21
100
ID 2.3
ID 3.1
22
23
ID 3.2
24
ID 3.3
ID 4.1
25
ID 4.2
26
ID 4.3
27
ID 5.1
28
ID 5.2
29
ID 5.3
30
ID 6.1
31
ID 6.2
32
33
ID 6.3
34
ID 7.1
35
ID 7.2
36
ID 7.3
37
ID 8.1
38
ID 8.2
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
10
11
ID 11.2
ID 11.3
ID 12.1
12
ID 12.2
ID 12.3
ID 13.1
ID 13.2
ID 13.3
13
300.00
ID 8.2
ID 8.3
ID 9.1
ID 9.2
ID 9.3
10
ID 10.1
ID 10.2
ID 10.3
ID 11.1
AB
AC
11
47 ID 11.2
48 ID 11.3
49 ID 12.1
50 ID 12.2
51 ID 12.3
52 ID 13.1
12
13
53 ID 13.2
54 ID 13.3
55 ID 14.1
56 ID 14.2
14
57 ID 14.3
58 ID 15.1
15
59 ID 15.2
60 ID 15.3
61 ID 16.1
16
62 ID 16.2
63 ID 16.3
64 ID 17.1
17
65 ID 17.2
66 ID 17.3
67 ID 18.1
68 ID 18.2
69 ID 18.3
70 ID 19.1
18
19
71 ID 19.2
72 ID 19.3
73 ID 20.1
74 ID 20.2
75 ID 20.3
76 ID 21.1
20
21
77 ID 21.2
78 ID 21.3
79 ID 22.1
80 ID 22.2
81 ID 22.3
82 ID 23.1
22
23
83 ID 23.2
84 ID 23.3
85 ID 24.1
86 ID 24.2
87 ID 24.3
88 ID 25.1
24
25
89 ID 25.2
90 ID 25.3
91 ID 26.1
92 ID 26.2
93 ID 26.3
94 ID 27.1
26
27
ID 27.2
ID 27.3
ID 28.1
28
ID 28.2
ID 28.3
ID 29.1
ID 29.2
ID 29.3
29
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
25
ID 25.1
ID 25.2
ID 25.3
26
ID 26.1
ID 26.2
ID 26.3
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
111
112
113
114
115
116
117
118
119
120
121
AB
AC
27
28
29
30
31
32
ID 32.2
ID 32.3
ID 33.1
33
ID 33.2
ID 33.3
ID 34.1
34
ID 34.2
ID 34.3
ID 35.1
ID 35.2
ID 35.3
35
AD
AE
