Worksheet in C Users Akanksha Appdata Local Temp Em-636-Assignment-4

A
1
2
A Component-oriented Process Failure Risk Analysis Method (Ver. 5) by Professor Paul G. Ranky, PhD, NJIT/MERC
3
4
5
6
7
Product Name and Appearance Before Process
Intelli-Tools
PFRA Study ID Number
Name of Organization Responsible for the Process
Green Team Technologies
Date of This Study (mm/dd/yy)
7/21/2015
Partnering Organizations
Orignal Date of This Study
7/21/2015
Process Code
Engineering Release Date of Process
Methodology
Type of Product Processed
Revision Number
Product Group Classifier
Version 1.0
Engineering Release Date of the Product
Other Organizations Involved in the Process
10
Subcontractors, process Plants Effected
11
12
Product Serial Number and Optional Image Map
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
1 Comments
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
17
Dropped the hair dryer
Used my hands; no special fixtures were

Used my hands and a screw driver to re-assemble broken dryer
required
Intelligent Tool Voltage Tester Display showing

inncorrect Results
Used my hands and disassembled the driver,

replaced resistor in board to correct malfunction
Tool's Screw Driver Head chipped
Contacted Partnering Organization (Haimer) to

assign warranty claim to the device for
replacement and or repair
Contaminated Waste Depository
Fork Lift, Human Hands, Various Sorting

Machinery
Plant Ventilation Fans Malfunction
Building Electrical Fire
Theft of Proprietary Software and other Intellectual

Property
Tools with Faulty Battery causing shortage
Raw Material Shipping Delay
10
Tools Degradation Faster than expected
11
Waterproofing Technologies not keeping Water out

of tools
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Process
Cost
15.00
15
16
Process
Time
Hired external electrical contractor to determine

cause of electrical problem and repair it
Immediately escort ALL employees and Staff
and call Emergency 911 while you try to
extinguish the fire with a fire extinguisher if it is
not too large
Source the location of the computer that was
used to steal all data and retrieve data.
Terminate employee who is responsible for
breach in security
Used my hands; There were no special

clamps used within the process
Used Vice Grip holding technology from
Toolex. tool which provides a foundation to
use other tools designed by Toolex's Tool
Repair machinery
Toolex' once again provided Vice holding
Technologies to hold the Sorting tool onto the
Waste Depository Bin (4ftx4ft) to help the arm
stay static while sorting through depository for
contamination removal
[sec]
[USD]
240
1.00
2500
10.42
10000
41.67
5000
20.83
3455
14.40
Extinguished Fire. Saved Computers, Data, as well a 2000
8.33
First Retrieved the driver's chipset board, viewed

resistors on board and found one to be fried. The
resistor was then replaced with a new one and
the device began to function to spec.
High Temperature Steel was used in a mold
setting to recreate a new tip for the driver
Vice Holding / Sorting Machine Arm / Human
Power
Used a Phone and made a call. Electrical

Testing equipment used by contractor
Hands, Fire Extinguisher, Fire Saftey
Procedures
Pinging all computers on network to retrieve

and find weaknesses in the system. Located Retrieved Data. All lost data was found and
computer based on those data found. Used saved.
BI department
Retrieved Valuable data concerning the voltage
Contact Applied Energy Solutions (Our Battery
Electrical Engineers ran various tests using regulations for our chip boards in correlation with
partner) and come up with a new solution to a
voltage testers and computer diagnostics
the limits associated with Applied Energy Solution
faulty battery by determining the source
Batteries. Special Batteries were designed
Logistics Department takes a close look at
Found a new shipping route to enhance both
Discovered a route that shaves off 8 hours per
our shipping routes as well as rates to find the
speed and reliability of transporting raw
shipment as well as saves costs by reducing the
most efficient method of retrieving raw
materials
numbers of tolls per route for our vehicles
materials
Discovery of metal source for our tools was
Sent the Raw Materials Back as well as filed Retrieved funding back as well as a proper batch
found and discovered to be a bad batch of Steel
Suit against provider of steel to ensure we do of steel. Relationship was unhurt because of a
due to new employees at the steel Factory we
not suffer a loss because of their neglegence. mutual understanding.
use as a provider of raw Steel
Determined rubber gasket seals at joints of
Used thicker rubber gaskets and torqued
Delivered a tool set that was 100% reliable as
tools to be the culprit. Thicker seals with higher
torque on screws to hold tools together ensured
down screws harder at tool joint points
well as water sealed.
a water-tight performance
6000
25.00
4240
17.67
224
0.93
960
4.00
324
1.35
A
47
B
11
C
Waterproofing Technologies not keeping Water out
of tools
12
Shock Proof Screens Shattering
48
49
50
51
Determined rubber gasket

seals at joints of
D
E
tools to be the culprit. Thicker seals with higher
Used thicker rubber gaskets and torqued
torque on screws to hold tools together ensured
down screws harder at tool joint points
a water-tight performance
Mount for screens within tools were made of a
Went back to the drawing boards to design a
hard resin. This material was replaced with a
better mounting system for the tool's onboard
softer plastic backed by foam surrounds to
display
prevent breakage
F
Delivered a tool set that was 100% reliable as
well as water sealed.
G
324
H
1.35
Tool was now 100% shockproof as long as not

abused or misused.
42
0.18
52
53
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
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
Accumulated
RPN
Risk
Associated
1
2
Copyright by Paul G. Ranky, 1992-2002
3
4
5
6
7
Process Code
Engineering Release Date of Process
8
Methodology
GTT-001
This PFRA Study was Prepared By
Waqar Ahmad
PFRA Team
9
Type of Product Processed
Responsible Organization/ Department
10
Product Group Classifier
Comments
11 Date of the Product

Engineering Release
12
13
Accumulated
Process Cost
14
15
[USD]
16
17
1.00
18
19
20
11.42
21
25
28
31
34
121.65
36
40
Handle disintegrated: risk of electrical shock!
10
ID 1.3
ON / OFF switch separated: risk of electrical failure!
36
ID 2.1
Risk of electrical shock to body
10
40
ID 2.2
Wires exposed
10
200
43
sharp shrapnel from tool chipping off : Risk of bodily harm
45
46
0
0
Contact with waste materials can cause death or sickness
10
0.12,1=100%
0.12,1=100%
0.12,1=100%
96
1.00
1.00
1.00
1.00
96.00
Low
200
1.00
1.00
1.00
1.00
200.00
Low
64
1.00
1.00
1.00
1.00
64.00
Low
20
1.00
1.00
1.00
1.00
20.00
Low
360
1.00
1.00
1.00
1.00
360.00
HIGH
100
1.00
1.00
1.00
1.00
100.00
Low
40
1.00
1.00
1.00
1.00
40.00
Low
20
1.00
1.00
1.00
1.00
20.00
Low
70
1.00
1.00
1.00
1.00
70.00
Low
50
1.00
1.00
1.00
1.00
50.00
Low
600
1.00
1.00
1.00
1.00
600.00
HIGH
20
ID 4.2
ID 4.3
0
Lack of ventilation can cause asphyxiation
10
360
ID 5.2
ID 5.3
0
Risk of Burning down the factory plant as well as life risk
10
10
100
ID 6.2
ID 6.3
ID 7.1
Risk of losing proprietary data.
ID 7.2
Competitors getting a hold of our intellectual property
10
40
0
0
risk of data being used elsewhere
10
20
ID 8.2
ID 8.3
0
risk losing time and customers
70
ID 9.2
ID 9.3
0
risk losing partnering relationship
50
ID 10.2
ID 10.3
ID 11.1
145.60
0.12,1=100%
64
ID 3.3
ID 10.1
144.25
Clamping/
Any Other
Fixturing Skill Factor Factor You
Factor
Define
ID 3.2
ID 9.1
140.25
42
44
ID 1.2
ID 8.1
139.31
39
41
96
ID 7.3
37
38
ID 6.1
96.65
33
35
ID 5.1
88.31
30
32
(1-10)
ID 4.1
73.92
27
29
(1-10)
Heating element separated: risk of burning my hands!
ID 3.1
53.08
24
26
(1-10)
ID 1.1
ID 2.3
22
23
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)
Risk of tools not holding up under rigorous use
10
10
600
47
I
145.60
J
ID 11.2
48
ID 11.3
49
ID 12.1
50
145.77
51
52
53
145.78
54
55
56
145.78
57
58
59
145.78
60
61
62
145.79
63
64
65
145.79
66
67
68
145.80
69
70
71
145.80
72
73
74
145.80
75
76
77
145.81
78
79
80
145.81
81
82
83
145.82
84
85
86
145.82
87
88
89
145.83
90
91
92
145.83
93
94
145.83
O
0
Same as waterproofing risk level
10
10
100
P
600
Q
1.00
R
1.00
S
1.00
T
1.00
U
600.00
V
HIGH
100
1.00
1.00
1.00
1.00
100.00
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
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
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
95
I
145.83
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
145.84
99
100
101
145.84
102
103
104
145.85
105
106
107
145.85
108
109
110
145.85
111
112
113
145.86
114
115
116
145.86
117
118
119
120
121
145.87
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
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)
16
Unit cannot heat: serious hazard!
Unit and system failure!
Visual inspection
Attempt re-assembly
Assembled and tested OK!
17
Danger of electrical shock!
Unit and system failure!
Visual inspection
Attempt re-assembly
Assembled and tested OK
18
Unit cannot be turned ON / OFF
System failure!
Visual inspection
Attempt re-assembly
Assembled and tested OK
19
Can cause death
Tool Failure
Visual inspection
send tool for recycling and part salvage
20
Potential Hazard
Visual inspection
attempt repair
Immediate action needed
visual inspection
send tool for repair
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
21
22
23
24
25
visual inspection
26
27
28
visual inspection
29
30
31
visual inspection
32
33
34
visual inspection
35
visual inspection
36
37
visual inspection
38
39
40
visual inspection
41
42
43
visual inspection
44
45
46
Visual inspection
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
86
87
88
89
90
91
92
93
94
Visual inspection
AA
W
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
100
300
400
500
600
700
0.00
100.00
200.00
300.00
400.00
500.00
600.00
ID 1.1
16
ID 1.2
17
18
ID 1.3
19
ID 2.1
2
ID 2.2
20
21
200
ID 2.3
ID 3.1
22
23
ID 3.2
24
ID 3.3
ID 4.1
25
26
ID 4.2
27
ID 4.3
ID 5.1
28
29
ID 5.2
30
ID 5.3
ID 6.1
31
32
ID 6.2
33
ID 6.3
ID 7.1
34
35
ID 7.2
36
ID 7.3
ID 8.1
37
38
ID 8.2
39
ID 8.3
ID 9.1
40
41
ID 9.2
42
ID 9.3
10
ID 10.1
43
44 ID 10.2
45 ID 10.3
46
11
ID 11.1
ID 11.2
ID 11.3
12
ID 12.1
ID 12.2
ID 12.3
ID 13.1
ID 13.2
ID 13.3
13
700.00
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
AB
AC
ID 11.1
AD
47 ID 11.2
48 ID 11.3
12
ID 12.1
49
50 ID 12.2
51 ID 12.3
52 ID 13.1
13
53 ID 13.2
54 ID 13.3
55 ID 14.1
14
56 ID 14.2
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
AE
11
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
AB
AC
27
95 ID 27.2
96 ID 27.3
97 ID 28.1
98 ID 28.2
28
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
113
114
115
116
117
118
119
120
121
ID 33.1
29
30
31
32
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

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Worksheet in C Users Akanksha Appdata Local Temp Em-636-Assignment-4

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A

Product Name and Appearance Before Process

PFRA Study ID Number

Name of Organization Responsible for the Process

Green Team Technologies

Date of This Study (mm/dd/yy)

Orignal Date of This Study

Product Group Classifier

Engineering Release Date of the Product

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

Specify the Tool(s) Used in Each Process

Specify the Fixtures / Clamps Used in

List / Identify the Parts / Components

Dropped the hair dryer

Used my hands; no special fixtures were

Intelligent Tool Voltage Tester Display showing

Used my hands and disassembled the driver,

Tool's Screw Driver Head chipped

Contacted Partnering Organization (Haimer) to

Contaminated Waste Depository

Fork Lift, Human Hands, Various Sorting

Plant Ventilation Fans Malfunction

Building Electrical Fire

Theft of Proprietary Software and other Intellectual

Tools with Faulty Battery causing shortage

Raw Material Shipping Delay

Tools Degradation Faster than expected

Waterproofing Technologies not keeping Water out

Hired external electrical contractor to determine

Used my hands; There were no special

Extinguished Fire. Saved Computers, Data, as well a 2000

First Retrieved the driver's chipset board, viewed

Used a Phone and made a call. Electrical

Pinging all computers on network to retrieve

Shock Proof Screens Shattering

Determined rubber gasket

Tool was now 100% shockproof as long as not

Copyright by Paul G. Ranky, 1992-2002

This PFRA Study was Prepared By

Responsible Organization/ Department

11 Date of the Product

Handle disintegrated: risk of electrical shock!

ON / OFF switch separated: risk of electrical failure!

Risk of electrical shock to body

sharp shrapnel from tool chipping off : Risk of bodily harm

Risk of losing proprietary data.

Competitors getting a hold of our intellectual property

risk of data being used elsewhere

Heating element separated: risk of burning my hands!

The PFRA Team Describes / Illustrates the Potential Process Failure

Risk of tools not holding up under rigorous use

Same as waterproofing risk level

The Effect of Each Process Step Failure

The Effect of Each Process Step Failure

Recommended Corrective Action(s)

Corrective Action(s) Taken and Date

Unit cannot heat: serious hazard!

Unit and system failure!

Assembled and tested OK!

Danger of electrical shock!