Assignment 4
Process Failure Risk Analysis
Author: Hardik Bharatkumar Gala
Class code: IE673 live
Date: November 11, 2011
eLearning Pack ID : IE 673-Fall 2011-60-35
Statement: All contents of this assignment were submitted by Hardik Gala
Updated Notes:
Dr. Paul G. Ranky’s Comment: In your Assignment 4, I would like to see more discussion on what you actually advise your team to do with the data you have obtained as a result of the PFRA calculations. Please read the syllabus again and explain your results in more depths.
At present 6/10
Grade: 6/10
Action Taken by Me: I have updated this assignment with data I have obtained as a result of PFRA calculations.
Contents:
· Introduction and objectives
· Brief description of methodologies applied
· Main body of project
· Risky, unsustainable processes identified in full length videos
· Panorama navigation map
· Summary
· Further work required
· References
Introduction and objectives:
Process-related failure risk analysis method belongs to the family of failure mode and effect analysis (FMEA) methods, and is part of our TQM and Six-Sigma approach. It represents a systematic, rule-based, quantitative and open-source computational method developed by Ranky first for disassembly (DFRA), and then for other processes (PFRA) to identify and minimize potential failure risks, and / or failures of processes in general, including disassembled sub-assemblies, objects and components, and their effects on the customer. PFRA is a Team Oriented Problem Solving (TOPS) method, aimed at minimizing dissatisfaction, and financial loss for process related failure risks. PFRA is applied during the planning stages of a process, and then updated on a regular basis to document changes.
Our approach is component-oriented, meaning that as we analyze and decompose the product / process (based on our object-oriented process modeling method, CIMpgr), or as we disassembly the product, and review the DBOM (Disassembly Bill Of Materials) file, the DFRA team focuses on each subassembly and then the components.
The objective of this assignment is to identify the risks associated with certain failure modes in RNR, using the Process Failure Risk Analysis (PFRA) method. This method will help identify the riskiest process. Once the process is identified, corrective action can be taken to eliminate or mitigate that process. Using this PFRA method, any sort of additional risks can be identified.
Brief description of methodologies applied:
There are 7 key aspects of this generic methodology. They are
1. Define, scope, function and purpose:
It defines the system or sub-system, or any product, or process (including service) design to be analyzed.
2. Identify potential failure risks and failure modes and their effects:
This means that by applying the PFRA technique during the process, and creating, or analyzing the existing BOM (Bill of Material) file, the team should be able to gradually deepen the product, process or system design analysis and locate all potential failures at the earliest possible stage.
3. Prioritize potential failures:
This means that all faults should be ranked and critical quality, or cost, or safety related faults should be located and eliminated by the cross-functional team as early as possible.
4. Select and manage subsequent actions:
This aspect of PFRA means, that in cases in which the risk of potential failures is high, following our basic TQM principles, an immediate control plan must be devised and subsequent actions should be taken to control the situation.
5. Observe and learn:
For each system or product/process design, PFRA / DFRA represent a dynamic, living knowledge-managed document that needs to be kept up-to-date.
6. Document the process:
Team stores the PFRA / DFRA contained information in a widely accessible format (preferably, both electronically, such as our spreadsheet and optionally on paper based media) for the current as well as for future teams.
7. Enter the values into the PFRA/DFRA spreadsheet on a relative scale:
This is determined by the local PFRA / DFRA Team, as well as by the local, customized standards they follow.
Such rating values and standards are industry wide, enabling teams to compare data, and learn from each other. In order to support this standardization process for the disassembly industry, we have included three important files in our DFRA / PFRA software tool, which are hyper linked to the spreadsheet too.
These being the rating rules, regarding
1. Severity: Severity is a rating corresponding to the seriousness of the effect(s) of a potential failure mode. Severity applies only to the effect of a failure mode. The purpose of establishing a value of process severity is to be able to quantify the seriousness of failing during one or more process steps.
For simplicity, and in compliance with basic statistical rules, the value range for severity rating is set between 1 and 10, where 1 is least severe, and 10 is most severe.
2. Detection: Detection is a rating corresponding to the likelihood that the currently executed process controls will detect the failure mode before the part/ subassembly/ component leaves the workstation/ cell/ line, responsible for the process in question. Note, that such process controls can be visual inspection, machine inspection/ test, or others.
The process controls are considered in terms of the likelihood of detecting the failure mode and carry a rating value of 1 to 10, where 1 is assigned if it is 'almost certain' that the failure mode will be detected, and 10, if it is 'almost impossible' that the process controls will detect the failure mode. (Note, that the value of 10 is also assigned if there are no formal (i.e. well defined) process controls available, as it is the case in many operations/ processes.
3. Occurrence: Occurrence, in terms of process failure risk analysis, is a rating corresponding to the rate at which a first level cause and its resultant failure mode will occur under currently employed process controls. The rate of occurrence (of each first level cause) is estimated by the process analysis team, and/or in more complex cases calculated based on statistical evidence, that is either based on reliable, collected (e.g. historical) and analyzed data, or on generated. The values we enter into a PFRA / DFRA (Disassembly Failure Risk Analysis) spreadsheet are on a relative scale, determined by the local PFRA Team, as well as by the local, customized standards they follow. Often, such rating values and standards are industry wide, enabling teams to compare data, and learn from each other.
Severity rating is the most important rating of the three. The rating is from 1-10. A rating of 1 means that, that process is least severe and a rating of 10 means that, that process is the most severe.
Main body of project
Identifying a risky process is an essential step for maintaining the quality of products. Recycling involves a lot of processes. These processes are analyzed and the risks are identified.
The processes which are analyzed and following failure modes are identified:
· Inspection of raw materials from collaborative companies
· Designing plastic products using the CGI scanner software
· Sorting the plastic according to their Resin Identification Code and also by color
· Shredding plastic, removing impurities and molding the plastic to usable form
· Finishing of the products
· Labeling and packaging
· Quality control
The risks involved are explained as follows. The raw materials collected from the collaborating companies have to be inspected before processing it. Any unwanted material is been discarded. The software is used to design the products keeping the customer requirements in mind. Then the plastic is sorted according to Resin Identification Code. Before recycling the plastic it has to shred and impurities are removed and then it is molded to usable form. Then the products are labeled and finally given to quality control.
All these processes have some kind of failure mode. They need to be analyzed properly. This is done using PFRA spreadsheet.
PFRA spreadsheet(Click here to view the spreadsheet)
Analysis of chart:
If the Risk Priority Number is more than 200 the process will be shown as a risk. The RPN is calculated based on severity, detection and occurrence rating. Based on the rating process 5 is shown to have risk.
Any process which has an RPN number of less than 200 is considered to be at a lower risk. But any process which has an RPN of more than 150 also needs attention, so process 2 and 3 need attention too. But before this process is addressed, it is important to address those processes which are at a higher risk. Severity rating is also given a lot of importance. Any process which has a severity rating of ten needs immediate attention too. This rating indicates possible hazardous/dangerous effect.
Process Improvement:
Process 5 is the process with the highest RPN. This process is of finishing of the products before labeling and packing. This process includes sprayers and checking for dimensions. The sprayer has to coat the surfaces uniformly. The speed at which liquid is let out of sprayers is the most important factor. The nozzles have to be checked and cleaned regularly. They should not be clogged. The other factor is of dimension mismatch. The dimensions should be according to the users. If there are changes in dimensions the product would not be acceptable. Thus all this work should be documented to eliminate any errors related to the equipment.
Panorama navigation map
Panorama navigation map is a tool which displays the 360 degree view of an image. It reproduces the image in a live format. It allows us to view the place even though we are not physically present. All the minute details can be viewed.
This tool will be very useful when set up in the industries. All the work can be performed sitting in the office only. There will not be any need to physically go and see the machines. This method will save a lot of time. All the levels of management can watch the processes in the industry.
It can prove as a boon to all the industries. It provides an excellent view. Any mistake been done can be rectified easily with this tool. It will allow the management to take decisions quickly without even being on site.
Risky, Unsustainable Processes Noted in the Full Length Videos
AISIN-Auto Components:
Customization provided by the company in the engines can be faulty sometimes. If the gear ratio is faulty the car will not run properly. It can even burn more fuel thus leading to pollution. It could even lead to fatal accidents thus endangering life. The parking assist system if fails to detect any obstacle under its range it may lead the car to crash in that obstacle thus dents the car. If the display meter shows wrong reading of the place available for parking the car, it could lead to the car going over the footpath or other obstacle near it while parking.
ALT-Energy sources:
The risks identified here are transportation of hydrogen to the fuel stations. It is very dangerous to transport hydrogen from one place to another. If there even a small amount of leakage it can lead to an explosion. So we need to be very cautious while transporting hydrogen. It is an expensive form of fuel. So it may happen that it would not be feasible for all customers to buy hydrogen powered vehicles.
Antigua island tour:
The first risk identified is the dock yard. It could be very dangerous in a flood situation. If it rains a lot or there is some oceanic currents which could lead to flow of water in high speeds could destroy the yards. This will also destroy all the transport going on through the docks. The other risk identified is the ropeway. It should be checked properly for the rope. The rope should not be weared out.
Atlantic City:
The risk identified here in that if any kind of dangerous impurity is not removed in the purification process and if the water is let in the oceans it could harm the flora and fauna of the ocean.
Baumer Electric:
The risky process identified here is the measurement of ground clearance. The distance from the ground to the tires should be measured properly. If it is not the computer will set the gear ratios wrong and the car will not run properly. The other risk is that if the tire is over heated, it will change the gear ratios drastically which will again lead to faulty running of the car.
Bentley- Quality design:
Bentley is a leading luxury car manufacturer. Finding risks in the car produced by them is very difficult. The risks identified could be precision issues with the mirrors and other parts.
BOSH-ESP-ABS:
The risk identified in this video is if the ABS fails the car would not be able to take a sharp turn and thus crash in the nearby car or the divider of the road. This could lead to fatal accidents. The other risk is about traction control technique. It calculates wheel spin and matches it with the drivers steering capability. If any of the readings are miscalculated it could lead in crash.
Car wash:
The whole process is fully automated so we should take care that all the steps are done in order. If any re ordering is done risk is that the car would not be washed properly. The other risk is that water should be sprayed thoroughly after applying foam. If foam stays on the tires it could be slippery and will be difficult for the driver to control the car on turns.
ChemEng-Proc-Siemens:
This video shows like machines like pressure transmitter, temperature transmitter used for safety applications. The risks are wrong readings and thus mis-calculations done due to that. This could lead to changes in threshold value thus malfunctioning the whole process.
COGNEX vision inspect:
It describes a machine vision system for zero defect focused visual factories. The risks involved here are if the camera readings are taken wrong it will give wrong output result. If the camera is damaged it will not give readings and thus will halt the process.
Continental TEVES ESP:
This video shows the testing of the ESP i.e. electronic stability program installed in cars. The ESP helps cars in better breaking. Any problem in ESP, the car will not be able to break properly. This will create hazards for the driver.
Summary
This assignment uses the PFRA tool to analyze the risks and also provides for preventive measures to eliminate those risky processes. Thus use of this will help us to produce a green and sustainable product thus increasing customer satisfaction.
Further work required
The risky processes should be taken into consideration as soon as possible and company should try to remove any kind of risks involved. RNR suggests its collaborative companies to inculcate the PFRA technology in their manufacturing units in order to minimize risks and failures thus yielding greener products.
References
1. Ranky P.G. PhD, IE 673 Total Quality Management Fall 2011 eLearning Pack ID: IE673-Fall2011-60-35
2. http://www.transtech.com/index.php
3. http://www.contrinex.ch/defaultCountry.asp?idSite=101&langage=1
4. http://www.mitsuiseiki.com/
5. http://www.wildrepublic.com/WildRepDefault.aspx
