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QSE

Quality Systems Engineering Pipe Fixture

Master Original Date: 5/4/03

QSE

Title page

Prototype Pre launch Pre-launch Production Production

Part Number:

546876413 - 165468469465468

Enter header data for all documents from one place. Track revision and status history.

Flow Number: 123456 123456 123456

Revision:

Status:

1.3 1.3 1.3

Controlled Controlled Controlled

Core Team:

Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis,

FMEA Number: Control Plan Number:

Part Numbers & Rev Level: 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3) , 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3) QSE suggests putting all Header information in this field so the no header view can be printed using less pages per printout. Model: Key Date: Responsible Engineer:

Master Revision Date History 9/27/03 5/4/04 9/14/05

Master Revision Status Controlled Controlled Controlled 1.1 1.2 1.3

Master Revision Level

Person Responsible

Jim Bim Jackson Mississippi April Somebody

Printed on

08/19/06

© 2000/2006 All Rights Reserved Quality Systems Engineering @ 810-499-1015

QSE

CHARACTERISTICS FAILURE WORKSHEET

Quality Systems Engineering

Data entered populates the Flow, FMEA and the Control Plan.

Responsible Engineer: Brighton Key Date: Jack Joseph 810-499-1015 11/17/03 Prepared By: Original Date: 05/27/05 Initial RPN Pp Ppk Cp Cpk Specification and/or Tolerances Operator must Insure Material Label is correct. Potential Failure Mode(s) Potential Effects of Failure S e v Potential Cause(s) Mechanism(s) of Failures O c c FMEA Number: 7778 Page 1 2003

QSE

Part Name: Part Number: Model Year(s) Vehicle(s): Core Team: EC Level

Counter

Title Page 546876413 - 165468469465468 B-4589

of

2

Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis, IV Function ID Operation Description Receiving Receiving / Incoming Material Verification Receiving Inspection Receiving / Incoming Material Transfer Position Part On Pallet EC Status

Put Anything

Sandra Werwega Revision Date: 900 Final RPN 09/03/05 703 Int D RPN e t Risk 7 63 A

EC Date 09/15/05 User types info of choice Characteristics GD&T 1a Put Anything 2a Part ID condition Put Anything Product Process

Row No Process ID Op ID 1 A Op005 2 A Op005 3 3 2 1

PCID

Class *

Current Process Controls Prevention / Detection Purchasing (Provides supplier with correct specs). Material Handling / Non-Conforming Procedure

000-0000-000

Missing, Wrong Incorrect Label On 3 or Unreadable Container, PRR Written Label

B Op010 4 4

Step 1 Drill Drill Hole On Front Side

C Op011 5 5

Step 1 Drill Drill Hole On Front Side

C Op011 6 6

3 First 8 columns flow backwards to the Parts Proper Position 000-0000-000 using Due Care. Put Process Flow and Forwards to all Anything other documents. Locations ? 3a Storage Material Handler 6 Forks Not SpecificationCaution backwards to theMount Part, goes Damaged Part Impairs Operation Flow, Must Use Cannot Adjusted Part Condition Damage Part, Scrap Properly During forwards to the FMEA's (requirements) as Put Parts. Transport Anything well as the Control Plan and many others 4a Hole No 401 5.680 - 7.433 Off Location No Assembly, Rework 5 Wrong CNC where it is applicable. Program Hole Location All blue text fields populate Put Anything the FMEA's, up to the 5a 0.0025 Out of Round Leaks, Safety 10 * Improper Circularity of recommended Actions. Setup Issue,Rework, Impairs Machine Hole Part Placed in Hopper Jams Damage Parts Scrap Put Anything

3 Supplier Audits. Wrong parts Class popup lets users FIFO. shipped Tags verify drag and drop symbols. User is able to create 2 Training in Part Improper symbols of choice. AIAG Loading of Part Loading. Tags verify FIFO. symbols are included. 3 Training in Part Loading.

8

48 L

P

Visual Inspection 8

144 H

P

1 Training, SWI

Gage 2 Parts after every Tool Change

3

15 L

N

7 Training, SWI

Step 1 Drill Drill Hole On Front Side

6a Put Anything

C Op011 7 7

Step 1 Drill Drill Hole On Front Side

C Op011 8 8

Step 1 Drill Drill Hole On Front Side

GD&T symbols popup. A simple Pass 7a First drag and dropDepth of Hole to Put place symbols in Anything 8a documents. Final Pass

Diam of Hole Put Anything

First Pass Diam of Hole

Severity, Occurrence and Detection scales 2.224 +/- 0.20 Diam too Wide Impairs next operation, attachment giving user rework, scrap part scale definitions popup. Scales are user 15.434 +/- 0.20 Depth too Rework Impairs Next defined and Shallow can be Operation Loss Of Assembly Srap Parts edited at anytime.

3.823 +/- 0.20 Diam too Wide Impairs next operationLoss of Assembly Srap parts

Next Operation

Auto stop if the Tool Holder is not Properly seated. Automatic Spindle Lube System.

4

280 H

D

10

PQC

Premature Tool Wear

3 S.W.I. PM

5

150 H

P

5

SC

Improper Speed Setting

3 S.W.I. PM

Inspect First Part 7 After any D Abnormal Occurrence. Gage [email protected] start of every shift 5

105 H

5

FF

C Op011 9 C Op011 9

Improper Machine Setup

3 S.W.I. PM

75 A

P

Step 1 Drill Drill Hole On Front Side

9a Put Anything

Final Pass Depth of Hole

Thru

Depth too Shallow

Part will not Assemble, Scrap.

5

Incomplete Cycle

2 S.W.I. PM

Gage [email protected] start of every shift

2

20 L

N

Printed on

10/14/05

High Risk

Average Risk

Low Risk

Revision: 1.3

Status: DRAFT

© 2005 All Rights Reserved Quality Systems Engineering @ 810-499-1015

Process Flow user can select from 4 layouts.

QSE

Process Flow Diagram

QUALITY SYSTEMS ENGINEERING

Flow Number:

QSE

112749 02/02/05 Revision Date: Rob Bescoe Sandra Werwega 09/22/05

Part Name: Part Number: Model Year(s) Vehicle(s): EC Level

Counter

Pipe Fixture 546876413 - 165468469465468 B-4589 EC Status 2003 Brighton Original Date: Responsible Engineer: Prepared By:

IV

EC Date 09/15/05

Row No Process ID Op ID 1 1 Op005 A 2 2 Op005 A 3 3 Op010 B 4 4 Op011 C 5 5 Op011 C 6 6 Op011 C 7 7 Op011 C 8 8 Op011 C 9 9 Op011 C 10 10

Put Anything All Titles of documents, field names in headers and columns can be changed. User types info of choice

Function ID Operation Description Receiving Receiving / Incoming Material Verification Receiving Inspection Receiving / Incoming Material

GD&T Risk

Flow Symbols

PCID Put Anything 1a Put Anything

Characteristics Product Process 000-0000-000

Pp

Cp

Class *

Ppk

Cpk

Specification and/or Tolerances Operator must Insure Material Label is correct.

A

Part ID condition Put Anything 000-0000-000

Cut paste drag/drop symbols. 2a

L Put Anything

Part Placed in Proper Position using Due Care.

Transfer Position Part On Pallet

Step 1 Drill Drill Hole On Front Side

H Colored text showing data flow. First two 3a columns are common information in all Put Hole No 401 documents. Can be changed in any Anything Hole Location L document, changes are reflected in all 4a documents. Put Anything 5a H Circularity of Hole *

Storage Locations ? Part Condition

Material Handler Must Use Caution

5.680 - 7.433

Step 1 Drill Drill Hole On Front Side

0.0025

Step 1 Drill Drill Hole On Front Side

Put Anything 6a H

First Pass Diam of Hole

PQC

2.224 +/- 0.20

Step 1 Drill

Drill Hole On Front Side

Put First down SC Change symbol definitions with easy to edit drop Pass tables. Anything Depth of Hole 7a H

15.434 +/- 0.20

Step 1 Drill Drill Hole On Front Side

Put Anything 8a A

Final Pass Diam of Hole

FF

3.823 +/- 0.20

Step 1 Drill Drill Hole On Front Side

Put Anything 9a L

Final Pass Depth of Hole

Thru

528a 11 11 529a 12 12 530a 13 13 531a 14 14 532a

Printed on

10/10/05

Packaging

Inspection

Operation

Transfer

Storage

Rework

Page 1 of

2

© 2005 All Rights Reserved Quality Systems Engineering @ 810-499-1015

Status: Controlled

Revision: 1.1

Text has been colored showing data flow from one document to the other.

QSE

Process Flow Details

QUALITY SYSTEMS ENGINEERING

Flow Number:

QSE

112749 02/02/05 Revision Date: Rob Bescoe Sandra Werwega Pp Risk Class * Cp Cpk 09/22/05

Part Name: Part Number: Model Year(s) Vehicle(s): EC Level

Counter

Pipe Fixture 546876413 - 165468469465468 B-4589 EC Status 2003 Brighton Original Date: Responsible Engineer: Prepared By:

Put Anything

IV

EC Date 09/15/05

ROW NO PROCESS ID OP ID 1 A Op005 1

User types info of choice Characteristics Product Process

Ppk Specification and/or Tolerances Operator must Insure Material Label is correct.

Function ID Operation Description Receiving Receiving / Incoming Material Verification

Picture Flow

PCID GD&T 1a

Put Anything

000-0000-000 Part ID condition

A 2a Put Anything Part Placed in Proper Position using Due Care.

2 A Op005

2

Receiving Inspection Receiving / Incoming Material

Symbol field is replacedPut Anything 000-0000-000 with an object box...paste pictures,sound, L Quicktime movie, link to other files or programs....users choice.

3a

Put Anything

3 B Op010

3

Transfer Position Part On Pallet

Storage Locations ? Part Condition H

Material Handler Must Use Caution

4 C

Op011

4

Step 1 Drill

Drill Hole On Front Side

4a

Put Anything

Hole No 401

Hole Location

5.680 - 7.433

L

5 Step 1 Drill Drill Hole On Front Side

5 C

5a

Put Anything

Circularity of Hole

*

0.0025

Op011

6a

Put Anything

H 6 Step 1 Drill Drill Hole On Front Side PQC 2.224 +/- 0.20

6 C Op011

First Pass Diam of Hole

H 7 Step 1 Drill Drill Hole On Front Side 7a

Put Anything

7 C Op011

First Pass Depth of Hole

SC

15.434 +/- 0.20

H 8 Step 1 Drill Drill Hole On Front Side 8a

Put Anything

8 C Op011

Final Pass Diam of Hole

FF

3.823 +/- 0.20

A 9 Step 1 Drill Drill Hole On Front Side 9a

Put Anything

9 C Op011

Final Pass Depth of Hole L

Thru

10

10

528a

11

11

529a

12

12

530a

Printed on 10/10/05 © 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015 Revision: 1.1 Status: Controlled Page 1 of 2

QSE

Part Name: Part Number: Model Year(s) Vehicle(s): Core Team: EC Level IV Pipe Fixture 546876413 - 165468469465468 B-4589

PROCESS POTENTIAL FAILURE MODES AND EFFECT(S) ANALYSIS

QUALITY SYSTEMS ENGINEERING

Responsible Engineer: Brighton Key Date: Jack Joseph 810-499-1015 11/17/03 Prepared By: Original Date: FMEA Number: 7778 Page 1 2003

QSE

of

3

Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis, EC Status EC Date 09/15/05 Potential Failure Mode(s) Put S Anything e v Class 3 *

Running totals of initial and final RPN's

Initial RPN 900 Final RPN 703 D Int e t RPN 7 63 O c c Current Process Controls Prevention / Detection

Sandra Werwega 05/27/05 Revision Date: Actions Results 09/03/05

Counter Function ID Row No Operation Description GD&T Process ID Requirements Op ID

Potential Effects of Failure

Potential Cause(s) Mechanism(s) of Failures Wrong parts shipped

1

1

A Op005

Receiving Receiving / Incoming Material Verification

Operator must Insure Material Label is correct.

Missing, Wrong Incorrect Label On Container, PRR or Unreadable Written Label

3 Supplier Audits. Tags Purchasing (Provides verify FIFO. supplier with correct specs).

Put Anything Hopper Jams Damage Parts Scrap Parts 3 Improper Loading of Part Put Anything Damaged Part Impairs Operation Cannot Mount Part, Damage Part, Scrap Parts. 6 Forks Not Adjusted Properly During Transport Put Anything Off Location No Assembly, Rework 5 Wrong CNC Program Put Anything Out of Round Leaks, Safety Issue,Rework, Impairs Next Operation 10 * Improper Machine Setup 7 Training, SWI 3 Training in Part Loading. 2 Training in Part Loading. Tags verify FIFO.

2

2

A Op005

Receiving Inspection Receiving / Incoming Material

Part Placed in Proper Position using Due Care.

User selects from drop down for Severity, Occurrence and Detection / Material Handling Non-Conforming ratings.

Procedure

Recommended Actions None

Target Date Responsible:

Completion Date Actions Results

S e v 3 A

O c c 3

D e Final t RPN 7 63

3

3

B Op010

Transfer Position Part On Pallet

Material Handler Must Use Caution

Visual FMEA AIAG Process Inspection scales are included as well as option for user defined scales.

1 2 3 8 4 P 5 6 7 8 8 P 9

Calculates initial and final RPN

48 Schedule Training in Job Procedures. Implement Preventive Maintenance. 06/20/05 Process Engineer 07/01/05 Training completed 2-1-2004. Posted PM Schedule. 3 L 2 5 30 No

100%

144 Revise Visual Aids & Schedule Training . Implement marking tags

02/15/05 Supervisor Henry / 222

02/20/05

5 H

4

6

120 No 22 10%

Select from drop down of percent complete

5 Process Engineer L 1 3

4

4

C Op011

Step 1 Drill Drill Hole On Front Side

5.680 - 7.433

1 Training, SWI

Gage 2 Parts after every 3 Tool Change

15

None

15 35

N

5

5

C Op011

Step 1 Drill Drill Hole On Front Side

0.0025

Auto stop if the Tool Holder is not Properly seated.

4

Characteristic Failure Worksheet populates the FMEA up to the recommended Actions.

6 6 C Op011 Step 1 Drill Drill Hole On Front Side

2.224 +/- 0.20

Put Anything PQC

D

280 Go/No Go Gage 2 08/02/05 Process Parts @ Each Setup. Implement Engineer Preventive Maintenance.

10 6 Posted PM Schedule and implemented gauging 2 parts per shift 08/04/05 Posted PM Schedule and implemented gauging two parts per shift H

4

240 Yes 44 30%

Diam too Wide

Impairs next operation, rework, scrap part

10

Premature Tool Wear

3 S.W.I. PM

Automatic Spindle Lube 5 System.

Put Anything Depth too Shallow Rework Impairs Next 5 Operation Loss Of Assembly Srap Parts SC Improper Speed Setting 3 S.W.I. PM Inspect First Part After any Abnormal Occurrence.

N

150 Go/No Go Gage 2 06/02/05 Process Parts per shift. Engineer Implement Preventive Maintenance.

10 2 H

4

80 No

100%

7

7

C Op011

Step 1 Drill Drill Hole On Front Side

15.434 +/- 0.20

7

Put Anything

D

105 Go/No Go Gage 2 08/15/05 Process Parts per shift. Engineer Implement Preventive Maintenance.

5 H

3

5

75 Yes 31 60%

Printed on

10/10/05

High Risk

Average Risk

Low Risk

Revision: 1.3

Status: DRAFT

© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015

QSE

Prototype Part Number: Pre launch Pre-launch Production Latest Change Level:

PROCESS CONTROL PLAN

Quality Systems Engineering

Key Contact: Key Contact Phone: Supplier Plant Appr Date: Supplier Code: EC Status EC Date 09/15/05

Put Anything

QSE

Control Plan Number: Original Date: Supplier Phone: Revision Date: Cus Eng Approval Date: Cus Quality Appr Date: Other Approval Date: 112749 06/27/05 07/03/05 ? ? ?

Jack Pieron - 1-810-499-1015

546876413 - 165468469465468 Pipe Fixture

Part Description: Supplier / Plant: EC Level IV

Core Team: Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis,

ROW NO PROCESS ID OP ID 1 1

Function ID Operation Description Receiving Receiving / Incoming Material Verification Receiving Inspection Receiving / Incoming Material Transfer Position Part On Pallet

Machine, Device, Jigs, Tools for Mfgr PCID Automatic Conveyor

User types info of choice Characteristics Product Process 000-0000-000 Part ID condition

Special Class Risk * A Pp Ppk Cp Cpk Specification and/or Tolerances Operator must Insure Material Label is correct.

GD&T 1A

Put Anything

Evaluation Measurement & Technique In Process Instructions Template In Process Instructions #45895

Sample Size and Frequency Audit 4 Samples per lot.

Control Methods Concern No Colored Tags - Log Sheet

Responsible: Reaction No Recieving Inspector 005

A Op005 2 2

Print with or without Cp data.

Part Placed in Proper Position using Due Care.

A Op005 3 3

Automatic Conveyor

2A

Put Anything

Put Anything 000-0000-000

100% On Going

L

Colored Tags - Log Sheet # 6778

Operator 006

B Op010 4 4

Automatic Conveyor

3A

Put Anything

Storage Locations ? Part Condition

H

Material Handler Must Use Caution

In Process Instructions #45795

100% On Going

Enter on Log Sheet

Operator 006

Step 1 Drill

Control Plan is populated up to the EvaluationNo 401 Measurement (Gage & Number) when the Characteristics Worksheet is completed. Hole

789 Machining Center #1 4A 5.680 - 7.433 Hole Location

Put Anything

C Op011 5 C Op011 6 6 5

Drill Hole On Front Side

L

Plug Gage #272549

Gage 2 Parts after every Tool Change

X & R Bar Chart

Operator 005

Step 1 Drill Drill Hole On Front Side

Machining Center #1

5A

Put Anything

Circularity of Hole

* H First Pass Diam of Hole PQC H First Pass Depth of Hole SC H

0.0025

100% Set-up Plug Gage #272549

X & R Bar Chart

Production Operator

C Op011 7 7

Step 1 Drill Drill Hole On Front Side

Machining Center #1

6A

Put Anything

2.224 +/- 0.20

Plug Gage #272549

1 Part per Shift Change

X & R Bar Chart

Production Operator

C Op011 8 C Op011 9 9 8

Step 1 Drill Drill Hole On Front Side

Machining Center #1

7A

Put Anything

15.434 +/- 0.20

Plug Gage #272549

2 @ the beginning and end of each lot. Gage 2 Parts per Shift

X & R Bar Chart

Process

Step 1 Drill Drill Hole On Front Side

Machining Center #1

8A

Put Anything

Final Pass Diam of Hole

FF A

3.823 +/- 0.20

X & R Bar Chart

Process

Plug Gage #272549

C Op011

Step 1 Drill Drill Hole On Front Side

Machining Center #1

9A

Put Anything

Final Pass Depth of Hole

Thru L

Plug Gage #272549

2 @ start of every shift

X & R Bar Chart

Process

Printed on 10/10/05

High Risk

Average Risk

Low Risk

Revision: 1.2

Status: Controlled

© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015

Page 1 of 2

Number is referenced in the last column of the Control Plan.

QSE

Reaction Plan Number

Reaction Plans

USER TYPES COMPANY NAME

QSE

005

Low

Reaction Description INTERNAL GEAR QS-9000 Requirements Procedure must be setup for the control of Non conforming Receiving Product (Element 4.13). Must be identified and in specified area (Element 4.8 Inspection Product Identification & Traceability). Supervisor contacts supplier, is held accountable (have a corrective action in place Element 4.14). Receiving Inspection If new material is unacceptable notify supervisor or setup person. Cease operation until suspect parts are removed or are being sorted. If parts are in the system inform the supervisor so that they can be contained. Supervisor will determine a Text boxes the test fit course of action based onshrink to results. Non conforming parts are separated and returned to supplier. Operator reports serious concerns to Team Leader, who accesses the problem to determine course of action. The team leader appoints a problem solving team to the problem for evaluation and recommendations. It is the responsibility of the Team Leader to implement recommended actions and insure action results are recorded on Process FMEA. Operator stops the machine and notifies supervisor of suspect part. Supervisor contacts preventive maintenance team leader to access the problem and make recommendation.

010

High

011

Low

Sub-Assembly

012

Average

Sub-Assembly

Printed on: 09/26/2005

© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015

Page

1

of

1

Process Overview has multiple views (with Header data) this is an example of the No Header view.

QSE

Part Description: All Documents

Row No Process ID Op ID

Process Overview

Pipe Fixture

Control Plan

QSE

Part Number: 546876413 - 165468469465468 Control Plan Int Current Process Controls Prevention / Detection Supplier Audits. Tags verify FIFO. Purchasing (Provides supplier with correct specs). RPN Final 63 Gage Name & Number Control Methods Sample Size and Frequency In Process Instructions

Responsible:

QUALITY SYSTEMS ENGINEERING

Process Flow, Control Plan Specification and/or Tolerances Potential Failure Mode(s) Potential Effects of Failure Incorrect Label On Container, PRR Written Process FMEA Potential Cause(s) Mechanism(s) of Failures Wrong parts shipped

Function ID Operation Description

Receiving

Put User types info of choice Anything Machine, Pp Cp Device, Jigs, PCID Characteristics Tools for Mfgr Product Process Ppk Cpk GD&T Class

Reaction No Concern No Recieving Inspector 005

1 1 A Op005 2 2 A Op005 3 3 B Op010

Receiving / Incoming Material Verification

Receiving Inspection

Automatic Conveyor

1A

000-0000-000 Part ID condition

*

Put Anything

Operator must Missing, Insure Material Wrong or Label is correct. Unreadable Label

A Template Colored Tags - Log Sheet 63 Audit 4 Samples per lot. In Process Instructions

Automatic Conveyor

2A

Receiving / Incoming Material

Transfer

Put Anything 000-0000-000

Put Anything

Hopper Jams Part Placed in Proper Position using Due Care.

Damage Parts Scrap Parts

Improper Loading of Part

Training in Part Loading. Tags verify FIFO.

Material Handling / Non-Conformi ng Procedure

48

P

L #45895 Colored Tags - Log Sheet 30 100% On Going

Operator 006 # 6778

Position Part On Pallet

Automatic Conveyor

3A

Storage Locations ? Part Condition

A combination of all documents. AllHandler Damaged Training in Forks Not Material fields are populated from other documents. Information Impairs Visual Part Must Use Operation can be changed in this document...changes will be reflected inAdjusted Properly Part Loading. Inspection all documents. Caution Cannot Mount During Transport

Put Anything

Part, Damage Part, Scrap Parts. 5.680 - 7.433 Off Location No Assembly, Rework Wrong CNC Program Training, SWI

144 In Process Instructions H #45795 120 Enter on Log Sheet 100% On Going

Operator 006 789

P

4 4 C

Op011

5 5 C

Step 1 Drill

Drill Hole On Front Side

Machining Center #1

4A

Hole No 401 Hole Location

Put Anything

Gage 2 Parts after every Tool Change

15

Plug Gage

L

15

#272549 X & R Bar Chart

Gage 2 Parts after every Tool Change

Operator 005

N

0.0025 Out of Round Leaks, Safety Issue,Rework, Impairs Next Operation Improper Machine Setup Training, SWI

Auto stop if the Tool Holder is not Properly seated. Automatic Spindle Lube System.

Step 1 Drill

Drill Hole On Front Side

Machining Center #1

5A

Circularity of Hole

*

Op011

6 6 C Op011 7 7 C Op011 8 8 C Op011

Step 1 Drill Step 1 Drill Step 1 Drill

Put Anything

280 Plug Gage H #272549 240 X & R Bar Chart 100% Set-up

Production Operator

D

Drill Hole On Front Side

Machining Center #1

6A

First Pass Diam of Hole

PQC

2.224 +/- 0.20

Diam too Wide

Put Anything

Impairs next operation, rework, scrap part

Premature Tool Wear

S.W.I. PM

150 Plug Gage H #272549 X & R Bar Chart 80 1 Part per Shift Change

Production Operator

N

Drill Hole On Front Side

Machining Center #1

7A

First Pass Depth of Hole

SC

15.434 +/- 0.20

Depth too Shallow

Put Anything

Rework Impairs Next Operation Loss Of Assembly Srap Parts Impairs next operationLoss of Assembly Srap parts

Improper Speed Setting

S.W.I. PM

Inspect First Part After any Abnormal Occurrence.

105 Plug Gage H #272549 X & R Bar Chart 75 2 @ the beginning and end of each D lot. 75 A Plug Gage

Process Engineer

Drill Hole On Front Side

Machining Center #1

8A

Final Pass Diam of Hole

FF

3.823 +/- 0.20

Diam too Wide

Improper Machine Setup

S.W.I. PM

Gage [email protected] start of every shift

Put Anything

P

#272549 X & R Bar Chart 60 Gage 2 Parts per Shift

Process Engineer

Status and Revision Number are user defined.

Printed on 10/10/05 Modified 3:08:31 AM 10/10/05 High Risk Average Risk Low Risk © 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015 Status: Controlled Revision: 1.2 Page 1 of 2

QSE

RISK EVALUATION REPORTS

Current RPN Report Title:

Total RPN's per Process ID

ENTER TARGET

Target Count of All RPN's Ideal RPN

40

40

9 360

Initial RPN Total Final RPN Total Difference

834 678 -156

Ideal RPN Final RPN Difference

360 678 318

Difference Between Ideal and Actual

This icon will take user back to this screen. Make sure your target value is correct before running RPN

Target RPN

This icon will sort Final RPN's from Highest to Lowest.

Sort RPN

This icon will take user to the chart file user is able to link any chart to this file for common reporting. Default charts are in this file, user must have excel to use them.

RPN

RPN REPORT DEFINITIONS

Choice Total RPN's

Automatic reporting gives user choice of reports, user must select report and click the preview button to see the report (1) Subtotals RPN per operation number and includes a grand total. (2) Subtotals RPN per Process ID number and includes a grand total. It will show the weakest and strongest RPN's per process. The RPN reporting documents have a "Clear Title" button so user can Sort/Find and print reports of their choice.

Choice Summary

User must select report and click the preview button to see this report, this is an automatic summary report. This report is a useful tool when making a graph of the totals per operations. This report should be printed per month and the totals kept separate. Later the team can compare the totals per month, year etc. showing process improvement results overtime. This is an automatic RPN Report showing only the top five, giving the team the highest risk is per process. Before clicking the icon "Top 5 RPN's" user must click the "FindAll" and the "Clear Title" buttons. The "Top 5 RPN's can be seen in all documents. Click the SortSet button to perform sorts of five records. User can go to this form (layout) to see details of severity, occurrence and detection. Good report format for editing and identifying risk . Special reports can be created by user, all other reports will reflect these sorts.

Top 5 RPN's

Risk Management

Overview of Failures

User can click on icons to see reports in this form (layout) and/or run other reports of their choice. A nice tracking tool for sorting by causes or characteristics.

Printed on 09/20/05

© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015

QSE

RPN SPECIAL RPN REPORTS

REPORT ON ALL RPN'S ABOVE 100

QUALITY SYSTEMS ENGINEERING

Target Count of All RPN's Ideal RPN

QSE

40

3 120

Initial RPN Total Final RPN Total Difference

529 465 -64

Ideal RPN Final RPN Difference

Flow Number: Original Date: 02/02/05

120 465 345

112749 Revision Date: Rob Bescoe Sandra Werwega Completion Int Final RPN 09/22/05

Part Name: Part Number: Model Year(s) Vehicle(s): ECN Level ROW NO Process ID OP ID 1 B 3 IV

Pipe Fixture 546876413 - 165468469465468 B-4589 ECN Status 225 2003 Brighton

Responsible Engineer: Prepared By:

ECN Date 09/15/05 Effects Causes

Function Description Failure Mode Transfer Position Part On Pallet

Recommended Actions Responsible: Actions Taken

Target Date No

Impairs Operation Cannot Mount Revise Visual Aids & Schedule Training . Part, Damage Part, Scrap Parts. Implement - Gauging 2 parts per shift. Forks Not Adjusted Properly During Transport

144 120

Op010

Damaged Part Supervisor - Henry / 222

Feb 20, 2005 Feb 15, 2005

10% 2 C 5 Step 1 Drill Drill Hole On Front Side Leaks, Safety Issue,Rework, Impairs Next Operation Go/No Go Gage 2 Parts @ Each Setup. Implement Preventive Maintenance. Posted PM Schedule and implemented gauging 2 parts per shift Yes

280 240

Op011

Improper Machine Setup Out of Round Process Engineer

Aug 2, 2005

40% 3 C 7 Step 1 Drill Drill Hole On Front Side Rework Impairs Next Operation Loss Of Assembly Srap Parts Go/No Go Gage 2 Parts per shift. Implement Preventive Maintenance. Yes

105 105

Op011

Improper Speed Setting Depth too Shallow Process Engineer

Aug 15, 2005

60%

REPORT ON ALL RPN'S ABOVE 100

TOTAL FINAL

529 465

Printed on 09/20/05 High Risk Average Risk Low Risk

© 2005 All Rights Reserved Quality Systems Engineering @ 810-499-1015

Page 1 of 1

QSE

FMEA Number: Part Name: Part Number: Pipe Fixture 546876413 - 165468469465468 7778

RPN Risk Management, RPN Details

Quality Systems Engineering

Control Plan Number: Prepared By: Responsible Engineer: Target

QSE

112749 Sandra Werwega Jack Joseph 810-499-1015

RPN TOTALS PER OPERATION ID

OP ID

ROW NO PROCESS

40

Total Ideal RPN's

360

Initial

Total Actual RPN's

678

Final S O D

Difference Ideal / Actual

318

Final

RPN

Special Op005

Operation Description

Receiving

Potential Failure Mode(s)

Missing, Wrong or Unreadable Label

Potential Cause(s) Mechanism(s) of Failures

Wrong parts shipped

Initial D

RPN Percent

Target Date Completion

Responsible:

None

Recommended Actions

S

O

1 1 A 2 2 A

Receiving / Incoming Material Verification Op005

Receiving Inspection

3

Improper Loading of Part Process Engineer Schedule Training in Job Procedures. Implement Preventive Maintenance.

3

8

72

48 3 2 8

Hopper Jams

Receiving / Incoming Material

3

2

8

48

100%

3

2

5

Jun 20, 2005 Jul 1, 2005

30

No

Op005

3 3 B Op010

Transfer

120

Damaged Part Position Part On Pallet Forks Not Adjusted Properly Supervisor - Henry / During Transport 222 Revise Visual Aids & Schedule Training . Implement - Gauging 2 parts per shift.

78

5 4 6 Feb 15, 2005 Feb 20, 2005 120

No

6

3

8

144

10%

Op010

4 4 C 5 5 C 6 6 C 7 7 C 8 8 C 9 9 C Op011

Step 1 Drill

144

Step 1 Drill

120

15 5 1 3

Op011

Off Location

Wrong CNC Program

Process Engineer

None

Drill Hole On Front Side Op011

Step 1 Drill

5

Out of Round Improper Machine Setup Process Engineer Go/No Go Gage 2 Parts @ Each Setup. Implement Preventive Maintenance.

1

3

15

Drill Hole On Front Side Op011

Step 1 Drill

10

7

4

280

40%

10

6

4

Aug 2, 2005

240

Yes

Diam too Wide

Premature Tool Wear

Process Engineer

Drill Hole On Front Side Op011

Step 1 Drill

Go/No Go Gage 2 Parts per shift. Implement Preventive Maintenance.

5

3

5

75

100%

5

2

4

Jun 2, 2005 Aug 4, 2005

40

No

Depth too Shallow

Improper Speed Setting

Process Engineer

Drill Hole On Front Side Op011

Step 1 Drill

Go/No Go Gage 2 Parts per shift. Implement Preventive Maintenance.

5

3

7

105

60%

5

3

7

Aug 15, 2005

105

Yes

Diam too Wide

Improper Machine Setup

Drill Hole On Front Side Depth too Shallow Incomplete Cycle

Process Engineer Rob Bescoe EXT: 276 Process Engineer

Implement Preventive Maintenance.

5

None

3

5

75

100%

5

3

4

May 17, 2005 Aug 19, 2005

60

No

Drill Hole On Front Side

5

2

2

20

N/A

20 5 2 2

Op011

570

480

Printed on 9/20/2005 High Risk Average Risk Low Risk Revision: 1.3 Status: Draft

© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015

Page 1 of 2

QSE

Summary of RPN's

Quality Systems Engineering

Monday, September 19, 2005

QSE

RPN Totals per Operation ID

Target

Part Name: Part Number: ECL: III

75

Pipe Fixture 546876413 - 165468469465468 ECL# 225 ECN Date: 03/02/03

FMEA Number: Original Date: 02/02/03

7778 Revision Date: Rob Bescoe Sandra Werwega 09/22/03

Responsible Engineer: Prepared By:

Total RPN's 2 1 6 9

Process ID

Operation Description Op005 Op010 OP011 GRAND TOTALS

Receiving / Incoming Material

Initial RPN 120 144 570 834

Final RPN 78 120 480 678

Total RPN's

Difference Ideal / Actual

A B C

Position Part On Pallet

675

3

Printed on

09/19/05

© 2004 All Rights Reserved - Quality Systems Engineering @ 810-499-1015

QSE

QUALITY SYSTEMS ENGINEERING INC.

QSE

Risk Priority Measurements

TOTAL RPN'S PER OPERATION

Project Totals

High Risk Priority Average Risk Low Risk

450 400 350 300

700 600 500

250

400

200

300 200 100 0

OP010 OP020 OP030 OP040 OP050 OP060

150 100 50 0 Pipe Fixture Door Fixture Quarter Panel Fixture Rear Door Fixture Luggage Fixture

450 400 350

350 300

Risk Reporting Risk Reporting per Operation

Number of Failure Modes

300 250 200 150 100 50

250 200 150 100 50 0

0 Part 1 Part 2 Part 3 Part 4 Part 5

10

20

30

40

50

60

70

80

90

100

© 2004All Rights Reserved - Quality Systems Engineering 1-810-499-1015

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