Canon Lens Pfra

A
Design, manufacturing and packaging Process Failure Risk Analysis Example, with a Sustainable Green Engineering Focus, Using Ranky's
Component-oriented Process Failure Risk Analysis Method (Ver. 5) by Abhiram Sridhara and Professor Paul G. Ranky, PhD, NJIT/MERC, Email:
ranky@njit.edu
2
3
4
5
6
7
Product Name and Appearance Before Process
Manufacturing of Canon lens
PFRA Study ID Number
EM-636 Summer 2015
Process Code
Name of Organization Responsible for the Process
Imaginary Motion Pictures
Date of This Study (mm/dd/yy)
7/26/2015
Engineering Release Date of Process Methodology
Other Organizations Involved in the Process
Collaborative Companies
Orignal Date of This Study
7/26/2015
Type of Product Processed
10
Subcontractors, Process Plants Effected
Pdn, Bell-howell, Haimer
Revision Number
Rev. 1
Product Group Classifier
11
12
Product Serial Number and Optional Image Map
EM 636-Summer-2015-34-28
Comments
Customer feedback
Engineering Release Date of the Product
13
14
Describe the Process for Each Process Step

Process
and Optionally Illustrate the State of the
ID
Device/ Part/ Subassembly/ Object AFTER the
Process is Complete
Specify the Tool(s) Used in Each

Process Step
Specify the Fixtures / Clamps Used List / Identify the Parts / Components in Each
in Each Process Step
Process Step
15
Process
Time
Per item
Process
Cost
[sec]
[USD]
[USD]
30000
100.00
100.00
Accumulated
Process Cost
86.53
16
1
Design
Human & machine
Human Hand, tools and computers
Design-Frame and shape
Melting and Pressing Glass
Machine
Manufacturing tools
Melting
600
14.42
114.42
Rough Grinding of Glass
Machine
Manufacturing tools
Rough Grinding
30
0.72
115.14
Precision Grinding
Machine
Manufacturing tools
Precision Grinding
30
0.72
115.86
Polishing
Machine
Manufacturing tools
Polishing
300
7.21
123.07
Cleaning
Human & machine
Manufacturing tools
Cleaning
1000
24.04
147.11
Process Inspection
Human & machine
Human Hand & Computers
Inspection
30
0.72
0.72
117
Centering and Cleaning
Human & machine
Manufacturing tools
Cleaning
30
16.00
16.00
118
Compounding
Machine
Manufacturing tools
Compounding
45
32.00
32.00
17
19
21
22
23
25
26
27
28
29
30
31
32
114
115
116
B
10
Coating
120
11
Jointing/Shipping inspection
Human & machine
121
12
Packing
Human & machine
119
D
Machine
E
Manufacturing tools
Coating
G
50
H
12.00
I
12.00
Human Hand, tools and computers
inspection
20
5.00
5.00
Human Hand,Machine & Computers
Packing
20
3.00
3.00
1
2
3
4
5
6
7
8
Release Date of Process Methodology
Canon lens Manufacturing
This PFRA Study was Prepared By
Abhiram Sridhara
7/26/2015
PFRA Team
Abhiram Sridhara, Prof. Paul Ranky
Responsible Organization/ Department Imaginary Motion Pictures

Safety, customer satisfaction and risk-based green engineering
Comments
design
uct Processed
Canon lens
up Classifier
10
Abhiram Sridhara
11
Release Date of the Product
12
13
14
7/26/2015
The PFRA Team Describes / Illustrates the Potential Process Failure

RPN (Risk
Mode and the Effect; the Risk of Failure
Severity Rating
Detection Rating
Occurrence Rating
Priority
Number)
Proc.ID
Failure Mode(s) and Effect(s)
15
16
ID 1.1
17
ID 1.2
19
21
22
ID 2.1
Instructions
notdo
followed
correctly
Audio
devices
not work
correctly
ID 3.1
Instructions not followed correctly
23
ID 3.2
25
ID 4.1
26
ID 4.2
27
ID 5.1
28
ID 5.2
29
ID 5.3
30
ID 6.1
31
32
ID 6.2
ID 6.3
(1-10)
(1-10)
(1-10)
80
10
200
7
10
10
7
2
7
5
1
5
245
20
350
200
10
70
63
10
250
180
Max. RPN
Tooling
Factor
Lack of
Accumulated
Clamping/ Fixturing Factor Skill Factor Attention to
RPN
Detail
Risk
Associated
0.12,1=100%
0.1-2,1=100%
200
1.00
1.00
1.00
1.00
200.00
Low
245
1.00
1.00
1.00
1.00
245.00
HIGH
350
1.00
1.00
1.00
1.00
350.00
HIGH
70
1.00
1.00
1.00
1.00
70.00
Low
250
1.00
1.00
1.00
1.00
250.00
HIGH
180
1.00
1.00
1.00
1.00
180.00
Low
112
1.00
0.50
1.10
1.20
73.92
Low
0.1-2,1=100% 0.1-2,1=100%
Missing parts
114 ID 7.1
115 ID 7.2


10
180
10
10
8
7
2
2
160
140
108
10
40
116 ID 7.3
112
117 ID 8
10
160
118 ID 9
162
J
119 ID 10
K
L
6
M
10
N
2
O
120
120 ID 11
121 ID 12
90
10
80
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)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Process delayed; can't continue with

production until ready
Direct measurable effect
Operations Engineering Department
Operations
Engineering Department
Testing
Engineer
Inform manager and people in charge of

inventory
Inform the
assembly team
worker
to fix the for
Contact
engineering
responsible
condition
the
wings
Audit to ensure proper use of robots
Cost impact
Perform regular checks to ensure proper

use and condition of robots
25

Inventory Control

inventory
26
Design Problem of body
Engineering Team
27

Inventory Control

inventory
Late Delivery
Testing Engineer
Inform Engineering Team/ Testing
Immediate action needed
Late Delivery
Improve engineering/assemble of wings
Engineering Team
Dissassemble and fix

quality unsattisfied

Improve engineering/assemble of engine

Quality Control
Engineering Team
Quality Engineer
Major cost impact
Operations Department
Perform regular audits to ensure proper

use of material handling devices
Major cost impact
Shipping and Handling Department
Delivery personnel training/instructions
17
19
21
22
23
28
Process delayed; customer not going to

receive product on time
production
ready
Later when until
testing
it will not work
Inform the assembly worker to fix the body
Email / phone calls
50
100
RPN 150
for Ea
ID 1.1
Email / phone calls
ID 4.1
ID 4.2
29
30
31
32
114
115
ID 5.3
ID 6
panel of technicians
116
117
118
ID 6.3
W
119
120
121
AA
AB
AC
AD
AE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
50
100
RPN 150
for Each200Failure250
Mode
300
350
400
0.00
50.00
Accumulated
100.00
150.00
RPN for
200.00
Each250.00
Failure300.00
Mode 350.00
ID 1.1
17
ID 1.2
19
21
22
ID 2.1
23
ID 3.1
25
ID 3.2
26
4
ID 4.1
27
ID 4.2
28
ID 5.1
29
ID 5.2
30
ID 5.3
31
32
114
115
116
117
118
ID 6.1
ID 6.2
ID 6.3
400.00
AB
119
120
121
AC
AD
AE

Canon Lens Pfra

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Canon Lens Pfra

Enviado por

Direitos autorais:

Formatos disponíveis

A

Product Name and Appearance Before Process

Manufacturing of Canon lens

PFRA Study ID Number

EM-636 Summer 2015

Name of Organization Responsible for the Process

Imaginary Motion Pictures

Date of This Study (mm/dd/yy)

Engineering Release Date of Process Methodology

Other Organizations Involved in the Process

Orignal Date of This Study

Type of Product Processed

Subcontractors, Process Plants Effected

Pdn, Bell-howell, Haimer

Product Group Classifier

Product Serial Number and Optional Image Map

Engineering Release Date of the Product

Describe the Process for Each Process Step

Specify the Tool(s) Used in Each

Human & machine

Human Hand, tools and computers

Design-Frame and shape

Melting and Pressing Glass

Rough Grinding of Glass

Human & machine

Human & machine

Human Hand & Computers

Centering and Cleaning

Human & machine

Human & machine

Human & machine

Human Hand, tools and computers

Human Hand,Machine & Computers

Canon lens Manufacturing

This PFRA Study was Prepared By

Abhiram Sridhara, Prof. Paul Ranky

Responsible Organization/ Department Imaginary Motion Pictures

The PFRA Team Describes / Illustrates the Potential Process Failure

Instructions not followed correctly

Instructions not followed correctly

Instructions not followed correctly

Instructions not followed correctly

Instructions not followed correctly

Instructions not followed correctly

Instructions not followed correctly

Instructions not followed correctly

Instructions not followed correctly

The Effect of Each Process Step Failure

The Effect of Each Process Step Failure

Recommended Corrective Action(s)

Corrective Action(s) Taken

Process delayed; can't continue with

Direct measurable effect

Operations Engineering Department

Direct measurable effect

Operations Engineering Department

Direct measurable effect

Inform manager and people in charge of

Direct measurable effect

Operations Engineering Department

Audit to ensure proper use of robots

Direct measurable effect

Operations Engineering Department