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Climax Company Starch Separation Process Failure Risk Analysis Example - Template created by
2 Analysis Method (Ver. 5) Created by: Matthew Warta, NJIT email: mw269@njit.edu
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7 Product Name and Appearance Before Process Organic Plant Pulp Product
8 Name of Organization Responsible for the Process Climax Company
9 Other Organizations Involved in the Process
10 Subcontractors, process Plants Effected Chemical Vendors, Waste Management
11 Product Serial Number and Optional Image Map
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Describe the Process for Each Process Step and

13 Optionally Illustrate the State of the Device/ Part/ Specify the Tool(s) Used in Each Process
Process ID
Subassembly/ Object AFTER the Process is Step
Complete
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17 Delivered chemical inspection. Check for visible Human eye and inspection wipes. Scanning
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damage to containers and any leaking containers equipment to identify delivered chemicals.
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Chemical transportation and storage. Store in a
2 location with restricted access and ensure Material Human hand and forklift
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Safety Data Sheet procedures are followed
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3 Plant pulp materials delivered Human hand and forklift

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3 Plant pulp materials delivered Human hand and forklift
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26 Tranfer of materials (Pulp & Chemical) for
4 Human hand and pallet jack equipment
processing
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Chemical decomposition equipment, computer
Hazardous chemical transfer and pulp
5 controlled and hazardous waste storage
29 decomposition by-product capture and storage
containers.
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Separation of usable starch material from chemical Starch seperation skimmer equipment,
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32 slurry computer controlled.
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Chemical drying equipment, computer
7 Chemical Drying Process
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Contaminated Chemical/hazardous waste collection Human hand, pallet jacks, fork lifts and
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and storage. hazardous waste containers.
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41 Automated, computer controlled power supplies
9 Baseline testing of finished insulation materials
and electronic test equipment
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10 Transfer of insulation materials to packaging Automated, conveyor belts
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Automated, computer controlled with robotic
11 Final Packaging of Insulation
sealing, conveyor belts
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Automated, computer controlled with robotic
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sealing, conveyor belts
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Hazardous chemical transfer to final Human hand, pallet jacks, fork lifts and
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mitigation/reclaimation/storage facility hazardous waste containers.
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 E F G H I
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alysis Example - Template created by Dr. Ranky's Component-oriented Process Failure Risk
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mail: mw269@njit.edu
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7 PFRA Study ID Number Warta-Climax-7291701 Process Code
Engineering Release Date of Process
8 Date of This Study (mm/dd/yy) 7/29/2017
Methodology
9 Orignal Date of This Study 7/29/2017 Type of Product Processed
10 Revision Number Rev. 1 Product Group Classifier
11 Comments PFRA - Assignment 4 Engineering Release Date of the Product
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Process
13 Specify the Fixtures / Clamps Used in List / Identify the Parts / Components Process Accumulated
Cost
Each Process Step Retrieved in Each Process Step Time Process Cost

14 60.00
15 [sec] [USD] [USD]
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Used Hands with gloves Chemicals received from vendor 300 5.00 5.00
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Chemical storage room, limited access. Follow
Used Hands with gloves 1800 30.00 35.00
20 MSDS

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Used hands with gloves Plant Pult from Vendor 1200 20.00 55.00
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Used hands with gloves Plant Pult from Vendor 1200 20.00 55.00
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26 Used Hands with gloves Plant pult and Chemicals 1800 30.00 85.00
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Used hands with gloves, ceramic coated tools Plant pulp mixed with chemicals, hazardous by-
14400 240.00 325.00
29 for moving contaminated pulp materials product formed from decomposition process

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Skimmers, hands with gloves Decomposed Plup and Chemical Materials 3600 60.00 385.00
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Drying racks, hands with gloves starch material 600 10.00 395.00
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Hazardous waste and hazardouswaste storage
Hands, hazmat equipment 1800 30.00 425.00
facility, limited access.
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41 Hands, pallets, conveyor belt Processed starch materials (insulation) 600 10.00 435.00
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hands with gloves, conveyor belt approved inspected insulation materials 21600 360.00 795.00
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Robotics, conveyor belt isulation materials 300 5.00 800.00
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47 Robotics, conveyor belt isulation materials 300 5.00 800.00
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50 Hands with gloves, pallets, metal straps Hazardous waste by-product 600 10.00 810.00
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 J K L M N O P
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2 Copyright by Paul G. Ranky,

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7 This PFRA Study was Prepared By Matthew Warta
e Date of Process
8 7/29/2017 PFRA Team Matthew Warta / Dr. Ranky
ocessed 9 Starch based insulation product Responsible Organization/ Department Climax, Project Management Team
Green and Sustainable Focus Oriented R
sifier 10 Climax Manufactured Product (CMP) Comments
Analysis
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e Date of the Product 29-Jul-17
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The PFRA Team Describes / Illustrates the Potential Process RPN (Risk
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Failure Mode and the Effect; the Risk of Failure Severity RatingDetection Rating
Occurrence Rating
Priority Max. RPN
Number)
14 Proc.ID Failure Mode(s) and Effect(s)
15 (1-10) (1-10) (1-10)
16 ID 1.1 Products not received - no production 8 10 2 160
17 ID 1.2 Incorrect products - no production 8 10 2 160
160
18 ID 1.3 10 8 1 80
Damaged, leaking, contaminated products - health hazard

19 ID 2.1 No storage room - Unsecured hazardous materials 8 7 3 168

180
20 ID 2.2 Misplaced items - loss of productivity, decreased efficiency 6 5 3 90

21 ID 2.3 Contaminated materials - EPA audit/health concerns 10 9 2 180

22 ID 3.1 Products not received - no production 8 8 3 192

192
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23 ID 3.2 Incorrect products - no production 8 8 3 192
192
24 ID 3.3 8 7 2 112
Damaged incoming product - no production
Spill chemicals - production halted, hazardous chemical clean
25 ID 4.1 10 8 3 240
up
26 ID 4.2 Damage Pulp Containers - loss of productivity 5 5 7 175 240
27 ID 4.3 0

28 ID 5.1 Incorrectly calibrated machinery - loss of product 8 7 5 280

Inability to collect hazardous by-product - hazardous work 280

29 ID 5.2 10 8 1 80
environment
30 ID 5.3 0

31 ID 6.1 Incorrectly calibrated machinery - loss of product 7 7 2 98

Spill chemicals - production halted, hazardous chemical clean 180
32 ID 6.2 up 10 6 3 180
33 ID 6.3 0

34 ID 7.1 Incorrectly calibrated machinery - loss of product 7 7 2 98

Spill chemicals - production halted, hazardous chemical clean 120
35 ID 7.2 10 7 1 70
up
36 ID 7.3 Vapors not properly collected 10 4 3 120
Spill chemicals - production halted, hazardous chemical clean
37 ID 8.1 10 3 1 30
up
38 ID 8.2 Damaged, leaking, contaminated products - health hazard 10 6 3 180
180
39 ID 8.3 Not enough storage - hazardous working environment 10 6 3 180

40 ID 9.1 Incorrectly calibrated test equipment - loss of productivity 5 7 6 210

41 ID 9.2 Incorrect handling - damaged product 6 2 5 60 210
42 ID 9.3 0

43 ID 10.1 Incorrectly calibrated machinery - loss of product 7 7 3 147

336
44 ID 10.2 Incorrect handling - damaged product 6 4 5 120
45 ID 10.3 Excessive dust particle distribution 8 6 7 336
46 ID 11.1 Misaligned equipment - loss of product 7 7 5 245
245
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47 ID 11.2 Incorrect handling - damaged product 6 4 5 120 245
48 ID 11.3 0
49 ID 12.1 Incorrect handling - damaged product 8 4 5 160
50 ID 12.2 hazardous waste spill - EPA audit and facility closure 10 6 3 180 180
51 ID 12.3 Damaged, leaking containers - evnironmetal contamination 10 8 2 160
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 Q R S T U V W
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Matthew Warta 7
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Matthew Warta / Dr. Ranky
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Climax, Project Management Team
Green and Sustainable Focus Oriented Risk
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Analysis
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13 Clamping/ Any Other

Tooling Accumulated Risk The Effect of Each Process Step Failure
Fixturing Skill Factor Factor You
Factor RPN Associated Risk on Other Processes
Factor Define
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15 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100%
16 Production Process delayed
17 Production Process delayed
1.00 1.00 1.00 1.00 160.00 Low
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Production Process delayed

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Safety issues
1.00 1.00 1.00 1.00 180.00 Low
20 Production Process delayed
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Safety issues and loss of productivity
22 Production Process delayed

1.00 1.00 1.00 1.00 192.00 Low

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23 Production Process delayed
1.00 1.00 1.00 1.00 192.00 Low
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Production Process delayed
25 Un-met production schedule
26 1.00 1.00 1.00 1.00 240.00 HIGH Schedule and cost
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Schedule and cost
1.00 1.00 1.00 1.00 280.00 HIGH
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Safety issues
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Schedule and cost
1.00 1.00 1.00 1.00 180.00 Low
32 Safety issues and loss of productivity
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Schedule and cost
1.00 1.00 1.00 1.00 120.00 Low
35 Un-met production schedule
36 Safety issues
37 Safety, shcedule, major cost
38 Safety and major cost
1.00 1.00 1.00 1.00 180.00 Low
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Safety issues
40 Schedule and major cost impact
41 1.00 1.00 1.00 1.00 210.00 HIGH Schedule and cost
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Schedule and cost
1.00 1.00 1.00 1.00 336.00 HIGH
44 Schedule and cost
45 Safety issues
46 Schedule and major cost impact
1.00 1.00 1.00 1.00 245.00 HIGH
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47 1.00 1.00 1.00 1.00 245.00 HIGH Schedule and cost
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49 Schedule, time, major cost, customers
50 1.00 1.00 1.00 1.00 180.00 Low Schedule, time, major cost, customers
51 Schedule, time, major cost, customers
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 X Y Z
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13 The Effect of Each Process Step Failure

Risk on Other Parts (I.e. components/
objects)
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16 Loss of time, money and product
17 Loss of time, money and product
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Loss of time, money and product
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Loss of time, money and product
20 Loss of time, money and product
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Loss of time, money and product
22 Loss of time, money and product
Detection Mode
Receiving Department
Receiving Department
Receiving Department
Material Safety Department
Material Safety Department
Material Safety Department
Receiving Department
Recommended Corrective Action(s)
Email/phone calls to vendor
Email/phone calls to vendor
Document, email/phone vendor, contact
on-site hazmat trained team
Inventory audits. Review of storage facility
and improve inventory management
systems and techniques
Inventory auditscommunication with
Open effective
Vendor / warning system to alert for
potential hazards
Email/phone calls to vendor
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23 Loss of time, money and product
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Loss of time, money and product
25 Loss of time, money and product
26 Loss of time, money and product
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Loss of time, money and product
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Loss of time, money and product
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Loss of time, money and product
32 Loss of time, money and product
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Loss of time, money and product
35 Loss of time, money and product
36 Damage to environment
37 Loss of time, money and product
38 Loss of money and product
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Loss of time, money and product
40 Loss of time, money and product
41 Loss of time, money and product
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Loss of time, money and product
44 Loss of time, money and product
45 damage to environment
46 Loss of time, money and product
Receiving Department
Receiving Department
Operations Engineering
Operations Engineering
Operations Engineering & Equipment
Calibration
Operations Engineering
Operations Engineering & Equipment
Calibration
Material Safety Department
Operations Engineering & Equipment
Calibration
Operations Engineering
Material Safety Department
Material Safety Department
Material Safety Department
Material Safety Department
Testing Engineering & Equipment
Calibration
Testing Engineering
Operations Engineering & Equipment
Calibration
Operations Engineering
Manufacturing Engineering
Manufacturing Engineering
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Email/phone calls to vendor
Document damaged product, email/phone
calls to vendor
Document, contact on-site hazmat team.
Training
Perform periodic callibration and audits
Perform periodic callibration and audits
Perform
Documentperiodic callibration
and contact and
on-site audits
hazmat
team
Perform periodic callibration and audits
Document, contact on-site hazmat team.
perform periodic callibration and audits
Document, contact on-site hazmat team.
Document, contact on-site hazmat team.
Inventory audits. Review of storage facility.
Better material management or build lager
facility.
Perform periodic callibration and audits
Training
Perform periodic callibration and audits
Training
perform periodic callibration and audits
Perform periodic callibration and audits
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47 Loss of time, money and product Manufacturing Engineering Training
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Document and contact on-site hazmat
49 damage to environment Material Safety Department team
Document and contact on-site hazmat
50 damage to environment Material Safety Department team
Document and contact on-site hazmat
51 damage to environment Material Safety Department team
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 AA AB AC
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0 50 100 RPN 150

for Each200Failure250
Mode 300 350 400
13 Corrective Action(s) Taken and Date
(mm/dd/yr) ID 1.1

14 ID 1.2
15 ID 1.3
16 Phone Call to Vendor
ID 2.1
17 Phone Call to Vendor
ID 2.2
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ID 2.3

19 ID 3.1

ID 3.2
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ID 3.3
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Immediate action needed ID 4.1
22 Phone Call to Vendor
ID 4.2

ID 4.3

ID 5.1

ID 5.2
 ID 3.1

ID 3.2

ID 3.3

ID 4.1
AA AB AC
ID 4.2
23 Phone Call to Vendor
ID 4.3
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ID 5.1
25 Immediate action needed
26 Immediate action needed ID 5.2

27 ID 5.3

28 ID 6.1
Immediate action needed
ID 6.2
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Immediate action needed
ID 6.3
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ID 7.1
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ID 7.2
32 Immediate action needed
33 ID 7.3

34 ID 8.1
immediate action needed
35 immediate action needed ID 8.2
36 Immediate action needed ID 8.3
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ID 9.1
38 Immediate action needed
ID 9.2
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ID 9.3
Immediate action needed
40 ID 10.1
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ID 10.2
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ID 10.3
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ID 11.1
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ID 11.2
45 Immediate action needed
46 Immediate action needed ID 11.3

ID 12.1

ID 12.2

ID 12.3
 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

ID 11.2

AA ID 11.3 AB AC
47 ID 12.1
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ID 12.2
49 Immediate action needed
50 Immediate action needed ID 12.3
51 Immediate action needed
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 AD AE
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0 50 Accumulated
100 RPN
150 for Each Failure
200 250 Mode
300 350 400
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AD AE
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AD AE
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