Assignment 3 Pfra

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
Hydrogen Fuel Cell Powered Motercycle
PFRA Study ID Number
Name of Organization Responsible for the Process
Blace Jacobus
Date of This Study (mm/dd/yy)
11/2/2016
Other Organizations Involved in the Process
Orignal Date of This Study
11/2/2016
Process Code
Engineering Release Date of Process
Methodology
Type of Product Processed
10
Subcontractors, process Plants Effected
Revision Number
Rev. 01
Product Group Classifier
11
12
Product Serial Number and Optional Image Map
Comments
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
Specify the Tool(s) Used in Each Process

Step
Specify the Fixtures / Clamps Used in Each

Process Step
17
30
0.13
Examine the eletric motors
Adult human and tire, motor, & breaking

inspection station
Human hand, motercycle holding fixture to

secure to inspection station
45
0.19
Examine fuel cell system
1200
5.00
Examine the break system

inspection station

30
0.13
Examine the regrenative breaking system

inspection station

30
0.13
Examine the eletrical control system
Eletrical Engineer and eletrical testing

equipment
Human hand & multimeter
30
0.13
Examine the accesoriies (headlights, radio,

horn..etc)

equipment
Human hand & multimeter
10
0.04
Examine motercycle frame
Mechanical engineer and frame testing

equipment
Human hand, and fixture to hold motercycle to

frame stress testing equipment
25
0.10
Examine battery

equipment
Human hand, battery load jig & multimeter
35
0.15
10
Examine throttle

equipment
Human hand, battery load jig & multimeter
25
0.10
24
25
27
28
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
[USD]

22
29
[sec]
inspection station
21
26
Process
Cost
Examine the Tires
19
23
Process
Time
18
20
List / Identify the Parts / Components

Retrieved (if any) in Each Process Step
15.00
15
16
Engineering Release Date of the Product
Educated fuel cell speciolist and inspection

equipment
25
0.10
46
47
11
Examine exaust
Adult human
Human hand and exaust checking system
12
Examine body
Adult Human
Human eye
48
49
50
0.00
51
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
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
95
27
0.00
28
0.00
29
0.00
30
0.00
31
0.00
32
0.00
33
0.00
34
0.00
35
0.00
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
Max. RPN
Tooling
Factor
1
2
Copyright by Paul G. Ranky, 1992-2002
Copyright by Paul G. Ranky, 2002 to date
4
5
6
7
Process Code
Engineering Release Date of Process
8
Methodology
9
Type of Product Processed
This PFRA Study was Prepared By
10
Product Group Classifier
Comments
Blace Jacobus
PFRA Team
Responsible Organization/ Department
Assignment 3
11 Date of the Product

Engineering Release
12
13
Accumulated
Process Cost
14
15
0.13
18
0.31
21
5.31
24
28
31
5.69
33
5.73
36
37
38
5.83
39
43
45
10
180
6.08
Clamping/
Fixturing Skill Factor
Factor
Other
Factor:
Accumulated
Design
RPN
Experience
0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100%
243
1.00
0.50
1.00
1.00
121.50
45
1.00
0.50
1.00
1.00
22.50
90
2.00
1.00
2.00
0.20
72.00
180
1.00
0.50
1.00
1.00
90.00
72
1.00
0.50
1.00
1.00
36.00
144
1.50
0.50
1.50
1.00
162.00
224
1.50
0.50
1.50
1.00
252.00
180
1.25
0.50
1.25
1.00
140.63
96
1.00
0.50
1.00
1.00
48.00
144
1.00
1.00
1.00
1.00
144.00
ID 2.1
Motercycle loses power
ID 2.2
Moterclcyle goes into low power mode
45
0
0
ID 3.1
Fuel cell stops produceing energy
64
ID 3.2
fuel cell explodes
10
90
0
Motercycle loses breaks
10
180
ID 4.2
ID 4.3
0
Efficency of the motercycle is reducded
72
ID 5.2
ID 5.3
ID 6.1
Loss of control of motor
144
ID 6.2
Mimimal control of motor or accessories
126
0
ID 7.1
headlights don't work
224
ID 7.2
radio fails
72
ID 7.3
horn fails
96
ID 8.1
Frame brakes under lower than epected stress
10
180
ID 8.2
Frame brakes sooner then expected
10
160
ID 9.1
5.98
42
44
Tire leaves motercycle
ID 8.3
40
41
ID 1.2
ID 6.3
34
35
243
ID 5.1
5.56
30
32
ID 4.1
5.44
27
29
ID 3.3
25
26
(1-10)
ID 2.3
22
23
(1-10)
Tire pops
ID 1.3
19
20
(1-10)
ID 1.1
[USD]
16
17
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)
0
Energy is not stored by regrentive brakeing/loss efficency
96
ID 9.2
ID 9.3
ID 10.1
Can not properly adjust speed
72
ID 10.2
Can not give motor power
144
ID 10.3
Gives to much power
81
I
46
47
6.19
48
52
6.20
54
55
56
6.20
57
58
59
6.20
60
61
62
6.21
63
64
65
6.21
66
67
68
6.22
69
70
71
6.22
72
73
74
6.23
75
76
77
6.23
78
79
80
6.23
81
82
83
6.24
84
85
86
6.24
87
88
89
6.25
90
91
92
93
M
7
N
3
O
126
ID 11.2
Fuel Cell is operateing properly
192
192
1.00
1.00
1.00
1.00
192.00
48
1.00
1.00
1.00
1.00
48.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.60
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
1.00
1.00
1.00
1.00
0.00
ID 12.1
6.19
51
53
L
6
Efficency is properly adjusted
ID 11.3
49
50
J
ID 11.1
6.25
0
Cosmetic blemishes
48
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
J
ID 27.1
6.25
94
95
96
97
98
6.26
99
100
101
6.26
102
103
104
6.27
105
106
107
6.27
108
109
110
6.28
111
112
113
6.28
114
115
116
6.28
117
118
119
120
121
6.29
O
0
ID 27.2
1.00
1.00
1.00
1.00
0.00
ID 27.3
ID 28.1
ID 28.2
1.00
1.00
1.00
1.00
0.00
ID 28.3
ID 29.1
ID 29.2
1.00
1.00
1.00
1.00
0.00
ID 29.3
ID 30.1
ID 30.2
1.00
1.00
1.00
1.00
0.00
ID 30.3
ID 31.1
ID 31.2
1.00
1.00
1.00
1.00
0.00
ID 31.3
ID 32.1
ID 32.2
1.00
1.00
1.00
1.00
0.00
ID 32.3
ID 33.1
ID 33.2
1.00
1.00
1.00
1.00
0.00
ID 33.3
ID 34.1
ID 34.2
1.00
1.00
1.00
1.00
0.00
ID 34.3
ID 35.1
ID 35.2
1.00
1.00
1.00
1.00
0.00
ID 35.3
AA
Risk
Associated
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)
Driver could losse control and crash
Tire/Control relationship critical
Quality inspection
Contact all costomers to prevent further

ingery
a fix to prevent further
Contactand
all issue
costomers
Driver will crash
Tire/Control relationship critical
Quality Inspections
ingery and issue a fix
Driver can no longer operate vehical
Strap/ briefcase hook relationship critical
Quality inspection

Motor will lose power
Quality inspection
Issue a fix and roll out asap
Driver dies
Devistateing to entier company
Quality Inspection
Recall all products
Driver might losse control and crash
Quality inspection

Reduce efficency/ unhappy costomer
More strain on fuel cell
Quality Inspections
Dangerous to costomer
Quality Inspections

ingery and
Contact
all issue
costomers
Vehical Operation will be dangerous
Quality Inspections
Quality Inspections

ingery and
Contact
all issue
costomers
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Low
18
19
20
Low
Immediate action needed
Driver can slowly operate vehical
21
22
23
Low
24
25
26
Low
27
28
29
Low
30
31
32
Low
33
34
35
HIGH
Cause rider discomfert
36
Quality Inspections
37
Motercycle will break and rider will crash
Quality Inspections
Motercycle will break and rider will crash
Quality Inspections
Will require more fule then expected
More strain on fuel cell/ unhappy coustomer Quality Inspections
Quality inspections

ingery
Contactand
all issue
costomers
Quality inspections
Quality inspections
38
Low
ingery
Contactand
all issue
costomers
39
40
41
Low
42
43
44
45
Low
ingery and
Contact
all issue
costomers
V
46
47
Low
W
X
Quality inspections
Contact all costomersZto prevent further

ingery
Contactand
all issue
costomers
Quality inspections
48
49
50
Apearance will be flawed

Low
51
52
53
Low
54
55
56
Low
57
58
59
Low
60
61
62
Low
63
64
65
Low
66
67
68
Low
69
70
71
Low
72
73
74
Low
75
76
77
Low
78
79
80
Low
81
82
83
Low
84
85
86
Low
87
88
89
Low
90
91
92
93
Low
Coustomer will be unhappy with apperiance Quality inspections
Appologize to coustomer and increase

quality control
AA
V
94
95
Low
96
97
98
Low
99
100
101
Low
102
103
104
Low
105
106
107
Low
108
109
110
Low
111
112
113
Low
114
115
116
Low
117
118
119
120
121
Low
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
50
100
150
200
250
15
20
ID 2.3
21
ID 3.2
ID 3.3
ID 4.2
26
ID 4.3
27
ID 5.1
28
ID 5.2
29
ID 5.3
30
ID 6.1
31
ID 6.2
ID 6.3
33
ID 7.1
34
ID 7.2
35
ID 7.3
36
ID 8.1
37
42
ID 4.1
25
41
250.00
ID 3.1
24
40
200.00
22
39
150.00
ID 2.1
ID 2.2
38
100.00
ID 1.2
19
32
50.00
ID 1.3
18
23
0.00
ID 1.1
16
17
300
ID 8.2
ID 8.3
ID 9.1
ID 9.2
ID 9.3
10
ID 10.1
43
ID 10.2
44
ID 10.3
45
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
13
300.00
ID 8.2
ID 8.3
ID 9.1
ID 9.2
ID 9.3
10
ID 10.1
ID 10.2
AB
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
ID 10.3
AC
ID 11.1
AD
ID 11.2
ID 11.3
12
ID 12.1
ID 12.2
ID 12.3
ID 13.1
13
ID 13.2
ID 13.3
ID 14.1
14
ID 14.2
ID 14.3
ID 15.1
15
ID 15.2
ID 15.3
ID 16.1
16
ID 16.2
ID 16.3
64
ID 17.1
65
ID 17.2
66 ID 17.3
67 ID 18.1
17
18
68 ID 18.2
69 ID 18.3
70 ID 19.1
19
71 ID 19.2
72 ID 19.3
73 ID 20.1
20
74 ID 20.2
75 ID 20.3
76 ID 21.1
21
77 ID 21.2
78 ID 21.3
79 ID 22.1
22
80 ID 22.2
81 ID 22.3
82 ID 23.1
23
83 ID 23.2
84 ID 23.3
85 ID 24.1
24
86 ID 24.2
87 ID 24.3
88 ID 25.1
25
89 ID 25.2
90 ID 25.3
91 ID 26.1
26
92 ID 26.2
93 ID 26.3
ID 27.1
27
ID 27.2
ID 27.3
ID 28.1
28
ID 28.2
ID 28.3
ID 29.1
ID 29.2
29
11
AE
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
94 ID 27.1
AB
AC
AD
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
29
30
104 ID 30.2
105 ID 30.3
106 ID 31.1
107 ID 31.2
108 ID 31.3
109 ID 32.1
31
32
110 ID 32.2
111 ID 32.3
112 ID 33.1
113 ID 33.2
114 ID 33.3
115 ID 34.1
116 ID 34.2
117 ID 34.3
118
119
120
121
ID 35.1
ID 35.2
ID 35.3
33
34
35
AE

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Assignment 3 Pfra

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A

Product Name and Appearance Before Process

Hydrogen Fuel Cell Powered Motercycle

PFRA Study ID Number

Name of Organization Responsible for the Process

Date of This Study (mm/dd/yy)

Other Organizations Involved in the Process

Orignal Date of This Study

Subcontractors, process Plants Effected

Product Group Classifier

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 Each

Examine the eletric motors

Adult human and tire, motor, & breaking

Human hand, motercycle holding fixture to

Examine fuel cell system

Examine the break system

Adult human and tire, motor, & breaking

Human hand, motercycle holding fixture to

Examine the regrenative breaking system

Adult human and tire, motor, & breaking

Human hand, motercycle holding fixture to

Examine the eletrical control system

Eletrical Engineer and eletrical testing

Human hand & multimeter

Examine the accesoriies (headlights, radio,

Eletrical Engineer and eletrical testing

Human hand & multimeter

Examine motercycle frame

Mechanical engineer and frame testing

Human hand, and fixture to hold motercycle to

Eletrical Engineer and eletrical testing

Human hand, battery load jig & multimeter

Eletrical Engineer and eletrical testing

Human hand, battery load jig & multimeter

Human hand, motercycle holding fixture to

Examine the Tires

List / Identify the Parts / Components

Engineering Release Date of the Product

Educated fuel cell speciolist and inspection

Human hand and exaust checking system

Copyright by Paul G. Ranky, 1992-2002

Copyright by Paul G. Ranky, 2002 to date

This PFRA Study was Prepared By

11 Date of the Product

0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100%

Motercycle loses power

Moterclcyle goes into low power mode

Fuel cell stops produceing energy

fuel cell explodes

Motercycle loses breaks

Loss of control of motor

Mimimal control of motor or accessories

headlights don't work

Frame brakes under lower than epected stress

Frame brakes sooner then expected

Tire leaves motercycle

The PFRA Team Describes / Illustrates the Potential Process Failure

Can not properly adjust speed

Can not give motor power

Gives to much power