You are on page 1of 21

A B C D

1
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
3
4
5
6
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
12

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
14
15
16
17 Delivered chemical inspection. Check for visible Human eye and inspection wipes. Scanning
1
damage to containers and any leaking containers equipment to identify delivered chemicals.
18

19
Chemical transportation and storage. Store in a
2 location with restricted access and ensure Material Human hand and forklift
20
Safety Data Sheet procedures are followed
21

22

3 Plant pulp materials delivered Human hand and forklift


A B C D
23
3 Plant pulp materials delivered Human hand and forklift
24

25
26 Tranfer of materials (Pulp & Chemical) for
4 Human hand and pallet jack equipment
processing
27

28
Chemical decomposition equipment, computer
Hazardous chemical transfer and pulp
5 controlled and hazardous waste storage
29 decomposition by-product capture and storage
containers.
30

31
Separation of usable starch material from chemical Starch seperation skimmer equipment,
6
32 slurry computer controlled.
33

34
Chemical drying equipment, computer
7 Chemical Drying Process
35 controlled.
36
37
38
Contaminated Chemical/hazardous waste collection Human hand, pallet jacks, fork lifts and
8
and storage. hazardous waste containers.
39

40
41 Automated, computer controlled power supplies
9 Baseline testing of finished insulation materials
and electronic test equipment
42

43
10 Transfer of insulation materials to packaging Automated, conveyor belts
44
45
46
Automated, computer controlled with robotic
11 Final Packaging of Insulation
sealing, conveyor belts
A B C D
Automated, computer controlled with robotic
47 11 Final Packaging of Insulation
sealing, conveyor belts
48
49
Hazardous chemical transfer to final Human hand, pallet jacks, fork lifts and
50 12
mitigation/reclaimation/storage facility hazardous waste containers.
51
52
53
54
55
E F G H I
1
alysis Example - Template created by Dr. Ranky's Component-oriented Process Failure Risk
2
mail: mw269@njit.edu
3
4
5
6
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
12

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]
16
17
Used Hands with gloves Chemicals received from vendor 300 5.00 5.00
18

19
Chemical storage room, limited access. Follow
Used Hands with gloves 1800 30.00 35.00
20 MSDS

21

22

Used hands with gloves Plant Pult from Vendor 1200 20.00 55.00
E F G H I
23
Used hands with gloves Plant Pult from Vendor 1200 20.00 55.00
24

25
26 Used Hands with gloves Plant pult and Chemicals 1800 30.00 85.00
27

28
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

30

31
Skimmers, hands with gloves Decomposed Plup and Chemical Materials 3600 60.00 385.00
32
33

34
Drying racks, hands with gloves starch material 600 10.00 395.00
35
36
37
38
Hazardous waste and hazardouswaste storage
Hands, hazmat equipment 1800 30.00 425.00
facility, limited access.
39

40
41 Hands, pallets, conveyor belt Processed starch materials (insulation) 600 10.00 435.00
42

43
hands with gloves, conveyor belt approved inspected insulation materials 21600 360.00 795.00
44
45
46
Robotics, conveyor belt isulation materials 300 5.00 800.00
E F G H I
47 Robotics, conveyor belt isulation materials 300 5.00 800.00
48
49
50 Hands with gloves, pallets, metal straps Hazardous waste by-product 600 10.00 810.00
51
52
53
54
55
J K L M N O P
1

2 Copyright by Paul G. Ranky,

3
4
5
6
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
11
e Date of the Product 29-Jul-17
12

The PFRA Team Describes / Illustrates the Potential Process RPN (Risk
13
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
J K L M N O P
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
J K L M N O P
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
52
53
54
55
Q R S T U V W
1

3
4
5
6
Matthew Warta 7
8
Matthew Warta / Dr. Ranky
9
Climax, Project Management Team
Green and Sustainable Focus Oriented Risk
10
Analysis
11
12

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
14
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
18
Production Process delayed

19
Safety issues
1.00 1.00 1.00 1.00 180.00 Low
20 Production Process delayed
21
Safety issues and loss of productivity
22 Production Process delayed

1.00 1.00 1.00 1.00 192.00 Low


Q R S T U V W
23 Production Process delayed
1.00 1.00 1.00 1.00 192.00 Low
24
Production Process delayed
25 Un-met production schedule
26 1.00 1.00 1.00 1.00 240.00 HIGH Schedule and cost
27

28
Schedule and cost
1.00 1.00 1.00 1.00 280.00 HIGH
29
Safety issues
30

31
Schedule and cost
1.00 1.00 1.00 1.00 180.00 Low
32 Safety issues and loss of productivity
33

34
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
39
Safety issues
40 Schedule and major cost impact
41 1.00 1.00 1.00 1.00 210.00 HIGH Schedule and cost
42

43
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
Q R S T U V W
47 1.00 1.00 1.00 1.00 245.00 HIGH Schedule and cost
48
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
52
53
54
55
X Y Z
1

3
4
5
6
7
8
9
10
11
12

13 The Effect of Each Process Step Failure


Risk on Other Parts (I.e. components/ Detection Mode Recommended Corrective Action(s)
objects)
14
15
16 Loss of time, money and product Receiving Department Email/phone calls to vendor
17 Loss of time, money and product Receiving Department Email/phone calls to vendor
18 Document, email/phone vendor, contact
Loss of time, money and product Receiving Department on-site hazmat trained team
Inventory audits. Review of storage facility
19 and improve inventory management
Loss of time, money and product Material Safety Department systems and techniques
20 Loss of time, money and product Material Safety Department Inventory auditscommunication with
Open effective
21 Vendor / warning system to alert for
Loss of time, money and product Material Safety Department potential hazards
22 Loss of time, money and product Receiving Department Email/phone calls to vendor
X Y Z
23 Loss of time, money and product Receiving Department Email/phone calls to vendor

24 Document damaged product, email/phone


Loss of time, money and product Receiving Department calls to vendor
25 Loss of time, money and product Operations Engineering Document, contact on-site hazmat team.
26 Loss of time, money and product Operations Engineering Training
27

28 Operations Engineering & Equipment


Loss of time, money and product Calibration Perform periodic callibration and audits
29
Loss of time, money and product Operations Engineering Perform periodic callibration and audits
30

31 Operations Engineering & Equipment


Loss of time, money and product Calibration Perform
Documentperiodic callibration
and contact and
on-site audits
hazmat
32 Loss of time, money and product Material Safety Department team
33

34 Operations Engineering & Equipment


Loss of time, money and product Calibration Perform periodic callibration and audits
35 Loss of time, money and product Operations Engineering Document, contact on-site hazmat team.
36 Damage to environment Material Safety Department perform periodic callibration and audits
37 Loss of time, money and product Material Safety Department Document, contact on-site hazmat team.
38 Loss of money and product Material Safety Department Document, contact on-site hazmat team.
Inventory audits. Review of storage facility.
39 Better material management or build lager
Loss of time, money and product Material Safety Department
Testing Engineering & Equipment facility.
40 Loss of time, money and product Calibration Perform periodic callibration and audits
41 Loss of time, money and product Testing Engineering Training
42

43 Operations Engineering & Equipment


Loss of time, money and product Calibration Perform periodic callibration and audits
44 Loss of time, money and product Operations Engineering Training
45 damage to environment Manufacturing Engineering perform periodic callibration and audits
46 Loss of time, money and product Manufacturing Engineering Perform periodic callibration and audits
X Y Z
47 Loss of time, money and product Manufacturing Engineering Training
48
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
52
53
54
55
AA AB AC
1

3
4
5
6
7
8
9
10
11
12

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
18
ID 2.3

19 ID 3.1

ID 3.2
20
ID 3.3
21
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
24
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
29
Immediate action needed
ID 6.3
30
ID 7.1
31
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
37
ID 9.1
38 Immediate action needed
ID 9.2
39
ID 9.3
Immediate action needed
40 ID 10.1
41
ID 10.2
42
ID 10.3
43
ID 11.1
44
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
48
ID 12.2
49 Immediate action needed
50 Immediate action needed ID 12.3
51 Immediate action needed
52
53
54
55
AD AE
1

3
4
5
6
7
8
9
10
11
12

0 50 Accumulated
100 RPN
150 for Each Failure
200 250 Mode
300 350 400
13
1

14
15
16
2
17

18

19 3

20

21
4
22

5
3

4
AD AE
23

24
5
25
26
27

28 6

29

30
7
31

32
33

34 8

35
36
37
38 9

39

40 10
41
42

43
11
44
45
46

12
8

10

11

AD AE
47 12
48
49
50
51
52
53
54
55