Version Control

Version Revision notes

0
1
2 Update to Gold Standard
3
4
5

Template Instructions
1 For Reference PFMEA press option 1.
For Process / Product application press option 2. to expand the full PFMEA
2 columns.
 Qua
Version Control
GPO
Date Who GPO Notes R McIntyre

1/10/2018 Roy McIntyre, Matt Watts Roy McIntyre

 Quality Check
GPO Head of ME (Central Team)
R McIntyre Phil Holmshaw
WARNING STATEMENT AND DESTINATION CONTROL STATEMENT

Export Control
Jurisdiction Classification Date
(Rating)
UK Not Listed 22-Jan-18

© 2017 Rolls-Royce Plc. All Rights Reserved.

This document and the information embodied herein is the property of and proprietary to
Rolls-Royce Corporation, and shall not, without prior written permission of Rolls-Royce
Corporation, be used or disclosed in whole or in part to third parties. This legend shall be
included on any reproduction of this document in whole or in part.

This document contains information which is proprietary and confidential to Rolls-Royce

and may not be used or reproduced, in whole or in part, or communicated to any person
not employed by Rolls-Royce, without the express written consent of Rolls-Royce.
ATEMENT

Rated by

P Morrell
 Requirements (Product
Characteristics)
What is the Product Characteristic
we need to achieve during the
process (diameter, depth, length, What could be wrong with the
radius, CME, surface finish,
metallurgy standard, adhesion, big, hole too small, CME outside
residual stress, coverage etc - or spec, too rough surface finish)
avoid such as damage, weld
spatter etc)
6.3.0.1 Coating Location
Potential Failure Mode Potential Cause(s) of Failure
1st level why of the 5 whys (the
top things we would look at)…if I
get this occuring when I use this
Product Characteristic (hole too Typical prevention controls used
FMEA then I need an
to avoid potential causes occuring
improvement activitiy that would
understand root cause and close
out plan.
Incorrect location Part incorrectly loaded in fixture
Spray stream location changed
Masking incorrectly positioned
Damaged mask
Airjets causing deflection
Ineffective masking
Programme amended incorrectly
Run the wrong programme
Incorrect parameters
Control (Prevention) Control (Detection)
How would we detect that the
failure mode has occurred
Clear Data card instruction.
Visual Inspection
Dimensional checks.
Visual inspection of spray stream.
Use of Camera verification e.g. Accuraspray. Visual Inspection
Spot plate check.
Clear Data card instruction
Inspection templates. Visual Inspection
Operator training
Masking asset care Procedure. Visual Inspection
PokeYoke airjet locations.
Visual Inspection
Clear Data card instruction.
Clear Data card instruction. Visual Inspection
Dry run / validation of programme prior to
Visual Inspection
spraying.
Dry run / validation of programme prior to
spraying.
Visual Inspection
Human to Machine Interface to confirm part
number (for Robots).
Human to Machine Interface to confirm part
Visual Inspection
number (for Robots)
 Requirements (Product
Characteristics)
What is the Product Characteristic
we need to achieve during the
process (diameter, depth, length, What could be wrong with the
radius, CME, surface finish,
metallurgy standard, adhesion, big, hole too small, CME outside
residual stress, coverage etc - or spec, too rough surface finish)
avoid such as damage, weld
spatter etc)
6.3.0.2 Coating Adhesion
Potential Failure Mode Potential Cause(s) of Failure
1st level why of the 5 whys (the
top things we would look at)…if I
get this occuring when I use this
Product Characteristic (hole too Typical prevention controls used
FMEA then I need an
to avoid potential causes occuring
improvement activitiy that would
understand root cause and close
out plan.
Coating delamination Contamination
Insufficient grit blasting
Excessive grit blasting
Grit breakdown
Coating too thick
Post process machining abuse
High deposition rate (increased stress)
Control (Prevention) Control (Detection)
How would we detect that the
failure mode has occurred
Appropriate and approved work intructions for
cleaning.
Post process visual inspection and laboratory
Process sign off and audit.
inspection
Production planning and in process part
protection.
Appropriate and approved work intructions for Post blast tests, post spray inspection and
blasting. Appropriate asset care for process laboratory testing.
equipment. Post spray lab tests
Appropriate and approved work intructions for Post blast tests, post spray inspection and
blasting. Appropriate asset care for process laboratory testing.
equipment. Post spray lab tests
Post blast tests, post spray inspection and
Appropriate Asset care and grit life control laboratory testing.
Post spray lab tests
Process instructions limiting final toatl coating
Post coat inspection
thickness.
See appropriate machining instruction PFMEA.#
Powder feed rate checks
Appropriate traverse rates Laboratory tests
Appropriate spray parameters
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Robust process control.

Post process visual inspection and laboratory
6.3.0.3 Coating thickness Too thick Too many passes Process instruction limiting the number of
inspection
passes.

Robust process control detailing the number of Post process visual inspection and laboratory
Inconsistent process / wrong calculations
passes required. inspection

Powder feed rate checks, or equipment that

Post process visual inspection and laboratory
High powder feed rate used monitors feed rate. Asset care cof feeding
inspection
equipment.

Post process visual inspection and laboratory

Slow transverse speed. Automate and control spray process.
inspection

Powder feed rate checks, or equipment that

Post process visual inspection and laboratory
Too thin Low powder feed rate used monitors feed rate. Asset care cof feeding
inspection
equipment.
Process instruction limiting the number of Post process visual inspection and laboratory
Insufficient passes
passes. inspection
Post process visual inspection and laboratory
Equipment Failure Asset care.
inspection
Minimum powder level, or powder top up Post process visual inspection and laboratory
Ran out of powder
procedure to be defined. inspection
Post process visual inspection and laboratory
Worn process hardware Asset care. Process lifing.
inspection
Post process visual inspection and laboratory
Fast traverse speed. Automate and control spray process.
inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Coating too Dense Detailed checks in data card Post process hardness test and laboratory
6.3.0.4 Coating porosity Spray distance too short
inspection

Powder feed rate checks Post process hardness test and laboratory
Feed rate too low
inspection

For robot controlled process use confirmation code Post process hardness test and laboratory
Incorrect parameters used to allow process to proceed. inspection

Coating too Porous Feed rate too high Powder feed rate checks Post process hardness test and laboratory
inspection

Incorrect parameters used For robot controlled process use confirmation code Post process hardness test and laboratory
to allow process to proceed. inspection

Spray distance too long Detailed checks in data card Post process hardness test and laboratory
inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Coating too Hard Incorrect parameters used For robot controlled process use confirmation code Post process hardness test and laboratory
6.3.0.5 Coating hardness to allow process to proceed. inspection

Excessive oxide content Data card / process control Post process hardness test and laboratory
inspection

Feed rate too low Powder feed rate checks Post process hardness test and laboratory
inspection

Maintenance of assets / consider effect of changes Post process hardness test and laboratory
Atmospheric conditions in conditions inspection

Batch acceptance testing of powder Post process hardness test and laboratory
Powder drift
inspection

Coating too Sof Incorrect paarmeters used For robot controlled process use confirmation code Post process hardness test and laboratory
to allow process to proceed. inspection

Data card / process control Post process hardness test and laboratory
Excessive Unmelted particles
inspection
Excessive porosity Data card / process control Post process hardness test and laboratory
inspection
Batch acceptance testing of powder Post process hardness test and laboratory
Powder drift
inspection
Maintenance of assets / consider effect of changes Post process hardness test and laboratory
Atmospheric conditions in conditions inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Non Uniform appearance Appropriate asset care

6.3.0.6 Coating appearance Component Overheating Automate cooling sources Post process inspectionand laboratory inspection

Geometrical considerations Appropriate process instructions Post process inspectionand laboratory inspection

Consumable checks
Contamination Robust Powder handling procedure Post process inspectionand laboratory inspection

Robust Powder handling procedure

Incorrect powder Clear labelling Post process inspectionand laboratory inspection

Appropriate masking
Overspray Appropriate data card instructions Post process inspectionand laboratory inspection
Appropriate cleaning / fettling
Appropriate data card instructions
Correct Measurement / coating calculation
Coating locally too thin / thick Appropriate process control Post process inspectionand laboratory inspection
Powder feed checks
Appropriate packaging
Component handling Appropriate instructions Post process inspectionand laboratory inspection

Appropriate training
Damage during masking removal Appropriate masking technique. Post process inspectionand laboratory inspection

Staining. Appropriate processes and control Post process inspectionand laboratory inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Coating cracked - when not by design See 6.3.0.5 Coating Hardness Post process inspection and laboratory
6.3.0.7 Coating Cracking Coating too hard
inspection

Appropriate asset care Post process inspection and laboratory

Component or coating over heating Automate cooling sources inspection

See 6.3.0.3 Coating Thickness Post process inspection and laboratory

Coating too thick
inspection

Appropriate packaging Post process inspection and laboratory

Component handling Appropriate instructions inspection

Appropriate and approved work intructions for

cleaning.
Post process inspection and laboratory
Contamination Process sign off and audit.
inspection
Production planning and in process part
protection.
See 6.3.0.4 Coating porosity Post process inspection and laboratory
Coating too dense
inspection

Appropriate asset care Post process inspection and laboratory

Coating cooled too fast Automate cooling sources inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Coating oxide content too high Incorrect parameters used For robot controlled process use confirmation code
6.3.0.8 Coating Oxide to allow process to proceed. Post process laboratory inspection

Powder drift Batch acceptance testing of powder Post process laboratory inspection

Appropriate asset care

Over heating part and powder Automate cooling sources Post process laboratory inspection

Coating oxide content too low Incorrect parameters used For robot controlled process use confirmation code
to allow process to proceed. Post process laboratory inspection

Powder drift Batch acceptance testing of powder Post process laboratory inspection
Poor injection conditions Asset care Post process laboratory inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Incorrect Coatings deposited Robust Powder handling procedure Post process laboratory inspection and possibly
6.3.0.9 Correct Coating Mis labelled powder Clear labelling final visual inspection

Robust Powder handling procedure Post process laboratory inspection and possibly
Wrong hopper used Clear labelling final visual inspection

Appropriate data card checks Post process laboratory inspection and possibly
Data card wrong
final visual inspection

For robot controlled process use confirmation code Post process laboratory inspection and possibly
Wrong programme selected to allow process to proceed. final visual inspection
Robust Powder handling procedure Post process laboratory inspection and possibly
Hopper topped up with wrong powder Clear labelling final visual inspection
Robust approval Post process laboratory inspection and possibly
Interstage drawing wrong
final visual inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

6.3.0.10 Coating Un-melted Particles (un- UMP too high Incorrect parameters used For robot controlled process use confirmation code Post process laboratory inspection and possibly
reacted and non flattened) to allow process to proceed. final visual inspection

Batch acceptance testing of powder Post process laboratory inspection and possibly
Powder drift
final visual inspection

under heating of the powder by poor injection Appropriate asset care Post process laboratory inspection and possibly
conditions Automate cooling sources final visual inspection

UMP too low Incorrect parameters used For robot controlled process use confirmation code Post process laboratory inspection and possibly
to allow process to proceed. final visual inspection

Batch acceptance testing of powder Post process laboratory inspection and possibly
Powder drift
final visual inspection
Over heating of the powder by poor injection Appropriate asset care Post process laboratory inspection and possibly
conditions Automate cooling sources final visual inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too Typical prevention controls used How would we detect that the
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside to avoid potential causes occuring failure mode has occurred
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Too much Process parameters incorrect. Data card / process control Post process laboratory inspection and possibly
6.3.0.11 Other phases Poor consumable control final visual inspection

Too little Process parameters incorrect. Data card / process control Post process laboratory inspection and possibly
Poor consumable control final visual inspection

Poor distribution Process parameters incorrect. Data card / process control Post process laboratory inspection and possibly
Poor consumable control final visual inspection

Contamination Process parameters incorrect. Data card / process control Post process laboratory inspection and possibly
Poor consumable control final visual inspection
 Cause Description
Carrier gas leak, blocked injector, incorrect
Spray stream location changed
injector
Masking tape lifting / metal masking moving
Ineffective masking
during spraying / no masking / wrong masking
Poor initial cleaning regime
Contamination Failure to follow cleaning process
Failure to protect cleaned surface
Exhaust airflow, cooling conditions, outside
Atmospheric conditions
temperature etc.