PFMEA Participants: Personal Details Session Attendance Record

PFMEA Participants
Personal Details Session Attendance Record
Name Representing 1-Jan-00
Name 1 Area 1
Name 2 Area 2
Name 3 Area 3
PROCESS FLOW DIAGRAM
PART NUMBER/S: PREPARED BY:
PART / FAMILY DESCRIPTION: DATE:
ENG. CHANGE LEVEL:
TRANSFORMATION
OTHER (SPECIFY)
ADMINISTRATION
CLASS (KCC)
CLASS (KPC)
LIFT (mechanical /
LOAD / INSTALL
FABRICATION /
INTERACTION
PACKAGING
KEY PRODUCT KEY CONTROL
REWORK
INSPECT
CONTROL
STORE
MOVE
STEP
other)
CHARACTERISTICS CHARACTERISTICS
METHODS
OPERATION (OUTPUTS) (INPUTS)
STEP DESCRIPTION
Page 2 of 41
PROCESS FLOW DIAGRAM
PART NUMBER/S: PREPARED BY:
PART / FAMILY DESCRIPTION: DATE:
ENG. CHANGE LEVEL:
TRANSFORMATION
OTHER (SPECIFY)
ADMINISTRATION
CLASS (KCC)
CLASS (KPC)
LIFT (mechanical /
LOAD / INSTALL
FABRICATION /
INTERACTION
PACKAGING
KEY PRODUCT KEY CONTROL
REWORK
INSPECT
CONTROL
STORE
MOVE
STEP
other)
CHARACTERISTICS CHARACTERISTICS
METHODS
OPERATION (OUTPUTS) (INPUTS)
STEP DESCRIPTION
Page 3 of 41
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Version: 3
Process Failure Mode and Effects Analysis (PFMEA)

Process Location: PFMEA 'Process / Manufacturing Method Owner': Date originated:
Product Details / Part nos: Process Details: Dates Revised: Issue #
Current Specified Process Controls: Recommendations Action results
Planned Completion
Classification
Responsibility
Current Process Current Process Actual
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Op Seq Potential Failure Potential Effect(s) of Potential Cause(s) of
Date
Step Function Requirement Controls Controls RPNi Recommended Action Actions Taken Completion RPNr
Number Mode Failure Failure
(Prevention) (Detection) Date
8 MCC 0 8 0
9 KCF 0 9 0
10 CCF 0 10 0
7 A 0 7 0
P 0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
RRPS PFMEA Template Printed 12/11/2020

Page 5 of 41
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Page 6 of 41
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Page 7 of 41
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Page 8 of 41
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
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0 0 0
0 0 0
0 0 0

Page 9 of 41
Version: 3
Process Failure Mode and Effects Analysis (PFMEA)

Process Location: PFMEA 'Process / Manufacturing Method Owner': Date originated:
Product Details / Part nos: Process Details: Dates Revised: Issue #
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
Insert stub-shaft into grinding fixture Shaft ground undersize Shaft not set hard against Check end float with Integrate end-float sensor poka-yoke Integrate end-float sensor poka-yoke
140 3 Max end float 0.003mm End float > 0,003mm 7 MCC 3 None 5 105 JC 6/9/2016 6/7/2016 7 2 2 28
XY3 leading to scrap datum feeler gauge in fixture in fixture
0 0 0
0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Page 10 of 41
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Page 11 of 41
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Page 12 of 41
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Page 13 of 41
Planned Completion
Classification
Responsibility
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Severity Occurrence Detection
Severity of Effect on Product Severity of Effect on Process
Effect Ranking Effect Likelihood of Cause Time-Based Example Ranking Likelihood of Detetection by Process Control - Category Likelihood of Detetection by Process Control - Criteria
(Customer Effect) (Manufacturing / Assembly Effect)
Process PPM Likelihood of Cause Time-Based

Ranking Description (AIAG Reference) Example
Potential failure mode affects safe operation and/or involves Low volume production
noncompliance with regulations without warning 10 May endanger operator, machine or assembly without warning. 500 parts or less per year 10 Absolute Uncertainty No current process control; Cannot detect or compliance analysis not performed
Failure to meet safety and/or Failure to meet safety and/or

regulatory requirements regulatory requirements
Potential failure mode affects safe operation and/or involves Very High: Persistent Failure (Failure ≥ 1 per
9 May endanger operator, machine or assembly with warning. 10 500,000 PPM 1 in 2 occurrence 100% of production ≥ 1 per occurrence per shift 9 Difficult to Detect Defect (Failure Mode) and/or Error (Cause) is not easily detected (e.g. Random audits)
noncompliance with regulations with warning is almost inevitable)
per shift
≥1 per
Loss of primary function (product inoperable, does not affect safe 8 Major disruption 100% of product may have to be scrapped. Line shutdown or stop ship 9 Very High: Persistent Failure (Failure 50,000 PPM 1 in 20 occurrence 50% of production ≥1 per occurrence per day 8 Defect Detection Post Processing Defect (Failure Mode) detection post-processing by operator through visual/tactile/auditable means with no
operation) occur almost as often as not) boundary samples
per day
Loss or degradation of primary
function
Degradation of primary function (product operable, but at a reduced level A protion of the production run may have to be scrapped. Deviation from High: Frequent failures (Repeated ≥1 per 2-3 Defect (failure Mode) detection in-station by operator through visual/tactile/audiable means or post-
of performance) 7 Significant disruption primary process; decreased line speed or added manpower. 8 failures) 20,000 PPM 1 in 50 days 20% of production ≥1 per 2-3 days 7 Defect Detection at Source processing through use of attribute gauging (go/no-go, manual torque check/clicker wrench, etc.,) with no
boundary samples
Loss of secondary function (product operable but service life greatly High: Frequent failures (Failures Defect (failure Mode) detection post-processing by operator through use of variable gauging or in-station by
reduced, convenience item(s) inoperable, customer dissatisfied) 6 100% of production run may have to be reworked off line and accepted 7 occur often) 10,000 PPM 1 in 100 ≥1 per Week 10% of production ≥1 per Week 6 Defect Detection Post Processing operator through use of attribute gauging (go/no-go, manual torque check/clicker wrench, etc.,) with
boundary samples
Loss or degradation of
secondary function Moderate disruption
Degradation of secondary function (product operable but appearance A proportion of the production run may have to be reworked off line and ≥1 per 2 Defect (Failure Mode) or Error (Cause) detection in-station by operator through use of variable gauging or by
affected, convenience item(s) operable at a reduced level, customer 5 6 High Moderate: Occasional failures 5,000 PPM 1 in 200 5% of production 1 per month 5 Defect Detection at Source automated controls that will detect discrepant part and notify operator (light, buzzer, etc.,). Gauging
accepted weeks
dissatisfied) performed on setup and first-piece check(for set-up causes only)
Appearance, fit and finish type items do not conform, defect noticed by 100% of production run may have to be re-worked in station before it is Moderate: Occasional failures ≥1 per Defect (Failure Mode) detection post-processing by automated controls that will detect discrepant part and
4 5 1,000 PPM 1 in 1,000 0.5% of production 2 per year 4 Defect Detection Post Processing
most of the customers (> 75%) processed (minor proportions) quarter lock part to prevent further processing
Moderate disruption
Annoyance
Appearance, fit and finish type items do not conform, defect noticed by A proportion of the production run may have to be reworked in-station ≥1 per half- Defect (Failure Mode) detection in-station by automated controls that will detect discrepant part and
about half of the customers (50%) 3 before it is processed 4 Moderate Low: Infrequent failures 100 PPM 1 in 10,000 year 0.1% of production 1 per year 3 Defect Detection at Source automatically lock part in station to prevent further processing
Appearance, fit and finish type items do not conform, defect noticed by 2 Minor disruption Slight inconvenience to process, operation or operator 3 Low: Relatively few failures. 10 PPM 1 in 100,000 ≥1 per year 0.05% of production 1 per 5 years 2 Error Detection and/or Defect Prevention Error (Cause) detection in-station by automated controls that will detect error and prevent discrepant part
discriminating customers (<25%) from being made
Low: Failures are few and far

No effect No discernable effect 1 No effect No discernible effect 2 between (isolated incidents) 1 PPM 1 in 1,000,000 <1 per year 0.01% of production 1 per 10 years 1 Detection not applicable Error (Cause) prevention as a result of fixture design, machine design or part design
1 Remote: Failure is eliminated thru Less than 0.01% of <1 per 10 years
Preventive Control production
Zero Zero Never

1. Content list (Hyperlinks)
Worksheet:
2. Update request
Process related content: Last updated: Issue level:
3. Component Marking 6
4. Component Load & transfer 26 June 2013 7
5. Tooling 6
6. Loading program 6
7. Probing 6
8. Deburring 6
9. Visual inspection 6
10. Running Operations 6
11. CMM Inspection 6
12. Grinding 6
13. Laser 6
14. TIG Weld 6
15. Manual dressing 6
16. Auto polish 6
17. Heat Treatment 6
18. Glass bead peening 6
19. Metal Spray 6
20. Sandblasting 6
21. Degreasing 6
22. Assembly 6
23. Cleaning / preparation of faying surface 9
Identified 'failure mode lessons learned' form
Process/Worksheet Process Step Identified Failure Mode Potential Effects Potential Cause of Failure Possible Detection Possible Prevention
To suggest additions to the failure mode list:

Enter the process/worksheet to be added to or if required enter a new process category
State the process step (could be existing or new)
List the failure modes related to that process step
List the potential effects of the failure modes
List the potential causes that could initiate the failure mode
List the ways in which the cause(s) could be detected
List the ways in which the failure mode could be prevented from occuring
Back to Content links
Process Step Identified Failure Mode Potential Effects Potential Cause of Failure Possible Detection Possible Prevention
Check component ID matches up with Component ID does not match up Loss of traceability resulting in
Component marked wrongly
batch card with batch card scrap component
Check component ID matches up with Component ID does not match up Loss of traceability resulting in Paperwork swapped to another
batch card with batch card scrap component part
Mistake on data entry - faulty bar
Check component marked correctly Component marked incorrectly Lost traceability
code scan
Wrong route card scanned for Arrange drop down area to
Check component marked correctly Component marked incorrectly Scrap component
serial number mitgate any confusion
Operator enters incorrect use bar code scanner to
Check component marked correctly Component marked incorrectly Lost traceability
information enter part mark data
Check component marked in correct Component marked in wrong Use physical mask with
Rework/concession/scrap Operator chose the wrong location
location location location window
Check component marked in correct Component marked in wrong Fixture not placed on the marker
Rework/concession/scrap
location location correctly
Check component marked in correct Component marked in wrong Part not loaded into the fixture Baulk fixture to prevent wrong
location location correctly part being loaded
Check component marked in correct Component marked in wrong Wrong marking program is
location location selected
Check component marked in correct Component marked in wrong
Rework/concession/scrap Marker selected the wrong location
location location
Check stylus prior to each
Check component mark legible Component mark unreadable Rework/concession/scrap Stylus is worn
marking batch
Check component mark legible Component mark unreadable Rework/concession/scrap Stylus is worn Monitor stylus condition
Check component mark legible Component mark unreadable Rework/concession/scrap Marker has a fault Monitor marker condition
Monitor machine for E-stop or

Check component mark legible Component mark unreadable Rework/concession/scrap Marking is incomplete
interlock activation
Component may not scan Technical Instruction (TI) not Component may not scan
Check component mark legible Component mark unreadable
correctly on future Ops followed correctly on future Ops
Can wrong / illegible numbers be Rework or production delay > 30 External trolley mistaken for
Check component and engraving
accepted? mins & < 1 day internal
Process Step Identified Failure Mode Potential Effects Potential Cause of Failure Possible Detection Possible Prevention Comments
Damage to machine / fixture. Lifting method must be agreed at fixture concept design stage.
Transport fixture from storage, load to Fixture collides with machine Wrong lifting equipment Lifting equipment to be unique to fixture - Lifting equipment to be unique to fixture - cannot lift
Process delay. Lifting method must be subject to H&S Risk Assessment. Incorporate risk
machine table and secure in correct position and / or operator used cannot lift fixture incorrectly fixture incorrectly
Lost-time injury mitigations into lifting equipment design and method statement.
Transport fixture from storage, load to Fixture collides with machine Lifting equipment damages Lifting equipment to be unique to fixture - Lifting equipment to be unique to fixture - cannot
machine table and secure in correct position and / or operator fixture cannot damage fixture damage fixture
Damage to machine / fixture. Machine design to assure free access for

Transport fixture from storage, load to Fixture collides with machine Fixture collides with Requirements to be stated in machine specifications
Process delay. crane and load, with good visibility during
machine table and secure in correct position and / or operator machine - Fixture and Machining strands to action
Lost-time injury loading.
None. (Note - failure is usually detected

Lost-time injury
Transport fixture from storage, load to once the effects are seen. The first sign of
Fixture dropped Damage to fixture Failure of lifting equipment Regular certification of lifting equipment
machine table and secure in correct position failed lifting equipment is 'damage' to
Damage to machine
people and machinery.)
Lost-time injury
Transport fixture from storage, load to Incorrect lifting equipment Positive lifting equipment provided on Review during pre-production to assure no use of
Fixture dropped Damage to fixture
machine table and secure in correct position used fixture (eg lifting eyes) slings and 'variable' lifting devices
Damage to machine
Lost-time injury
Transport fixture from storage, load to
Fixture dropped Damage to fixture Failure of crane / lifter None Regular certification of lifting equipment
machine table and secure in correct position
Damage to machine
Lost-time injury Operator compares TI with fixture tool number prior

Transport fixture from storage, load to
Fixture dropped Damage to fixture Wrong fixture loaded Correct part will not fit wrong fixture to loading.
machine table and secure in correct position
Damage to machine RFID tag on fixture read by machine to prevent
selection of wrong fixture
Transport fixture from storage, load to Part scrap / rework. Fixture secured in wrong Fixture supplied with register and / or Use automated 'Speedy Zero Point' or 'Erowa'
Fixture not correctly positioned
machine table and secure in correct position Process delay. position timing pin to assure correct position. systems to locate fixture into equipment.
Transport fixture from storage, load to Part scrap / rework. Fixture positioning device Asset Care Routine completed by Operator /
Fixture not correctly positioned Visual inspection prior to loading fixture
machine table and secure in correct position Process delay. missing / damaged Maintenance prior to storage.
Loading SOP provided, with check routine.

Part scrap / rework.
Transport fixture from storage, load to Securing device not tight Calibration of torque wrench. Use automated 'Speedy Zero Point' or 'Erowa'
Fixture not correctly secured Process delay.
machine table and secure in correct position enough Asset Care of fixture securing systems to systems to locate fixture into equipment.
Lost-time injury.
maintain performance.

Transport fixture from storage, load to Wrong securing device Securing devices common to machine, and Use automated 'Speedy Zero Point' or 'Erowa'
Fixture not correctly secured Process delay.
machine table and secure in correct position used fit all fixtures systems to locate fixture into equipment.
Lost-time injury.
Scrap / rework Lifting method must be agreed at fixture concept design stage.
Lift part from packaging and correctly locate Wrong lifting equipment Lifting equipment to be unique to part - cannot lift
Part not correctly located in fixture Process delay. Positive lifting equipment provided on part. Lifting method must be subject to H&S Risk Assessment. Incorporate risk
in fixture used part incorrectly
Scrap / rework Lifting method must be agreed at fixture concept design stage.
Lift part from packaging and correctly locate Lifting equipment damages Positive lifting equipment provided on Lifting equipment to be unique to part - cannot
Part not correctly located in fixture Process delay. Lifting method must be subject to H&S Risk Assessment. Incorporate risk
in fixture part fixture (eg lifting eyes) damage part
Scrap / rework
Lift part from packaging and correctly locate Fixture 'guides' to be developed to protect part and
Part not correctly located in fixture Process delay. Part collides with fixture None
in fixture fixture during loading
Lost-time injury
All clamps and locators in fixture automatically spring

Scrap / rework
Lift part from packaging and correctly locate Operator provided with SOP for correct back to open position when unclamped.
Part not correctly located in fixture Process delay. Fixture not in 'open' position
in fixture loading sequence All clamps and locators are automated so cannot be
Lost-time injury
left 'closed'.
Scrap / rework
Lift part from packaging and correctly locate Operator compares part number to fixture Each fixture has unique features for 'its' part and will
Part not correctly located in fixture Process delay. Wrong part
in fixture number in TI not allow loading of incorrect part.
Lost-time injury
Process delay.
NOTE - TORQUE IS NOT EQUAL TO LOAD. A torque wrench is better than
Manual - torque wrench setting.
Potential lost-time injury if part not secured to nothing but varying bolt condition can later the load on the component by a
Part not correctly clamped in Hydraulic - pressure setting on power pack.
Clamp part correctly in fixture fixture Clamping force incorrect None factor of 6.
fixture Gauge on fixture confirms correct pressure prior to
In all cases, powered clamping through hydraulics or electrics is the only
lock-off.
Potential damage to product, tooling, fixturing or prevention for incorrect clamping load.
equipment if part not correctly located and/or
securely loaded to fixture
Process delay.
Asset Care regime
Potential lost-time injury if part not secured to Clamping force not Manual - confirmation of bolt/clamp Hydraulic - pressure setting on power pack.
Part not correctly clamped in
Clamp part correctly in fixture fixture maintained during condition. Manual - clamps designed to be within safe limits for
fixture
processing Hydraulic - pressure test of actuators to stress
Potential damage to product, tooling, fixturing or detect leaks / failures.
Process delay.
Potential lost-time injury if part not secured to Location device design prevents mis-loading. Avoid any use of 'clocking' to remove variability of position.
Part not correctly clamped in Measure part position prior to start of
Clamp part correctly in fixture fixture Location position incorrect Use of mandrels and chucks for centring. Utilise mandrels, chucks and other automated position devices to assure
fixture machining
prevention of mis-location.
Potential damage to product, tooling, fixturing or
Process delay.
Manual - use of SOP detailing clamping
sequence. Hydraulic clamping sequence set automatically
Potential lost-time injury if part not secured to
Part not correctly clamped in Clamping sequence Hydraulic - clamping sequence set through power pack.
Clamp part correctly in fixture fixture
fixture incorrect automatically through power pack. Use automated clamping systems to assure correct
Measure part position prior to start of sequencing of clamps.
machining.
Process delay.
Potential lost-time injury if part not secured to Probe part prior to start of machining. Barring or error-proofing device safely prevents load
Part not correctly clamped in Part not to condition of Ensure that previous operations have verified that the correct part is sent to
Clamp part correctly in fixture fixture (NOTE - may not be able to probe location of part not in condition of supply for current this operation.
fixture supply
diameters - masked by fixture) operation.
Process delay.

Part not correctly clamped in Fixture location point not
Clamp part correctly in fixture fixture Asset Care regime (If necessary) probe fixture prior to start of batch.
fixture calibrated / worn / broken
Process delay.

Part not correctly clamped in (NOTE - fixture location points will be obscured when part is in position, so
Clamp part correctly in fixture fixture Fixture damaged Asset Care regime (If necessary) probe part prior to start of batch.
fixture probing fixture calibration points may be impossible)
Process delay.
Hydraulic - pressure set in power pack, automatic
Potential lost-time injury if part not secured to All clamping sequences to be pre-set in hydraulic power packs / fixture
Part not correctly clamped in Clamping pressure operation.
Clamp part correctly in fixture fixture None hydraulic circuits, and operated by single operator-initiated start sequence.
fixture incorrect Manual - torque wrench setting prior to tightening
Manual - calibrate torque wrench
nuts/bolts.
Process delay.

Part not correctly clamped in Clamping point damaged / None for fixture - assure Asset Care regimes are
Clamp part correctly in fixture fixture Asset Care regime (If necessary) probe fixture prior to start of batch.
fixture broken completed to time and quality
Process delay.

Part not correctly clamped in Hydraulic - pressure required will not be achieved, process stops.
Clamp part correctly in fixture fixture Clamp damaged / broken Visual check prior to clamping Asset Care regime
fixture Manual - Obvious from operating equipment.
Process delay.

Part not correctly clamped in No clamping pressure - Fixture clamps fail to operate, unable to achieve
Clamp part correctly in fixture fixture None None for fixture - assure Asset Care regimes are completed to time and quality
fixture hydraulic pressure.
Process delay.

Part not correctly clamped in No clamping pressure -
Clamp part correctly in fixture fixture None None
fixture manual
Load fixture and part to equipment (Use

this step if the part is loaded off machine, Fixture not loaded correctly to Part scrap / rework Fixture dislodged during See all items above relating to fixture and part transport, lifting and clamping
Probe part prior to start of machining. None
and then part & fixture are loaded to machine Process delay part loading procedure to assure correct calmping loads and avoid collisions
machine.)
this step if the part is loaded off machine, Fixture not loaded correctly to Part scrap / rework Fixture loaded in wrong Fixture supplied with register and / or timing pin to
Loading SOP provided, with check routine
and then part & fixture are loaded to machine Process delay position assure correct position.
machine.)
this step if the part is loaded off machine, Fixture not loaded correctly to Part scrap / rework Fixture dislodged during Fixture supplied with register and / or timing pin to
Loading SOP provided, with check routine
and then part & fixture are loaded to machine Process delay fixture loading procedure assure correct position.
machine.)
Part scrap / rework

Clamping pressure not
Process delay
Part not retained in fixture during maintained during
Retain part in fixture during processing None Manual - torque wrench setting. Assure Asset Care regimes are complete to time and quality
processing processing - manual
Potential damage to machine and / or fixture.
clamping
Potential lost-time injury
Part scrap / rework Hydraulic - pressure setting on power pack.

Where hydraulic clamping is provided through the machine tool, monitoring
Gauge on fixture confirms correct pressure is locked
Clamping pressure not can be via the machine controller.
Process delay into fixture prior to loading.
Part not retained in fixture during maintained during Check valaves must be fitted to all connections to assure pressure retention
Retain part in fixture during processing None Check valve fitted to maintain pressure during
processing processing - hydraulic during disconnection of power packs.
Potential damage to machine and / or fixture. disconnection/processing.
clamping Remote transmitter fitted to fixture linked to machine controller - shuts
Automated pressure monitoring linked to machine
machine down if pressure drops below pre-set level.
Potential lost-time injury controller.
Part scrap / rework
Process delay
Part not retained in fixture during Tool / machine collides with Tool paths confirmed using Vericut prior to use of Error-proofing required to ensure that only verified tool progams are used on
Retain part in fixture during processing None
processing fixture during processing process program. production parts - Machining strand
Part scrap / rework
Process delay
Part not retained in fixture during Excess force imparted to Use of process monitoring for spindle / machine load
Retain part in fixture during processing None
processing part during processing with shut-off for excess load
Manual - clamps are swung away from part, visual

Clamping force not fully check.
Cannot remove part
removed Hydraulic - all hydraulic clamps swing away from part
automatically; visual check
Unload part-fixture from machine and Part not removed from fixture and Process delay. Manual - number/colour code clamps to show
unclamp part / or part damaged during removal Part scrap / rework. Unclamping sequence sequence of removal.
Cannot remove part
incorrect Hydraulic - clamping sequence set automatically
through power pack.
Assure Asset Care regimes are completed to time and quality after any
Clamp damaged / broken Cannot remove part Visual examination of clamps prior to unloading.
damage is found
Unsecure fixture from machine table, unload Fixture collides with machine Wrong lifting equipment Lifting equipment to be unique to fixture - cannot lift
Process delay. None Lifting method must be subject to H&S Risk Assessment. Incorporate risk
from machine and place to storage. and / or operator used fixture incorrectly
None (Note - visual examination may be
Damage to machine / fixture.
Unsecure fixture from machine table, unload Fixture collides with machine Lifting equipment damages possible, but needs a very tight definition of Lifting equipment to be unique to fixture - cannot
Process delay.
from machine and place to storage. and / or operator fixture 'damage' and equipment to examine and damage fixture
Lost-time injury
measure damage.)
None. (Note - visual examination may be
Unsecure fixture from machine table, unload Fixture collides with machine Fixture collides with possible, but needs a very tight definition of Machine design to assure free access for crane and
from machine and place to storage. and / or operator machine 'damage' and equipment to examine and load, with good visibility during loading.
measure damage.)
None. (Note - failure is usually detected
Lost-time injury
Unsecure fixture from machine table, unload once the effects are seen. The first sign of
Fixture dropped Damage to fixture Failure of lifting equipment Regular certification of lifting equipment
from machine and place to storage. failed lifting equipment is 'damage' to
Damage to machine
people and machinery.)
Lost-time injury
Unsecure fixture from machine table, unload Incorrect lifting equipment Positive lifting equipment provided on fixture (eg
Fixture dropped Damage to fixture None Lifting method must be agreed at fixture concept design stage.
from machine and place to storage. used lifting eyes)
Damage to machine
Lost-time injury Lifting method must be agreed at fixture concept design stage.
Unsecure fixture from machine table, unload
Fixture dropped Damage to fixture Failure of crane / lifter None Regular certification of lifting equipment Lifting method must be subject to H&S Risk Assessment. Incorporate risk
from machine and place to storage.
Damage to machine mitigations into lifting equipment design and method statement.
Lost-time injury
Unsecure fixture from machine table, unload
Fixture dropped Damage to fixture Wrong fixture unloaded Operator compares TI with fixture tool Only one fixture to unload
from machine and place to storage.
Damage to machine number prior to unloading.
Unsecure fixture from machine table, unload Securing device not Use of automatic hydraulic systems providing assured position and clamping-
Fixture not correctly unsecured Process delay. Cannot remove fixture Unclamping SOP provided, with check routine
from machine and place to storage. correctly removed pressure feedback
Unsecure fixture from machine table, unload Wrong tool used to remove Unsecuring devices common to machine, and fit all
Fixture not correctly unsecured Process delay. Cannot remove fixture
from machine and place to storage. securing device fixtures
Pick up component
Lift component on to machine Component dropped Injury to operator and/or damage to part incorrectly causing
component to drop
Collision causing
Lift component on to machine Component dropped Injury to operator and/or damage to part
component to drop
Lifting equipment failure
Lift component on to machine Component dropped Injury to operator and/or damage to part causing component to
drop
Associate does not use
Lift component on to machine Component dropped Injury to operator and/or damage to part lifting equipment to
manipulate component
Equipment malfunction:
suction cups damaged or
Lift component on to machine Component dropped Injury to operator and/or damage to part
loose on lifting
equipment
Component incorrectly placed

No mechanism to
Load component into transportation box in transportation box (more Component and/or box damaged
prevent incorrect loading
detail may be needed)
Component loaded into Unclear as to which box
Load component into transportation box Component and/or box damaged
incorrect Transportation Box to use
Component not placed in No transportation boxes
Load component into transportation box Component and/or box damaged
transportation box available
Injury to operator, damage to fixture or

Load fixture correctly to machine Fixture dropped Incorrect sling used
machine
Injury to operator, damage to fixture or
Load fixture correctly to machine Fixture dropped Collision with other item
machine
Injury to operator, damage to fixture or Slippery surface due to
Load fixture correctly to machine Fixture dropped
machine oil on fixture
Fixture collides with fixed Damage to fixture Difficult to maneouvre
Load fixture correctly to machine
structure/machine HSE risk fixture into position
Fixture inadequately
Load fixture correctly to machine Incorrect fixture selected Time wasted
identified
Load fixture correctly to machine Incorrect fixture selected Time wasted Paperwork incorrect
Fixture not loaded / incorrectly Fixture not clamped to

Load fixture correctly to machine Fixture falls off machine Visual
loaded (may need more detail) table
Probe part and fixture prior to

Fixture not loaded / incorrectly Fixture loaded in
Load fixture correctly to machine Machine collides with fixture machining to confirm located and
loaded (may need more detail) incorrect position
fixtured correctly
Fixture not loaded / incorrectly Fixture not correctly

Load fixture correctly to machine Fixture moves on table
loaded (may need more detail) clamped to machine
Fixture not loaded / incorrectly

Load fixture correctly to machine Fixture dropped
loaded (may need more detail)

Load fixture correctly to machine Time wasted Incorrect fixture loaded

Load fixture correctly to machine Fixture lost
Fixture not loaded / incorrectly Dirt/swarf prevents
Load fixture correctly to machine Non-conformance
loaded (may need more detail) correct location
Fixture not loaded / incorrectly Fixture loaded in

Load fixture correctly to machine Non-conformance
loaded (may need more detail) incorrect orientation
Component loaded incorrectly

Component loaded in the
Load component correctly into fixture into fixture (may need more Component non-conformance, fixture damage
wrong way round
detail)
Component loaded incorrectly Component not be
Load component correctly into fixture into fixture (may need more Component non-conformance, fixture damage tightened in fixture
detail) securely
Component over
tightened into fixture
detail)
Load component correctly into fixture into fixture (may need more Fixture bolts ommitted
detail)
Clamp not centred
correctly
detail)
Operator locates part
Load component correctly into fixture into fixture (may need more
wrongly
detail)
Load component correctly into fixture into fixture (may need more Part not clocked
detail)
Load component correctly into fixture into fixture (may need more Component non-conformance, fixture damage Incorrect fixture used
detail)
Fixtures not maintained
or fit for purpose
detail)
Component damaged
when loaded into fixture
detail)
Load component correctly into fixture into fixture (may need more Component non-conformance, fixture damage Dirt/swarf on fixture
detail)
Non-conformance and/or tooling Tool incorrectly identified, tools easily

Select correct tool Wrong tool selected Probe tooling prior to cutting Provide pre-kitted tooling
damage confused, instructions incorrect
Worn and conforming tooling not Ensure all worn tooling is
Select correct tool Worn tool selected Non-conformance
segregated segregated
Tool not correctly secured in
Assemble toolholder Damage to part and/or toolholder Operator distracted
holder
Incorrect dimensions read from Wrong dimensions enter into machine
Measure tooling with pre-setter Non-conformance
pre-setter tool
Load tools into correct machine Location into which tool should go
Tools loaded into incorrect location Damage to part and/or tooling
location unclear
Load tools into correct machine
Tools loaded into incorrect location Damage to part and/or tooling Toolholder incorrectly marked
location
Production Delays, part non- Probe part and/or fixture to verify Use bar code to ensure correct
Load correct Program Incorrect program loaded Multiple programs available
conforming program correct selection,
Production Delays, part non- Probe part and/or fixture to verify

Load correct Program Incorrect program loaded Program incorrectly identified
conforming program correct
Improve legibility or input using bar

Loading program data Serial number incorrectly entered Production Delays Serial number read incorrectly
code reader
Loading program data Serial number incorrectly entered Production delay Serial number typed incorrectly Utilise bar code reader
Damage to tooling and/or non- Use tooling chip to read offsets

Loading program data Tooling offsets incorrectly entered Typing error Probe tool prior to cutting
conformance directly to program
Incorrect Measure cut offsets Damage to tooling and/or non- Probe part to directly measure and
Loading program data Component measured incorrectly
entered conformance load offset dimensions
Loading program data Offsets calculated incorrectly
Loading program data Offsets entered incorrectly
Correctly set probe sensitivity Probe sensitivity set incorrectly Programming error Trial probing on dummy objects
Fixture location not correctly Probe touches on wrong part of Warning if probed dimension out of Check probing with fixture in a series of
Probe fixture location probed Time wasted fixture expected range locations
Fixture location not correctly Warning if probed dimension out of Wash part and fixture with coolant
Probe fixture location probed Time wasted Swarf/dirt on fixture expected range prior to probing
Fixture location not correctly
Probe fixture location probed Time wasted Programming or data input error
Time wasted Warning if probed dimension out of Carry out probing trials over range of
Probe part Part not probed correctly Non-conformance generated Wrong section of part probed expected range possible positions
Time wasted Warning if probed dimension out of Carry out probing trials over range of
Probe part Part not probed correctly Non-conformance generated probe touches on fixture expected range possible positions
Time wasted Warning if probed dimension out of Wash part and fixture with coolant
Probe part Part not probed correctly Non-conformance generated Swarf/dirt on part expected range prior to probing
Time wasted Warning if probed dimension out of
Probe part Part not probed correctly Non-conformance generated Inappropriate probing angle expected range Trial probing on dummy objects
No clear visual standard for

Deburr to specification Excessive material removed Non-conforming part
deburring. Provide clear visual standards
Deburr to specification Excessive material removed Non-conforming part Incorrect tools used Ensure only correct tools are
instructed and available
component or tools slip resulting in Ensure machine programmes
Deburr to specification Excessive material removed Non-conforming part
damage remove burr material
Deburr to specification Burrs not removed Time waste & rework Instructions not explicit
Provide clear standards
Deburr to specification Burrs not removed Time waste & rework Operator disturbed & omits item Ensure no disturbance during
operation
Lighting conditions not sufficient to
Deburr to specification Burrs not removed Time waste & rework
allow spotting of problems Ensure adequate lighting
No clear visual standard for
Deburr to specification Insufficient material removed Time waste & rework
deburring. Provide clear standards
Lighting conditions not sufficient to
Deburr to specification Insufficient material removed Time waste & rework
allow spotting of problems Ensure adequate lighting
Operator injured by sharp Ensure machine programmes
Deburr to specification Lost time injury Excessive burr material on part
burr/edge remove burr material
Operator injured by sharp Ensure machine programmes
Deburr to specification Lost time injury Failure to wear PPE
burr/edge remove burr material
Enforce inspection order +
Non-conforming product leaves confirmation - consider deploying
Visually inspect part to specification Visual defects not identified inspection area Inspection order not explicit INSPECT
Enforce inspection order +
Non-conforming product leaves Inspection instructions not followed confirmation - consider deploying
Visually inspect part to specification Visual defects not identified inspection area correctly INSPECT
Regular check and confirmation of
Non-conforming product leaves light levels. Light meter with warning
Visually inspect part to specification Visual defects not identified inspection area Lighting conditions inadequate sound
Non-conforming product leaves Implement and enforce no
Visually inspect part to specification Visual defects not identified inspection area Inspector disturbed and misses defect disturbance rules
Non-conforming product leaves
Visually inspect part to specification Visual defects not identified inspection area Visual standards not adequate Improve visual standards
Acceptable issues identified as Non-conforming product leaves
Visually inspect part to specification defects inspection area Visual standards not adequate Improve visual standards
Regular check and confirmation of
Acceptable issues identified as Time wasted doing unneccessary light levels. Light meter with warning
Visually inspect part to specification defects rework Lighting conditions inadequate sound
Collect defect data Defect data not collected Unable to define required rework Defect list lost
Inspector disturbed and forgets to log Implement and enforce no
Collect defect data Defect data only partially collected Rework cannot be defined correctly defect disturbance rules
No action being taken to address Implement defect data collection
Analyse defect data Defect data not analysed defects - risk of escapes No process in place to analyse defect data and improvement process
No action being taken to address Data logged but not passed on for
Analyse defect data Defect data not analysed defects - risk of escapes analysis
Warning if coolant flow/pressure

Confirm coolant flow Lack of coolant Poor surface finish Blocked nozzle goes below set levels Regular check of coolant nozzle
Warning if coolant flow/pressure Regular maintance checks on

Confirm coolant flow Lack of coolant Poor surface finish Worn pump
goes below set levels pump
Confirm coolant flow Coolant incorrectly aim/pressure Poor surface finish Nozzle damaged Regular check of coolant nozzle
Confirm coolant flow Coolant incorrectly aim/pressure Poor surface finish Nozzle displaced Regular check of coolant nozzle
Temperature control system
Warning if temperature goes out of function monitored and machine
Confirm coolant flow Coolant temperature incorrect Poor surface finish Temperature control system failed
specified range refuses to start if system shows
faults
Remove material Material not fully removed Non-conformance Cutting tool damaged part way through Probe tool part way through Op Tool life management
operation Monitor spindle torque
Component loaded in wrong CMM collides with the part, Fixture does not preclude Probe component position prior to
Load component to CMM Fixture precludes incorrect loading of component
position possible damage incorrect loading starting measurement cycle
Component does not seat Dirt of burrs on component or Check cleanliness of part/fixture
Load component to CMM Incorrect measurement results
correctly fixture prior to loading
Incorrect CMM programme Probe component to check
Select CMM programme Collision with component Multiple programmes available Use bar code reader to select programme
selected consistent with programme
Incorrect CMM programme Probe component to check
Select CMM programme Incorrect measurement results Multiple programmes available Use bar code reader to select programme
selected consistent with programme
Non-conformance incorrectly Room temperature outside of
Measure part Measurement results incorrect Audible temperature warning in room CMM does not run if temp out of limits
identified or missed limits
Non-conformance incorrectly Warning on screen if CMM not
Measure part Measurement results incorrect CMM not calibrated CMM refuses to run if not in calibration
identified or missed calibrated
Non-conformance incorrectly
Measure part Measurement results incorrect Stylus worn Visual check of stylus for wear
identified or missed
Measure part Measurement results incorrect Stylus damaged Visual check of stylus for damage
Measure part Measurement results incorrect Stylus dirty Visual check of stylus for dirt Clean stylus & ensure part is clean prior to every run.
Measurement routine does not
Measure part Re-measure and time waste Lack of air pressure
complete
Measurement routine does not Probe component position prior to
Measure part Re-measure and time waste Collision with component Fixture prevents incorrect positioning of component
complete starting measurement
Measurement routine does not Check no other objects on table prior
Measure part Re-measure and time waste Collision with other object
complete to measurement run
Non-conformance not Incorrect tolerancing in CMM CMM programme tolerancing
Interpret CMM results Non-conformance escapes
identified programme overchecked before issue
Non-conformance not Inspector fails to note non- Produce separate print out/display of System does not allow component to move to next Op
Interpret CMM results Non-conformance escapes
identified conforming feature(s) non-conforming features until non-conformance has been sanctioned
Load correct diamond roll Incorrect diamond roll loaded Non-conforming part Diamond roll not checked against datacard Visual
Load correct diamond roll Incorrect diamond roll loaded Damage to grinding wheel and part Diamond rolls easily confused
Correctly grind component Component not to size Non-conformance Part movement due to a worn / damaged fixture Visual
Wrong diamond roll used as no checks completed against

Correctly grind component Component not to size Non-conformance Training matrix and record in place
diamond roll and datacard
Wrong diamond roll causing machine/fixture collision as no
Correctly grind component Impact damage on component Scrap/non-conformance Operator training and compliance
checks completed against diamond roll and datacard
Correctly grind component Impact damage on component Scrap/non-conformance Error in nozzle alignment causing machine/fixture collision SOP in place for nozzle alignment
Wrong nozzle used as no checks completed against nozzle Set-up trays available for each job with correct set-
Correctly grind component Surface finish not to specification Scrap/non-conformance
no. and datacard up kit
Error in nozzle alignment due to unclear/ambiguous op. Operator involved in creation of datacard and
Correctly grind component Burning of Component Scrap/non-conformance
drawings cross check datacard before shopfloor release
Incomplete grind due to corruption in server leading to non- IT partner maintenance of server and back up
Correctly grind component Can the control system be inaccurate? Dimensional errors
conforming component programmes
Moisture in optics causing poor

Laser component Laser cut not conforming Scrap/concession/rework quality beam
Chiller unit not stable causing
Laser component Laser cut not conforming Scrap/concession/rework poor quality beam
Laser component Laser cut not conforming Scrap/concession/rework Laser head not in position
Design head such that incorrect

Install welding head Welding head incorrectly installed Non-conforming weld Easy to incorrectly install head installation is not possible
Install welding head Incorrect welding head selected Non-conforming weld Welding heads are easily confused
Damaged welding heads not
Install welding head Damaged welding head fitted Non-conforming weld segregated
Only correct cleaning material
Clean weld surfaces Weld surfaces not clean Weld porosity incorrect cleaning agents used available
Clean weld surfaces Weld surfaces not clean Weld porosity Incorrect cleaning process Implement laser cleaning
Select correct gas Incorrect gas selected Contamination of weld Gas supply/bottles easily confused Only 1 supply available
Set gas flow rate Gas flow too low Oxidation of weld difficult to set correct flow Only 1 fixed flow
Set gas flow rate Gas flow too high Damage to gas shield Flow gauge difficult to interpret Only 1 fixed flow
Set correct weld current Weld current too high Component burned through Instructions misinterpreted Scan batch card to set current
Set correct weld current Weld current too low Lack of weld penetration Current indication incorrect Scan batch card to set current
Install gas shielding Shielding incorrectly installed Oxidation of weld Difficult to install shield correctly
Install gas shielding Shielding missing Oxidation of weld Not obvious when shield not installed
Load correct Grinding wheel to ID & Colour Code Already on

Wrong Wheel Used Poor Quality of Polished Part Unclear Identification on Wheels
machine Wheels
Load correct Grinding wheel to Wheel undertightened on Wheel released from machine, Torque settings and torque
machine machine HSE impact wrench not provided
Load correct Grinding wheel to Wheel overtightened on Wheel breaks up, HSE impact Torque settings and torque
machine machine wrench not provided
Incorrect Speed Readout Use of Technical Instructions and

Set correct Spindle Speed Set Incorrect Spindle Speed Poor Quality of Polished Part
Setting Disciplines Setting of LED Readout
Dress Grinding Wheel using Wrong Dressing Stone Used Carborundum Honing Stick or
Abrasive Stone Wheel Not correctly Dressed Poor Quality of Polished Part Rotary Grinding Torch Specified
in Technical Instructions
Dress Grinding Wheel using
Abrasive Stone Wheel Not correctly Dressed Poor Quality of Polished Part Worn dressing stone used
Correctly dress component Component over-dressed Non-conformance Poor lighting in area
Correctly dress component Component over-dressed Non-conformance Instructions not explicit
Correctly dress component Component under-dressed Rework required Poor lighting in area
Correctly dress component Component under-dressed Rework required Instructions not explicit
Fit masks to parts Masks not fitted to parts Surface damage to parts Masks difficult to fit Design masks to be simple to fit
Fit masks to parts Masks incorrectly fitted Surface damage to parts Masks difficult to fit Design masks to be simple to fit
Fit masks to parts Worn masks fitted Surface damage to parts No check on condition of masks Initiate regular condition checks
Polish component to achieve Sample check roughness of parts

Surface finish not achieved Rework required Initial surface roughness too high
required surface finish pre-polishing
Polish component to achieve Only correct media available at
Surface finish not achieved Rework required Incorrect media in bowl
required surface finish workstation
Polish component to achieve Specify and record checks of
Surface finish not achieved Rework required Worn media in bowl
required surface finish media condition
Polish component to achieve
Surface finish not achieved Rework required Incorrect media mix in bowl
required surface finish
Surface finish not achieved Rework required Media not flowing in bowl Bowl Fixturisation.
Polish component to achieve Only correct paste available at
Surface finish not achieved Rework required Incorrect paste used
required surface finish workstation
Surface finish not achieved Rework required Bowl not vibrating sufficiently Preventitive maintenance
Polish component to achieve Timer prevents interruption of
Surface finish not achieved Rework required Insufficient time in bowl
required surface finish process until complete
Polish component to achieve Remove all unneccessary
Surface finish not achieved Rework required Wrong program selected
required surface finish programs
Polish component to achieve Remove all unneccessary
Surface damage on parts Rework/non-conformance Wrong program selected
required surface finish programs
Surface finish uneven Rework/non-conformance Bowl weights not set.
Polish component to achieve Incorrect number of parts loaded
Surface damage on parts Rework/non-conformance
required surface finish into bowl
Surface damage on parts Masks fall off during process cycle
Check surface finish Surface finish read too rough Uneccessary rework Difficult to use gauge correctly
Check surface finish Surface finish read too smooth Non-conforming part escapes Difficult to use gauge correctly
Check surface finish Surface finish check missed Non-conformance moved on

Load components into correct Components loaded into Components treated at wrong No clear instructions on how to Holding fixtures baulked to prevent
position in furnace incorrect position in furnace temperature load furnace incorrect placement in furnace
Enter heat treat temperature Instructions misread, typing error, Inspection of Temperature -v- Temperature profile selected by
Temperature entered too high Component scrapped
to controller confusion with other parts time graph scanning batchcard
Enter heat treat temperature Material chemistry not Instructions misread, typing error, Inspection of Temperature -v- Temperature profile selected by
Temperature entered too low
to controller achieved - scrap/concession confusion with other parts time graph scanning batchcard
Heat treat to defined Material chemistry not Inspection of Temperature -v- Temperature profile selected by
Heat treat to wrong profile Timer(s) not correctly set
temperature v time profile achieved - scrap/concession time graph scanning batchcard
Heat treat to defined Material chemistry not Control Thermocouple not Use triplicate thermocouples Regular thermocouple calibration
Heat treat to wrong profile
temperature v time profile achieved - scrap/concession calibrated to isolate incorrect reading regime
Heat treat to defined Material chemistry not Control Thermocouple reading Use triplicate thermocouples Regular thermocouple calibration
temperature v time profile achieved - scrap/concession incorrectly to isolate incorrect reading regime
Heat treat to defined Material chemistry not Control thermocouple incorrectly Use triplcate thermocouples Regular thermocouple calibration
temperature v time profile achieved - scrap/concession positioned in furnace to isolate incorrect reading regime
Check media quality and Visual indicators on glass ball peen

Worn media not removed Uneven surface roughness Media not replaced regularly
remove worn media media hoppers
Check media quality and Media not separated (blocked Visual indicators on glass ball peen
Media worn Uneven surface roughness
remove worn media filter) media hoppers
Wrong grade of media Incorrect labelling of media
Select correct grade of media Uneven surface roughness
selected bags
Wrong grade of media
Select correct grade of media Uneven surface roughness Media bags easily confused Define laydown area
selected
Load with correct grade of Incorrect grade of media left Media build up inside of unit
Damage due to rogue shot
media in machine due to inadequate extraction
Timeframe for checking media Visual indicators on media hoppers.
Check media level correct Media level too low Uneven surface roughness
level not specified Machine tripped if incorrect
Visual indicators on media hoppers.
Check media level correct Media level too high Uneven surface roughness Media levels difficult to check
Machine tripped if incorrect
Fatigue resistance properties
Set correct blast pressure Blast pressure too low Faulty pressure regulator
diminished
Part damage / media
Set correct blast pressure Blast pressure too high Faulty pressure regulator
embedded in surface
Check nozzle angle Nozzle angle incorrect Uneven surface roughness
Check nozzle diameter Nozzle diameter incorrect Uneven surface roughness
Set part at correct angle Part not set to correct angle Uneven surface roughness
Overspray on Fixture markings (RRTs) not Regular fixture checks. Maintenance

Select correct fixture Incorrect fixture
aerofoil/platform(s) visible / faded programme.
Overspray onto Lack of fixture maintenance Check all fixtures. Establish sensible
Check fixture for wear Worn fixture
aerofoil/platform programme maintenance programme.
Metal spray defined areas of Overspray on wrong areas of Part not held in correct Ensure fixture can only hold part in
Rework/scrap
component component orientation correct orientation
Set correct spray pressure Spary pressure too high Metal spray may not bond Faulty pressure regulator Regular checks of pressure regulator
Set correct spray pressure Spray pressure too low Metal spray may not bond Faulty pressure regulator
Visual indicators on sandblast media

Check correct media level Media level too low Oxide layer not removed Media level not checked
hoppers? Separation of worn media?
No standard for media topping
Check correct media level Media level too low Machine damage
up
Check correct media level Media level too high Machine damage Media level difficult to interpret
Wrong grade of media Incorrect labelling of media

Check correct media Oxide layer not removed
selected bags
Wrong grade of media
Check correct media Part damaged
selected
Oxide layer not completely Visual indicators on sandblast media
Check correct media Media worn Media not replaced regularly
removed hoppers? Separation of worn media?
Oxide layer not completely Media not separated (blocked
Check correct media Media worn
removed filter)
Incorrect labelling of media
Check correct media Wrong grade of media Oxide layer not removed Define laydown area
bags
Incorrect labelling of media
Check correct media Wrong grade of media Pipework damaged/worn
bags
Part damage / media
Set correct blast pressure Blast pressure too high Faulty pressure regulator
embedded in surface
Set correct blast pressure Blast pressure too high Machine damage Faulty pressure regulator
Automated Sandblasting Blast pressure too low Oxide layer not removed Faulty pressure regulator
Check nozzle for

Nozzle worn/damaged Uneven surface roughness Nozzle not checked before use
wear/damage
Correctly Sandblast Component not blasted in Oxide layer not completely Part not held at correct angle Develop fixtures to ensure 100%
component correct areas removed - rework to ensure coverage coverage? Automation?
Correctly Sandblast Component not blasted in Oxide layer not completely Operator unable to see part
component correct areas removed - rework due to poor lighting
Correctly Sandblast Oxide layer not completely
Component underblasted Blasting time too short
component removed - rework
Degrease part Parts not properly degreased Contamination of next process Water Contaminated
Degrease part Parts not properly degreased Contamination of next process Soap concentration incorrect
No soap added (only water in

Degrease part Parts not properly degreased Contamination of next process
machine)
May need a clearly defined laydown area. Instructions are
Degrease part Parts not properly degreased Contamination of next process Incorrect soap used
available but may need to be more prominent
Extraction tank situated right next to degreaser - if
Degrease part Parts not properly degreased Contamination of next process Water not replaced
working, could facilitate more regular changes
Degrease part Parts not properly degreased Contamination of next process Water not replaced Replacement programme?
Faulty thermostat in
degeasing machine
Faulty motor in degreasing Could incorporate a 'wheel check' prior to job. It is
machine possible to check wheel rotates with lid open.
Degreasing cycle stopped
before complete
Fail to fit parts due to confusion Unable

Assemble in correct sequence Assembled in incorrect sequence to fit subsequent parts Parts not available in correct sequence
Assemble in correct sequence Assembled in incorrect sequence to fit subsequent parts Sequence not formally instructed
Assemble in correct sequence Assembled in incorrect sequence to fit subsequent parts Sequence ignored
Select correct part Incorrect part selected Escape to customer or rework Parts easily misidentified
Select correct part Incorrect part selected Escape to customer or rework Parts wrongly identified
Select correct part Incorrect part selected Escape to customer or rework Parts stored in wrong location
Select correct fastenings Incorrect fastenings selected Escape to customer or rework Fastenings easily misidentified
Select correct fastenings Incorrect fastenings selected Escape to customer or rework Fastenings wrongly identified
Select correct fastenings Incorrect fastenings selected Escape to customer or rework Fastenings stored in wrong location
Select tool(s) Incorrect tool(s) selected Damage to component/tool Tools easily mistaken
Select tool(s) Incorrect tool(s) selected Damage to component/tool Correct tool not available
Select tool(s) Incorrect tool(s) selected Damage to component/tool Tools poorly identified
Select tool(s) Incorrect tool(s) selected Damage to component/tool Tools not correctly specified
Time wasted
Remove covers Covers not removed Damage to product Covers not visually obvious
Heat component to prescribed Unable to fit component

temperature Component not heated Damage to component Instructions unclear
Heat component to prescribed Component not heated to correct Unable to fit component Thermostat incorrect
temperature temperature Damage to component Insufficient heating time
Heat component to prescribed Unable to fit component
temperature Component cools before fitting Damage to component Heater distant from component
Unable to fit component

Cool component (nitrogen) Component not cooled Damage to component Instructions unclear
Cool component (nitrogen) Component not sufficiently cooled Damage to component Insufficient cooling time
Cool component (nitrogen) Component warms before fitting Damage to component Cooler distant from component
Damage during fitting

Rework required at subsequent
operation
Install part Part attached in wrong orientation Escape to customer Correct orientation unclear
Rework required at subsequent Part not available
operation Assembly sequence altered
Install part Part not installed Escape to customer Assembly sequence not adhered to
Torque setting gives incorrect tension

Lubricate fastenings Fastening not lubricated Wear of component in service Lubricants easily confused Provide pre-lubricated fastenings
Torque setting gives incorrect tension
Lubricate fastenings Incorrect lubricant used Wear of component in service No lubricant available Provide pre-lubricated fastenings
Assembly sequence not adhered to

Insert fastenings All fastenings not installed Escape to customer Operator disturbed during assembly
Assembly sequence not adhered to
Insert fastenings Some fastenings not installed Escape to customer Operator disturbed during assembly
Time lost Incorrect tooling used
Insert fastenings Fastenings damaged during fitting Escape to customer Fitting requires excessive skill
Time lost Fit temporary covers to prevent parts
Insert fastenings Fastening dropped into product Escape to customer/FOD damage Difficult to access location falling into product
Not torquing in required sequence

Torque tighten fastenings in correct No defined torquing sequence
sequence Fail to torque Component detaches in service Fitter distracted/shift change
Torque tighten fastenings in correct Component detaches in service Torque tool not used
sequence Under torque Air/fluid leaks Torque tool incorretly set
Torque tighten fastenings in correct Fastenings fail & component detaches Torque tool incorrectly set
sequence Over torque and/or air/fluid leaks Torque tool not used
Sequence not clearly specified
Torque tighten fastenings in correct Component not seated correctly Sequence not easy to follow
sequence Incorrect sequence resultingin air/fluid leaks Fitter distracted/shift change
Unable to despatch product

Measure and record data Fail to record data Time waste and rework
Measure and record data Recording incorrectly Product performance not optimum
Unable to despatch product
Measure and record data Partially record data Time waste and rework
Process/Worksheet Process Step Identified Failure Mode Potential effects Potential Cause of Failure Possible Detection Possible Prevention
Preparation of faying surface

Cleaning performed using JES 221 instructs to use the hand gloves
for electrical bonding as per Cleaning of faying surface Improper cleaning Visual inspection
bare hand to carry out the cleaning process
JES221
Fitter training to dispose the

Preparation of faying surface contaminated solvent after every use
Contaminated cleaning
for electrical bonding as per Cleaning of faying surface Improper cleaning Visual inspection and store incharge ensures sufficient
solvent used for cleaning
JES221 solvents are available at work place &
COSHH board
Contaminated cleaning Fitter training to use the clean

equipments used for equipments and store incharge ensures
for electrical bonding as per Cleaning of faying surface Improper cleaning Visual inspection
cleaning. the continuous availability of cleaning
JES221
Non conformance. Delay in i.e.Wipes/Gloves. equipments
process as the contaminated
faying surface need re Poor lighting facility, fitter
cleaning may not notice the
for electrical bonding as per Cleaning of faying surface Improper cleaning Visual inspection Periodic illumination audit
contamination present on
JES221
Poor electrical conductivity the faying surface
during test, need rework.
Preparation of faying surface Hence delay in process Approved wipes/cleaning PL and store incharge ensures
for electrical bonding as per Cleaning of faying surface Improper cleaning agent/wet wipes not Visual inspection continuous availability of approved
JES221 available on the bay cleaning equipments/agent
Preparation of faying surface Approved wipes/cleaning PL and store incharge ensures

Cleaning residue on faying
for electrical bonding as per Cleaning of faying surface agent/wet wipes not Visual inspection continuous availability of approved
surface
Preparation of faying surface Fitter distracted and not

Cleaning residue on faying PL ensures that fitters are assigned
for electrical bonding as per Cleaning of faying surface completed the cleaning Visual inspection
surface single task at a time
JES221 Non conformance. Delay in process
process as the cleaning
Preparation of faying surface residue on faying surface to
Cleaning residue on faying Poor condition of cleaning Store incharge ensures that continuous
for electrical bonding as per Cleaning of faying surface be removed by re cleaning Visual inspection
surface equipment availability of cleaning equipments
JES221
Poor electrical conductivity
Preparation of faying surface during test, need rework.
Cleaning residue on faying Cleaning SOPs are approved by the
for electrical bonding as per Cleaning of faying surface Hence delay in process Inadequate work instruction Visual inspection
surface authorised department
JES221
Preparation of faying surface Approved wipes/cleaning PL and store incharge ensures
for electrical bonding as per Cleaning of faying surface Mating faces partially cleaned agent/wet wipes not Visual inspection continuous availability of approved
Preparation of faying surface Fitter distracted and not

PL ensures that fitters are assigned
for electrical bonding as per Cleaning of faying surface Mating faces partially cleaned completed the cleaning Visual inspection
single task at a time
JES221 process
Non conformance. Delay in
Preparation of faying surface process as the mating faces Fitter missed to clean the
JES 221 indicates the cleaning area and
for electrical bonding as per Cleaning of faying surface Mating faces partially cleaned to be re cleaned again entire area / extra periphery Visual inspection
fitter training on cleaning process
JES221 on the faying surface
Poor electrical conductivity
Preparation of faying surface during test, need rework. Cleaning SOPs are approved by the
for electrical bonding as per Cleaning of faying surface Mating faces partially cleaned Hence delay in process Inadequate work instruction Visual inspection
authorised department
JES221
Preparation of faying surface Inappropriate

Excess material removed / JES 221 specifies the correct
for electrical bonding as per Cleaning of faying surface abrasion/sanding technique Visual inspection
Damage on faying surface abrasion/sanding technique to be used
JES221 used
Non conformance. Delay in
Preparation of faying surface process as the faying surface
Excess material removed / to be repaired Poor condition of cleaning Store incharge ensures that continuous
for electrical bonding as per Cleaning of faying surface Visual inspection
Damage on faying surface equipment availability of cleaning equipments
JES221
Potential scrap of part due to
Preparation of faying surface excess material removal Store incharge ensures that continuous
Excess material removed / Approved abrasion material Visual inspection
for electrical bonding as per Cleaning of faying surface availability of approved cleaning
Damage on faying surface May deteriorate the life of not available
JES221 equipments
the joint
Excess material removed / Cleaning SOP's are approved by the
for electrical bonding as per Cleaning of faying surface Inadequate work instruction Visual inspection
Damage on faying surface authorised department
JES221
Damage/Surface scratch on No instruction to select the
for electrical bonding as per Cleaning of faying surface Visual inspection None
faying surface Delay in process as the Garnet paper grade
JES221
faying surface to be repaired
Preparation of faying surface to achieve the required Store incharge ensures that continuous
Damage/Surface scratch on
for electrical bonding as per Cleaning of faying surface surface finish Worn out Garnet paper used Visual inspection availability of garnet papers and fitter
faying surface
JES221 training on polishing process
Reduces the fatigue life of
Preparation of faying surface the joint
Damage/Surface scratch on Cleaning SOP's are approved by the
for electrical bonding as per Cleaning of faying surface Inadequate work instruction Visual inspection
faying surface authorised department
JES221
Preparation of faying surface PL and store incharge ensures the

Appropriate swarf removal
for electrical bonding as per Cleaning of faying surface Swarfs not removed Visual inspection continuous availability of swarf removal
brush not available
JES221 brush
Preparation of faying surface JES 221 instructs to remove the swarf

Fitter missed to remove the
for electrical bonding as per Cleaning of faying surface Swarfs not removed Visual inspection inorder to achieve the clean surface
swarf
JES221 Contamination on the faying after polishing
surface
Preparation of faying surface Poor electrical conductivity Poor lighting facility, fitter
for electrical bonding as per Cleaning of faying surface Swarfs not removed during test, need rework. may not notice the swarf Visual inspection Periodic illumination audit
JES221 Hence delay in process present on the faying surface
Preparation of faying surface PL and store incharge ensures the

Swarf trapped in Blanking plug/Masking tape
for electrical bonding as per Cleaning of faying surface Visual inspection continuous availability of blanking
holes/Threaded surface Applies less clamping not available
JES221 plug/masking tape
pressure
Preparation of faying surface Potential thread damage

Swarf trapped in Blanking plug/masking tape
for electrical bonding as per Cleaning of faying surface Visual inspection Fitter training on the cleaning process
holes/Threaded surface Potential FOD entry to open not used
JES221
holes
Non availability of safety PL issues safety equipments to
for electrical bonding as per Cleaning of faying surface None
equipments individual fitters and they maintain it
JES221 Safety equipments not used Injury to fitter
Preparation of faying surface (HS&E issue) Fitter informs production lead and PL
Non availability of safety
for electrical bonding as per Cleaning of faying surface None takes necessary action to provide the
data sheet
JES221 Safety equipments not used safety data sheet
To suggest additions to the failure mode list:

Enter the process/worksheet to be added to or if required enter a new process category
State the process step (could be existing or new)
List the failure modes related to that process step
List the potential effects of the failure modes
List the potential causes that could initiate the failure mode
List the ways in which the cause(s) could be detected
List the ways in which the failure mode could be prevented from occuring
When complete please e-mail this sheet to: mark.fall@rolls-royce.com (RRPS Core Team - Quality Operating System module co-ordinator)
Applicability: Global
Title: PFMEA
Author: Andrew Wall
Document Owner: Andtrew Wall
Version Number: 3
Issue Date and Change History: 10/22/2018

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KEY PRODUCT KEY CONTROL

KEY PRODUCT KEY CONTROL

Process Failure Mode and Effects Analysis (PFMEA)

Product Details / Part nos: Process Details: Dates Revised: Issue #

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Process Failure Mode and Effects Analysis (PFMEA)

Product Details / Part nos: Process Details: Dates Revised: Issue #

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Current Specified Process Controls: Recommendations Action results

RRPS PFMEA Template Printed 12/11/2020

Process PPM Likelihood of Cause Time-Based

Failure to meet safety and/or Failure to meet safety and/or

Low: Failures are few and far

Zero Zero Never

To suggest additions to the failure mode list:

Monitor machine for E-stop or

Damage to machine / fixture. Machine design to assure free access for

None. (Note - failure is usually detected

Lost-time injury Operator compares TI with fixture tool number prior

Loading SOP provided, with check routine.

Part scrap / rework.

All clamps and locators in fixture automatically spring

Potential lost-time injury if part not secured to

Potential lost-time injury if part not secured to

Potential lost-time injury if part not secured to

Potential lost-time injury if part not secured to

Potential lost-time injury if part not secured to

Potential lost-time injury if part not secured to

Load fixture and part to equipment (Use

Part scrap / rework

Part scrap / rework Hydraulic - pressure setting on power pack.

Part scrap / rework

Potential lost-time injury

Part scrap / rework

Potential lost-time injury

Manual - clamps are swung away from part, visual

Component incorrectly placed

Injury to operator, damage to fixture or

Fixture not loaded / incorrectly Fixture not clamped to