Venkata Sai Rishith Ghantasala

CONCURRENT ENGINEERING : IE655

Professor: PAUL G. RANKY, BS / MS (Hons) Mech. and Ind. Eng., MS (Eng. Edu.), PhD
(Automation Eng. with IT)

DATE: 27th March 2016

eLearning Pack ID: IE655-Spring 2016-36-27

Work completed by Venkata Sai Rishith Ghantasala

Collaborative Companies:

Seco tools
Edge-A magazine from SECO
EVINRUDE,E-tech
Schmaltz

Contents:

1. Introduction & Objectives of Project

2. Description of Methodology Applied
3. Main Body of Project
3.1 FMEA/DFRA
3.2.Main process failure modes and solution process
3.3 Potential failure modes for the images
3.4. Reliability analysis -Beta ver. Ranky-Weibull calculator
3.5. Collaboration

4. Summary
5. Further work
6. Social networking articles
7. References

1. Introduction & Objectives of Project

Our company GREEN APPLICATION is one of the highly exclusive band of
engineering applications that builds its own CNC-SPMs, allowing its customers to
benefit from a dual advantage cost-effectiveness and enhanced online
capabilities. Its vast machine pool and an expert engineering team with the highest
level of technical and professional competence produce products that are complex
and meet the high quality standard of its customers.
Our Mission is to contribute towards Green and Sustainable Environment. We do our
bit towards this by having constructed a Green buildings in our premises. The
corporate office, engineering division are platinum rated buildings. We have solar
water heater installed in all the buildings along with a huge water treatment plant
built to treat the water which is polluted from our machining processes. Also there is
a scrap yard to make sure the rejected components are either reworked or given a
new shape so that the metals are not wasted.

2. Description of the methodologies applied:

We will be implementing Process Failure Risk Analysis (PFRA) method and software
tool during the planning stages of a process. PFRA is a Team Oriented Problem
Solving (TOPS) method, aimed at minimizing dissatisfaction and financial loss for
process related failure risks. The seven key aspects of our generic methodology
which must be followed before beginning to work on any process failure risk study
with our PFRA Tool are as follows:

1. Defining the scope, function and purpose of the system or sub-system, or any
product, or process design to be analyzed.
2. Identifying the potential risks and failure modes and their effects by applying
the PFRA technique during the process, and creating, or analyzing the
existing BOM (Bill of Material) file. The PFRA will help the team to gradually
deepen the product, process or system design analysis and locate all
potential failures at the earliest possible stage
3. Prioritize potential failures by ranking the critical quality, cost, and safety
related faults and eliminate them by the cross-functional team as early as
possible.

4. The cases involving high risk of potential failures must be identified, selected
and managed by devising an immediate control plan to get the processes in
control by following our basic TQM principles.
5. Observe and learn by creating living knowledge-managed document that
needs to be kept up-to-date for each system or product/process design,
PFRA / DFRA. It should not be retrospective, but kept as a valuable source of
information for current, as well as for future products.
6. Documenting the process is an important aspect, as the team goes along,
and store the PFRA / DFRA contained information in a widely accessible
format (preferably, both electronically, such as our spreadsheet and
optionally on paper based media) for the current as well as for future Teams.
7. Enter the values into the PFRA / DFRA spreadsheet on a relative scale,
determined by the local PFRA / DFRA Team, as well as by the local,
customized standards they follow.
The rating rules are regarding:
Severity
Detection
Occurrence
The product with these rating values, gives a number called the risk priority number
[RPN] which can be used as a measure of the degree of failure risk.
The severity rating uses a scale from 1 to 10, where the lower rating is corresponds
to no effect on specified process or product performance and higher rating
corresponds to hazardous effects specified process or product performance. Here a
goal is achieving a lower rating.
The detection rating uses a scale from 1 to 10, where the lower rating is
corresponds to easily detecting process or product performance failure and higher
rating corresponds to impossibly detecting process or product performance. Thus,
the goal is achieving lower rating.
The occurrence rating uses the scale from 1 to 10, where the lower rating is
corresponds to lower failure rate i.e. less than 1 in 500,000 for specified process or
product, performance and higher rating corresponds to higher failure rate greater
than 1 in 3 for specified process or product performance. Also, the goal here is to
achieve low rating.

3. Main Body of the Project:

3.1.FMEA/ DFRA:

Our objective here is to identify a potentially at risk process, and analyze it using
the Process Failure Risk Analysis Method (PFRA).

In this case we have chosen to analyze our products which are using Sustainable,
Green Manufacturing Process for the Production of High Quality automobile
components.Our primary concern here is to identify any steps that may negatively
affect quality, sustainability and greening of our high quality automobile parts. We
also would like to identify any process steps that could cause our process to fail.
Once identified and correlated the results will be ranked and acted upon
accordingly. The purpose of applying the PFRA method is that it provides a
systematic, regulated, and measurable method to identify possible risks and to
prevent possible failures. The TQM team is able to help identify, understand and
rank the numerous problems that Engineers, Planners, Managers and Operators
face.
The PFRA spreadsheet can be found here:
https://drive.google.com/file/d/0B3DapaRrQktqMnQtUnYyYjlMeFE/view?usp=sharing

There are seven basic steps that should be applied when working with the PFRA
template. The PFRA spreadsheet is attached along with this. They are:

Setting up the website

Taking the reference of previous sites which are ecofriendly
Gathering the products which are of collaboration companies
Examing the products
Setting up the service for the delivery
Application testing with android,pc and apple
Usage and customers review analysis

Highest RPN and associated corrective actions:

Threading: Max RPN- 400 and Accumulated RPN 887.04

This has the highest RPN which shows that immediate attention is required. To
rectify this, the operators are subjected to more workshops and better equipments
are provided. Also, the quality engineers on the shop floor are asked to test the
threading more frequently. Also the equipments are subjected to destructive testing
to check the strength of the threads on the components.

Final Quality Control before packaging: Max RPN- 320 and Accumulated RPN- 511.10

This has the second highest RPN which requires immediate attention. The quality
department has adopted a more stringent quality checks before sending to the
packing. Also the earlier quality check are made more frequent. Also workshops are
organized to enlighten the operators and engineers about the value of 100% quality
and also certain easy but very important steps to increase the quality of each
component.

Storage of ready to ship products: Max RPN-288 and Accumulated RPNThis has the third highest RPN which requires immediate attention. The
maintenance department has decided to enhance the warehouse facilities by using
the latest weather control for the components. Also, the sales department is
frequently updated about the stock in the warehouse so that the sales can increase
when there in increase of finished goods in the warehouse.

3.2 Images review from Chapter 4 in the 3DeBook for Concurrent

Engineering:
Poor-Design-UnderwaterHousingPoster

The pictures above are of an underwater camera housing. On further

examining the pictures numerous examples of poor quality design are
illustrated.

In picture # IMG_1684 we can see rus5t and corrosion evident on the screws,
bolts washers and bent metal bar. This appears to be an example of poor
material choice when designing these components. These components need
to stand up to the conditions found when being submerged in water.

On close inspection, in picture # IMG_1685, there appears to be pitting and

imperfections in the clear Lexan like material used for the casing. This
suggests that a more appropriate material should have been chosen. Also the
round, black lens housing has some very small tapped holes with fine
threads. These small holes and the fine threads may not hold up well when
subjected to corrosive seawater.

Once again, in picture # IMG_1688, there appears to be pitting and

imperfections in the clear Lexan like material used for the casing. There also
appear to be scratches in the side of the casing. This would also indicate that

the material selected is not the most suitable for the application of housing
an underwater camera.

Picture # IMG_1689 shows the round, black lens housing with a lens installed.
The very small tapped holes with fine threads used to secure the lens in place
would not appear to hold up well when subjected to corrosive seawater. Also
it would be difficult to operate and access these screws without a tool and
this may be difficult if this operation needs to be done by a diver who is
possibly wearing gloves.

Picture # IMG_1692 shows the inside of the housing. On close inspection of

the threaded pieces sticking thru the side wall, the finish on these pieces
seems poor indicating poor or sloppy manufacturing. Also there seems to be
no type of protective coating to prevent possible corrosion on these threaded.

Picture # IMG_1693 shows the handle attached to the camera housing. The
bolts and nuts attaching the handle to the case seem to have evidence of
corrosion indicating poor material choice. Also the screws appear to be small
and easy to lose. They would be hard to assemble by a diver with gloves on.

Picture # IMG_1695 shows what appears to be a light/flash assembly for the

camera. There appears to be rounding of the Phillips screws holding the face
of the light/flash assembly. This indicates that a better design choice should
have been made when choosing a method to secure the face.

Pictures # IMG_1696 and # IMG_1697 shows what appears to be a hand

operated connector of some type. This connector appears to have a poor
finish to it and appears to be rather bulky and clumsy to operate.

Pictures # IMG_1699, # IMG_1701 and # IMG_1703 show an electrical

connection that has failed. The material used as the insulator between the
pins has broken and cracked off. This design was faulty and the material
chosen was not correct for the application.

Pictures # IMG_1704 shows a cap used to cover the failed electrical

connection that was described above. From a design stand point there should
be some kind of lanyard attaching the cap to the electrical connector so that
the cap does not become lost when removing it. Also this cap seems rather

small and hard to handle and would appear to be difficult for a diver with
gloves on.

3.3 Reliability Analysis Beta ver. Ranky-Weibull calculator

While performing the PFRA for the automobile parts, a problem surfaced during the
analysis. The problem was the Threading of the automobile parts. A max RPN of
400 made the to be attended immediately with the remedial work.
A corrective action was identified. To rectify this, the operators are subjected to
more workshops and better equipments are provided. Also, the quality engineers on
the shop floor are asked to test the threading more frequently. Also the equipments
are subjected to destructive testing to check the strength of the threads on the
components.

Corrective Action:
The results from our model indicated a Beta value of 1.06. Since this is greater than
(1) it is an indication that this process has an increasing failure rate. WEGA should
not take corrective action to prevent this failure of components.
As indicated earlier the preventive action would be to have more workshops on the
best use of the new components to achieve the highest quality. The other option is
to ensure there are more quality checks done by quality engineers on the shop floor
which prevents the number of components that do not conform to 100% quality.
The Ranky-Weibull calculator can be found here:
https://drive.google.com/folderview?
id=0B3DapaRrQktqZ1VJOVJFZjhSWTA&usp=sharing

3.4 Collaboration
Green application recognize all four collaborating companies as very important
partners which help is extremely valuable. As mentioned during analysis of PFRA,
Green application will actively collaborate with our partners to minimize the risk of
failure.
SECO-TOOLS
They make powerful cutters and inserts for milling which are suitable for machining
almost any work material, they work closely with manufacturers around the world to
develop a comprehensive understanding of the challenges and create the tools to
overcome them. They also specialize in manufacturing tools required for holemaking, turning and tool-holding products. They have acquired Niagara cutter, now
the combined product families produce cobalt and high speed steel end-mills which
are amongst industrys most productive product range of solid tools
Edge- A Magazine for Seco tools

"Edge is a customer Magazine from Seco Tools produced in different languages

worldwide. It is a model magazine containing new products and their benefits for
the customer, technical articles and customer care stories. it is not all about mental
cutting,fantastic photography, model layouts and well-written articles is the very
reason why edge has one the design wards. The Magazine production requires
paper printing which requires trees to be cut, instead of this we may opt for
alternate ideas which is provided by Go-Green App.
EVINRUDE E-Tech:
It is an American company that builds a major brand of outboard motors for boat. It
was founded by &le "vinrude in 2345. The quickest way to e6perience the power
that comes standard with every "vinrude product is to get out on the water and
open it up. The products provide good speed and torque and e6cellent fuel
efficiency, which gives the users more time on the water rather than at the pump.
The companys products are famous for instant throttle response, less fuel, high
torque, high 78, less weight and more power.This involves marine life and it is
essential that there are no fuel-leakages and other such precautions need to be
undertaken, the ideas which are give
Schmaltz:
It is a family run company and they focus on long term objectives, their philosophy
is based on sustainability, economic success combined with ecological and social
engagement, they ensure that we remain self-sufficient and afford the necessary
creative freedom, they e6pertise in (4 countries, vacuum solutions for automation
technology and clamping technology. With the advancements in Technologies and
automation we need to ensure increased protection to environment, as this
company involves ecological and social engagement, our application can be used to
broadcast the eco-friendly principles that need to be carried through the functioning

4. Summary:

By applying correctives fixes to the (3) process steps which had High values of
associated risk we are quickly able to diminish the potential of failure in our
Sustainable, Green Manufacturing Process for the Production of High Quality
automobile components.
The PRFA we performed not only identified the (3) potential problems but, provided
the order in which we should correct them. By doing this we are able to best utilize
our assets to maximize the corrective actions taken.

5. Further Work Needed:

There were (12) total process steps listed. Out of these we only concentrated on the
(3) failure modes that were rated as High. We should also review all of the other
modes of failure and take corrective actions to remove these potentials for failure.
This will not only help to create a TQM and TQC company but, it will potentially reap
the Sustainability and Greening benefits that removing these potential failures will
provide.

We must also continue to update and review this PFRA in the future to ensure all
modes of failure are identified and corrected.

6. Social networking articles

1.Feds Order Thousands Of Unsafe Tractor Trucks Off The Road
http://www.manufacturing.net/news/2016/03/feds-order-thousands-unsafetractor-trucks-road
I personally feel the government ordering federal and state inspectors to
remove certain Volvo tractor trucks from the road because of a steering
wheel defect that can cause a complete loss of control of the vehicle is a
very good sign as we can see that the major accidents occur by these volvo
tractors which can be seen by the statistics of road disasters is almost 12
percent. In the highways where the majority of vehicles are volvo trucks if
their is a high probability of vehicle imbalance which causes high risk. I feel it
was a proper move by the government.
2 Feds Order Thousands Of Unsafe Tractor Trucks Off The Road
https://prashanthmuralidhar.wordpress.com/2016/03/27/feds-orderthousands-of-unsafe-tractor-trucks-off-the-road/comment-page-1/#comment177
personally feel the government ordering federal and state inspectors to
remove certain Volvo tractor trucks from the road because of a steering
wheel defect that can cause a complete loss of control of the vehicle is a
very good sign as we can see that the major accidents occur by these volvo
tractors which can be seen by the statistics of road disasters is almost 12
percent. In the highways where the majority of vehicles are volvo trucks if
their is a high probability of vehicle imbalance which causes high risk. I feel it
was a proper move by the government
3 VW, Porsche recall of 800,000 SUVs
https://prashanthmuralidhar.wordpress.com/2016/03/27/social-networkingassignment-3/comment-page-1/#comment-175

This may be considered as a major debacle for the VW and porsche which
are known for their quality and comfort for the customers. It can be a major
setback for their business as the have to contact the customers and examine
the vehicle as which would cause a high discomfort for them. Any technically
flaws should be pre-examined and should be cleared out. I think it would
effect the future business of these companies as the customers will be in a
oscillating state of mind considering the previous flaws regarding the safety.
Well we have to see what does these companies do in the future to regain
their glory .

7. References:

Concurrent / Simultaneous Engineering An e-book by Dr..Paul G Ranky

Quality Management for Organizational Excellence by David.L.Goetsch and
Stanely.B.Davis