Version Control

Version Revision notes

0 Rewritten to the standard agreed in November 2017 ( by Drilling GPO)

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Template Instructions
1 For Reference PFMEA press option 1.
For Process / Product application press option 2. to expand the full PFMEA
2 columns.
ersion Control
Date Who GPO Notes GPO
Theodoros Panagiotidis Andy
12/14/2017 Andy Mantle Mantle Andy Mantle
Gregor Kappmeyer
 Quality Check
GPO Head of ME (Central Team)

Andy Mantle Phil Holmshaw

 WARNING STATEMENT AND DESTINATION CONTROL STATEMENT

Export Control
Jurisdiction Classification Date
(Rating)
UK Not Listed 14-Dec-17

© 2017 Rolls-Royce Plc. All Rights Reserved.

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

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

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

Rated by

Andy Mantle
 Requirements (Product
Characteristics)
What is the Product Characteristic
we need to achieve during the
process (diameter, depth, length, What could be wrong with the
radius, CME, surface finish,
metallurgy standard, adhesion, big, hole too small, CME outside
residual stress, coverage etc - or spec, too rough surface finish)
avoid such as damage, weld
spatter etc)
Hole Diameter
Potential Failure Mode Potential Cause(s) of Failure
1st level why of the 5 whys (the
top things we would look at)…if I
get this occuring when I use this
Product Characteristic (hole too
FMEA then I need an
to avoid potential causes occuring
improvement activitiy that would
understand root cause and close
out plan.
Wrong tool or/and wrong tool
Hole Too Big holder or/and tool setting
incorrect.
Tool wear / damaged tool
Incorrect program loaded to
machine and/or incorrect position
in program
Part distortion from residual
Stress
Part incorrectly loaded in fixture
Wrong tool or/and wrong tool
Hole Too Small holder or/and tool setting
incorrect.
Part distortion from residual
Stress
Tool wear / damaged tool
Not present Tool wear / damaged tool
Wrong tool or/and wrong tool
holder or/and tool setting
incorrect.
Incorrect program loaded to
machine and/or incorrect position
in program
Control (Prevention)
Typical provention controls used How would we detect that the
Tool preset check.
Power Monitoring
Tool preset check.
Power Monitoring
Coolant check - asset care
Independent Overcheck of
programs
Method sealed once approved
Method sealed once approved.
Error proof fixture.
fixture maintenance
operator fixture check
Tool preset check.
Power Monitoring
Manual check of tool grade
Method sealed once approved.
Error proof fixture.
Tool preset check.
Power Monitoring
Tool preset check.
Power Monitoring
Tool preset check
Independent Overcheck of
programs
Method sealed once approved
Control (Detection)
failure mode has occurred
Bore Micrometer Inspection
CMM Inspection
Bore Micrometer Inspection
CMM Inspection
Bore Micrometer Inspection
CMM Inspection
Bore Micrometer Inspection
CMM Inspection
Bore Micrometer Inspection
CMM Inspection
Bore Micrometer Inspection
CMM Inspection
Bore Micrometer Inspection
CMM Inspection
Bore Micrometer Inspection
CMM Inspection
Visual Inspection
Visual Inspection
Visual Inspection
 Requirements (Product
Characteristics)
What is the Product Characteristic
we need to achieve during the
process (diameter, depth, length, What could be wrong with the
radius, CME, surface finish,
metallurgy standard, adhesion, big, hole too small, CME outside
residual stress, coverage etc - or spec, too rough surface finish)
avoid such as damage, weld
spatter etc)
Surface finish/quality
Potential Failure Mode Potential Cause(s) of Failure
1st level why of the 5 whys (the
top things we would look at)…if I
get this occuring when I use this
Product Characteristic (hole too Typical provention controls used
FMEA then I need an
to avoid potential causes occuring
improvement activitiy that would
understand root cause and close
out plan.
Surface finish and visual defects Wrong tool or/and wrong tool
(smearing, burrs, etc.) out of holder or/and tool setting
spec. incorrect.
Tool wear / damaged tool
Swarf build up/nesting
Incorrect coolant application
Incorrect program loaded to
machine and/or incorrect position
in program
Part incorrectly loaded in fixture
Control (Prevention) Control (Detection)
How would we detect that the
failure mode has occurred
Tool preset check. Bino/ Penetrant / Manual
Power Monitoring Inspection.
Manual check of tool grade Surface Roughness Inspection.
Bino/ Penetrant / Manual
Tool preset check.
Inspection.
Power Monitoring
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Coolant check - asset care
Inspection.
Method sealed once approved
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Coolant check - asset care.
Inspection.
Coolant monitoring.
Surface Roughness Inspection.
Independent Overcheck of Bino/ Penetrant / Manual
programs Inspection.
Method sealed once approved Surface Roughness Inspection.
Bino/ Penetrant / Manual
fixture maintenance
Inspection.
operator fixture check
Surface Roughness Inspection.
 Requirements (Product
Characteristics)
What is the Product Characteristic
we need to achieve during the
process (diameter, depth, length, What could be wrong with the
radius, CME, surface finish,
metallurgy standard, adhesion, big, hole too small, CME outside
residual stress, coverage etc - or spec, too rough surface finish)
avoid such as damage, weld
spatter etc)
Countersink Size
Potential Failure Mode
Product Characteristic (hole too
Countersink too Small
Countersink too Big
Countersink angle incorrect
Potential Cause(s) of Failure
1st level why of the 5 whys (the
top things we would look at)…if I
get this occuring when I use this
Typical provention controls used
FMEA then I need an
to avoid potential causes occuring
improvement activitiy that would
understand root cause and close
out plan.
Datum setting issues
Wrong tool or/and wrong tool
holder or/and tool setting
incorrect.
Tool wear / damaged tool
Part incorrectly loaded in fixture
Incorrect program loaded to
machine and/or incorrect position
in program
Datum setting issues
Wrong tool or/and wrong tool
holder or/and tool setting
incorrect.
Part incorrectly loaded in fixture
Machine geometric/dynamic
errors / Machine wear
Wrong tool or/and wrong tool
holder or/and tool setting
incorrect.
Tool wear / damaged tool
Swarf build up/nesting
Part incorrectly loaded in fixture
Control (Prevention) Control (Detection)
How would we detect that the
failure mode has occurred
Part setting / checking CMM Inspection
Tool preset check.
CMM Inspection
Power Monitoring.
Tool preset check.
CMM Inspection
Power Monitoring
fixture maintenance
CMM Inspection
operator fixture check
Independent Overcheck of
programs CMM Inspection
Method sealed once approved
Part setting / checking CMM Inspection
Tool preset check.
CMM Inspection
Power Monitoring
fixture maintenance
CMM Inspection
operator fixture check
machine maintenance CMM Inspection
Tool preset check. CMM Inspection
Tool preset check.
CMM Inspection
Power Monitoring
Coolant check - asset care
CMM Inspection
Method sealed once approved
fixture maintenance
CMM Inspection
operator fixture check
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

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

Hole Depth Hole Depth too Shallow Datum setting issues Part setting / checking CMM Inspection
Wrong tool or/and wrong tool
Tool preset check.
holder or/and tool setting CMM Inspection
Power Monitoring.
incorrect.
Tool preset check.
Tool wear / damaged tool CMM Inspection
Power Monitoring
fixture maintenance
Part incorrectly loaded in fixture CMM Inspection
operator fixture check
Incorrect program loaded to Independent Overcheck of
machine and/or incorrect position programs CMM Inspection
in program Method sealed once approved
Tool preset check.
Cutting tool deflection CMM Inspection
Spindle check.
Hole Depth too deep Datum setting issues Part setting / checking CMM Inspection
Wrong tool or/and wrong tool
Tool preset check.
holder or/and tool setting CMM Inspection
Power Monitoring
incorrect.
fixture maintenance
Part incorrectly loaded in fixture CMM Inspection
operator fixture check
Tool preset check.
Cutting tool deflection CMM Inspection
Spindle check.
Machine geometric/dynamic
machine maintenance CMM Inspection
errors / Machine wear
Incorrect hole bottom radius Tool preset check.
Tool wear / damaged tool CMM Inspection
(counterbore) Power Monitoring
Wrong tool or/and wrong tool
holder or/and tool setting Tool preset check. CMM Inspection
incorrect.
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure Control (Prevention) Control (Detection)
Characteristics)

What is the Product Characteristic

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

Machine geometric/dynamic
Hole/CSK Position Out of Position machine maintenance CMM Inspection
errors / Machine wear
Datum setting issues Part setting / checking CMM Inspection
Tool preset check.
Tool wear / damaged tool CMM Inspection
Power Monitoring
Machine Calibration
Incorrect program loaded to
Independent Overcheck of
machine and/or incorrect position CMM Inspection
programs
in program
Method sealed once approved
fixture maintenance
Part incorrectly loaded in fixture CMM Inspection
operator fixture check
Tool-holder wear/damage Tool-holder preset check. CMM Inspection
 Cause Description
Cutting tool push-off, pull-out/push-
in.
Cutting tool deflection
Tool vibration.
Spindle distortion.

Machine datum incorrectly

manually/automatic set.
Incorrect application of coordinate
systems.
Incorrect verification settings
(probe errors: qualification, Foreign
Datum setting issues
Object Debris, worn/damaged
probe, ruby size, etc.).
Incorrect incoming Condition of
Supply.
Incorrect dimensional measurement
of part (inappropriate Gauge R&R).

Reset of program during processing

/ power cut / rework, wrong
Incorrect program loaded to
speed/feed/depth of cut/cutting
machine and/or incorrect position in
strategy.
program
Manually altered feed / speed rate.
Tolerance level used within CAM.

Wrong type, pressure, flow,

concentration, temperature,
Incorrect coolant application
direction, cleanliness.
Swarf obstructing coolant.

Machine axis
misalignement/backlash due to
machine wear/collision.
Insufficient machine warm up.
Kinematic errors.
Thermal induced errors.
Machine geometric/dynamic errors /
Controller positioning errors/ wrong
Machine wear
settings.
Spindle vibration / wear.
Axis run out.
Poor Spindle - Tool-holder interface
condition.
Incorrect pull-back forces.

Part distortion from bulk part

Part distortion from residual Stress Residual Stress, machining induced
residual stresses
 Fixture condition/wear.
Clamping sequence,
overclamping/underclamping
causes part distortion/movement.
Incorrect fixture.
Foreign Object Debris.
Part incorrectly loaded in fixture
Wrong component orientation.
Wrong fixture orientation/position.
Poor fixture design.
Incorrect documentation /
identification / label / serial
number.

Swarf build up interfering with m/c

Swarf build up/nesting
components
Tool wear/damage/breakage.
Tool wear / damaged tool
Built up edge.

Damaged tool-holder (tool-holder -

tool interface, Tool-holder -
machine interface).
Tool-holder wear/damage
Clamping mechanism and/or Taper
damage/wear/deterioration.
Movement of tool in holder.

Insert/tool/tool-holder not properly

located/clamped. Wrong tool/tool-
holder (operator's error / supplier),
Wrong offsets, wrong
length/overhang.
Inappropriate tool/tool-holder
Wrong tool or/and wrong tool holder stiffness.
or/and tool setting incorrect. Tool-holder's pull stud incorrect.
Incorrect tool shape/form/edge
rounding/honing.
Tool runout.
Incorrect documentation /
identification / label / serial
number.