Title: Assignment3

Author: Shruthi Thota

Class: IE655
Date: 11-06-2016
eLearning Pack ID: IE655-Fall 2016-33-05
Collaborative Companies:
1. SAE INTERNATIONAL AUTOMOTIVE ENGINEERING
2. SAE INTERNATIONAL AEROSPACE & DEFENSE
TECHNOLOGY
3. FORCE BEYOND
4. INDO-MIM
Statement:
The assignment work was finished and submitted by Shruthi
Thota.
Content:
1. Introduction and Objectives of the Project
2. Brief Description of the methodologies applied
3. Main Body of Project
3.1 FMEA / DFRA
3.2 Images review from Chapter 4 in the 3DeBook for
Concurrent Engineering.
3.3 Reliability analysis - Beta vs. Ranky Weibull
calculator
3.4 Collaboration
4. Social Networking Content
5. Summary
6. Further work needed / proposed
7. References and Bibliography
Introduction and Objectives of the Project:
The main objective of the project is to learn and apply risk analysis
methods. The risk analysis methods are Process Failure Risk Analysis
(PFRA), Disassembly Failure Risk Analysis (DFRA) and the Ranky-

Weibull Analysis. These methods will help Automotive Web Services to

reduce failure risk in company. It will increase the efficiency and overall
output of the company.
Brief Description of the methodologies applied:
We will implement 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, that aims at
minimizing dissatisfaction and financial loss for process related failure
risks. The seven key aspects of our generic methodology that must be
followed before we begin 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 subsystem or any product or process design to be analyzed.
2. Identifying the potential risks, failure modes and their effects by
applying the PFRA technique during the process, creating or
analyzing the existing BOM (Bill of Material) file. The PFRA
will help 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 should be kept as a valuable source of
information for both current and future products.
6. Documenting process is an important aspect, as the team goes
along and store the PFRA / DFRA contained information in a
widely accessible format for both current and future teams.

7. Enter the values in PFRA / DFRA spreadsheet on a relative

scale, that is determined by the local PFRA / DFRA team and
local customized standards they follow.
The rating rules are as follows:
1. Severity
2. Detection
3. Occurrence
The products with these rating values are given a number
called the risk priority number (RPN) that can be used as a measure of
the degree of failure risk.
The severity rating uses a scale from 1 to 10. The lower rating
corresponds to no effect on specified process or product performance.
The higher rating corresponds to hazardous effects on specified process
or product performance. The goal is to achieve a lower rating.
The detection rating uses a scale from 1 to 10. The lower rating
corresponds to easily detecting process or product performance failure.
The higher rating corresponds to impossible detecting process or product
performance. The goal is to achieve lower rating.
The occurrence rating uses the scale from 1 to 10. The lower rating
corresponds to lower failure rate i.e., less than 1 in 500,000 for specified
process or product performance. The higher rating corresponds to higher
failure rate greater than 1 in 3 for specified process or product
performance. The goal is to achieve lower rating.
Main Body of the Project:
FMEA / DFRA:
The objective is to identify a potential at risk process, and analyze
it using Process Failure Risk Analysis (PFRA)

In this case we decided to analyze our products which use

Sustainable and Green Manufacturing Process for the production of
High Quality Automobile Components. The primary concern is to
identify the steps that negatively affect quality, sustainability and
greening of our high quality automobile parts. We would like to identify
any steps that would cause our process to fail.
Once the steps are identified and correlated, the results will be
ranked and acted upon accordingly. The purpose of applying PFRA
method is that it provides a systematic, regulated and measurable
method to identify possible risks and prevent possible failures. The
TQM team is able to identify, understand and rank numerous problems
that Engineers, Planners, Managers and Operators would face.
Our Company PFRA Spreadsheet