Project/ Assignment No.

3: Process Failure Mode and Effects / Failure Risk Analysis in the

CE Context

1. In terms of assignment documentation method, please follow the Documentation

section of the 3D eBook in eLearning Pack.
2. Title, Author
Name, Kevin M. Moriarty,
Class, IE655,
Date, Nov 7th
eLearning Pack ID number IE655-Fall 2017-36-36
Four (4) collaborating companies :
Heimatec http://heimatecinc.com/,
JYOTI http://jyoti.co.in/
CW: Composite World http://www.compositesworld.com/,
PF: Product Finishing http://www.pfonline.com/
3. Statement on who has done the work,
This work has been done individually by Kevin M. Moriarty, utilizing IoT,( The
Internet of Things),
research, the IE655 eLearning packet, and individual research.

4. Page Contents
1- 1)Assignment 2) Author Details 3) Author Statement 4) Contents 5) Intro &
Objectives
6) Methodologies 7) Main Body Video reviews
2- Main Body Image reviews (continued)
3- Main Body Image reviews (continued),
4- Apendix B
5- 7,3,7) 5 Chapter Questions , 7,8) Social Networking
6- 8) Summary etc.

5. Introduction and Objectives of the Project

The objective of this project assignment is to utilize the resources provided to
investigate applications of Process Failure Mode and Effects / Failure Risk Analysis
As they pertain to Concurrent Engineering and Project Life Cycle Management as
they apply to the industry case developed by this research and this ad hoc
company and its product. This will be done through a review of the
provided images, and how to apply failure analysis and risk analysis to these
products.

6. A brief description of the methodologies applied.

The methodologies utilized are to investigate the chapters, 4 of the eLearning pack
and develop a FMEA/ DFRA, and draft an excel work book of the process.
7. The Main Body of the project:
1. Develop your FMEA/ DFRA (the same) model using the 3D eBook Excel
Template, for the product, that you are developing, in a collaborative fashion
with your eLearning Pack companies.

See appendix A

2. Show your main process failure modes, and solution processes in this
spreadsheet, that you have to customize, based on the DFRA Template
spreadsheet. Note: if a product / process fails it is not sustainable! Please
make sure to include at least 12 process steps in the FMEA / DFRA
spreadsheet at the left hand side of the spreadsheet where the main risky
process steps are listed.

Per my mock FMEA/PFRA spread sheet the highest risk factor for this product
is the manual process of moving and packaging the product.

3. Explain in detail what your engineering management decisions will be based

on the calculated results in the PFRA spreadsheet.

The management decisions to address these risks/failures will be to

implement sensitive handling methods and equipment to ensure we eliminate
and minimize the occurrences of these failures and damage.

4. In Chapter 4 in the CE 3DeBook,

review image set IMG_1684 to IMG_1704 and describe potential failure
modes.
It is a product you probably have never seen, therefore this should be an
interesting challenge! I am expecting you to write about 1 page on this
analysis.

This product is an underwater camera/video water proof case system. There

are several possibilities for failure on this product. The catastrophic failure will be
from water leaking into the case and damaging the camera system. This failure will
completely damage and render the entire system from ever working again, as one
would quickly recognize. The first risk failure is, at the closure points of the
enclosure. The openings of the enclosure must completely seal in order to prevent
any leakage. There are to aspects of sealing these openings; one is the rubber
seal, and the other is the clamping mechanism to pressure the seal to full closure.
There are also two possible causes of leakage. Seal failure and pressure failure.
Seal failure may occur ant any depth of submersion. The next is pressure failure.
Pressure will change as the depth increases. The rear opening is the larger of the
openings, as it must be large enough to enable the equipment to be placed inside
the enclosure system. The rear opening is sealed and closed with a matching cover
which is part of the waterproof enclosure system. The front opening is a smaller
opening only used to attach lens devices for the camera system. In any case both
openings must completely seal or a failure will occur. This opening is sealed by an
external component which is not an integral part of the waterproof enclosure
system.
The next possible failure points could be the several camera system activation
ports and devices. These are critically machined and sealed details of the system.
Another aspect of this system in the accessories and attachments utilized by the
system, e.g. electronic connections. These two are critical because a failure here
will damage components or the entire system. Many of these parts are tethered to
the system and therefore introduces another possible failure mode caused by the
component being snagged or pulled during operation.

5. In this assignment, we also use our Beta ver. Ranky-Weibull calculator (also
in the eBook DVD) for considering the reliability analysis for a given case
(samples in the CD). Read the Word file first, then study the spreadsheet
examples, then study the DFRA risk analysis method, and finally try to
calculate reliability related risk with the Ranky-Weibull spreadsheet, and then
integrate your findings with the rule-based approach in the DFRA
spreadsheet. Interesting research task; have fun! The rule-based method is
great, but if we can have data we can calculate with the Weibull math. Show
how this could be done using our templates. This is the new research in this
exercise. Also, look for bugs in the Ranky-Weibull spreadsheet! If you find one
I'll give you extra 10% for the entire course! Also, note, that Fanny is French,
therefore the English write up needs more work... it is beta, but will be very
good soon... The math is good though.

See Appendix B

6. Also, show how your (real or made up) company can collaborate with the
companies given you in your Learning Pack (there are 4 companies you have
to collaborate with; to avoid process failures. Explain HOW you are planning
to do this together with the collaborating companies.
The Machine tool suppliers, Heimatec http://heimatecinc.com/, &
JYOTI http://jyoti.co.in/, have been researched and determined to provide
the correct and adequate capabilities to perform the necessary
machining for the new products for Pneumatics Inc. This has been done
through a search of the technical documentation on the internet and reaching
out to them by phone to discuss the needs with a sale engineer.
follow-up discussion are expects .
The publications CW: Composite World
http://www.compositesworld.com/ & PF: Product Finishing
http://www.pfonline.com/ have also been contacted and investigated for
articles and information on certain finishing processes and environmentally
 friendly Green finishing methods,; i.e. powder coating and passivation
processing for the stainless steel parts as well as anodizing hard coating for
the aluminum parts.
7. Make sure, that in all cases you explain the results clearly. I want to see, that
you understand what you should be doing with the FMEA / DFRA spreadsheet
results you just created. This is a core engineering management aspect of this
assignment.
The appendices show that there are some clear tasks that have both
high and low values of risk associated with the outcome of the quality of the
products in the FMEA/PFRA spread sheet of Appendix B, which also
generates the estimated cost impacts The Weibull tell us that the expected
speed of the actuators is achieved and the parameters of the expected speed.
The graphical representation of these results are then generated and
presented in Appendix A

8. Social networking content for assignment, as part of it.

https://groups.google.com/a/njit.edu/forum/?hl=en#!forum/ie655-fall-2017-
group
Assignment 3 Topic 1
https://groups.google.com/a/njit.edu/forum/?hl=en#!topic/ie655-fall-2017-
group/OC__8Qlhs4E
Assignment 3 Topic 2
https://groups.google.com/a/njit.edu/forum/?hl=en#!topic/ie655-fall-2017-
group/UB6gP8-F-pA
Assignment 3 Topic 3
https://groups.google.com/a/njit.edu/forum/?hl=en#!topic/ie655-fall-2017-
group/DTSUiVD2IM4

8. Summary (i.e. what has been achieved)

What has been achieved through this assignment is a full review of the simulated
product process to develop a fully functioning design, engineering, and production
process for the simulated organization.
Key steps have been identified and reviewed. A FMEA / PFRA and Weibull
distribution simulation process has also been developed and applied.
9. Further work needed/proposed reach out to the publication to see what additional
research or publications can be applied to this work.
10. References and Bibliography (including the CDs, Internet as a main source of
information) eLearning packet IE655-Fall 2017-36-36,
IE655/CE-eBookMedia/ Chapters 1-3
11. Appendix (if necessary)
Appendix A - IE655 Assmt#3 KMMoriarty PFRA RevA
Appendix B - IE655 Weibull_testrun Assmt#3 KMMoriarty

Typical Mistakes: Why am I loosing grade points in this assignment?

 The assignment's administrative section is missing, and/or incomplete...
The above outline is NOT followed
The models / solutions are copied from the samples offered; Sorry, you must innovate and
create your OWN designs, and models.
The analysis of the calculated results is thin, or missing.
The collaborative companies are not included properly. Sorry, you MUST collaborate!
The PFRA/DFRA model is incomplete, and/or inaccurate.
The Ranky-Weibull method / calculator is not used.