FMEA Template and Rankings

Process Failure Mode and Effects Analysis (PFMEA)
Version Control
Version Date Change By
0 20-Jul-07 Original issue (FMEA) Dave Prodger
Version control tab added / Title changed to Process Failure Mode and Effects Analysis (PFMEA) / 'Help Box' function added to 'Blank Template' sheet / Addition of further reference scoring criteria for
Severity, Occurrence and Detection / Addition of column for highlighting classification of features, systems or other that may be influenced within the process step, esp. Controlled Processes, and
those that intentionally modify CCF's / Enhancement of 'hover-over' comments box contents (general) / 'Person responsible' now 'FMEA IPT members & functional areas' e.g. 'ME, Design, Operations,
Quality' / Process Control column definitions enhanced / Additional process control column added for Detection of Potential Failure Mode Cause / File location added to footer / Print date added to
1 12-Sep-11 footer / Issue level added to date revised box / 'Revised by' box added / Completed template example removed; awaiting update using new format / Automatic calculation of RPN inputs / Addition of Mark Fall (49180)
Responsible Business / Department column / Print area settings modified / Image added to help box / Process flow map prompter page added / 7M's / fishbone column added with drop-down menu
and conditional formatting added aligned to RRPS FPM colour scheme / Detection of Potential Failure Mode Cause process controls column 'deleted' / Minor modifications to text and 'help box'
contents
2 9-Dec-11 Spreadsheet unlocked to support increased flexibility / functionality Mark Fall (49180)
Conditional formatting added to 'Classification' column, highlighting CCFs (Conformance Control Features) and CPs (Controlled Processes, as derived through Characteristics Matrix / FVRA
3 12-Mar-12 discussions) / Help box macro removed as previous spreadsheet unlocking facilitates 'freeze' and 'slit screen' functions; this also removes significant data count from the server / 7Ms dropdown menu Mark Fall (49180)
items stored and hidden in AA1:AA7 / Word 'GUIDELINES' capitalised in worksheet and additional customer related examples added for reference
4 14-Jun-12 Layout at top of document amended to separate title details from associated data, preventing loss of title information during input Mark Fall (49180)
5 1-May-13 Process 'Method Owner' clarified as PFMEA owner, delegated via the PI Chief or Manufacturing Manager. Mark Fall (49180)
Process Failure Modes, Causes and Effects example tabs added
6 11-Jun-13 Mark Fall (49180)
Process Flow Diagram template incorporated
Component Load and Transfer potential failure modes updated / 'Lifting' added to Process Flow Diagram tab as a specific item / 'Risk Rankings - Process' - additional guidance criteria added with grey
7 26-Jun-13 Mark Fall (49180)
shaded title in table / 'Identified Failure Modes Lessons Learned - 1. Contents links' updated to show issue level of shared process failure mode materials
Issue judgement column (A/B/C) added to support improvement action prioritisation, management and reporting processes / Note added to 'Severity' rankings regarding Critical Part sensitive areas
subject to potential component lifing restrictions / increased Severity score / 'CP' designation for 'controlled process' changed to 'P' in-line with the new Characteristics Matrix designation
8 19-Nov-13 Mark Fall (49180)
Additional 'Change History record' tab added for 'closed item' copy and paste reference / 'KCF' conditional formatting added in classification column in advance of its formal launch for use
'A' conditional formatting added in classification column to highlight creation, modification or potential risk to 'Category A' features in line with GQP C.4.70 Appendix 10
New 'Blank PFMEA Template' header band and Rolls-Royce logo (in-line with general FMEA materials' corporate colour scheme)
Inclusion of 'faying surface preparation' potential failure modes, causes and effects examples
9 3-Feb-15 Mark Fall (49180)
Addition of FMEA Participant history sheet / attendees' details requirement removed from 'Blank PFMEA Template' tab
Links to 'RRPS PFMEA how-to' and Engineering Function 'General FMEA Guidance Materials' added to RRPS Version Control page below
10 24-May-16 Rationalisation / alignment of risk ranking scoring criterion / guidelines with International Standard SAE J1739 Mark Fall (49180)
Alignment of column headers, content and supporting text with xFMEA software in Blank PFMEA tab
11 10-Aug-16 Mark Fall (49180)
Inversion of scoring guidelines table for transactional processes (10 to 1 now shown top to bottom in descending order of score for Severity, Occurrence and Detection)
Addition of 'Requirements' column related to output expectation of the process 'Function' column
12 22-Sep-16 Mark Fall (49180)
Separation of 'Potential Effects of Failure' into External Customer (system level failure) and Internal Process (typ. SQCDP)
Addition of 'Value status' column in RRPS PFMEA template in support of Lean RFT process development and achieving the goal of Zero Defects
Introduction of RPN Reduction History Sheet (previously 'Change History' tab)
13 20-Jul-17 Integration of AS13004 (Aerospace Standard) min. std. template format Mark Fall (49180)
Addition of introductory 'read first' text boxes in key worksheets
New requirement for column 'H' to be hidden when using RRPS PFMEA template version (Potential Effects of Failure - External / Internal)
RRPS 'How to Compile a Failure General FMEA Guidance

RRPS
Mode'How to Compile
& Effects a Failure
Analysis' General FMEA Guidance
materials
Mode & Effects Analysis' materials
13 Write in this box, the latest version number, in order to update the top RH corner of each specific sheet
PFMEA Participants
Personal Details Session Attendance Record
Name Representing 1-Jan-00
Name 1 Area 1
Name 2 Area 2
Name 3 Area 3
Post Process Flow Diagram here for reference
Process Flow Diagram Template

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 4 of 43
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 5 of 43
Page 6 of 43
Version: 13

Please read before using.
Process Location: PFMEA 'Process / Manufacturing Method Owner': Date originated: Other relevant / supporting information:
PFMEA Template
Product Details / Part nos: Process Details: Dates Revised: Revised by: Issue #
The following spreadsheet contains the RRPS Best Practice template and the
AS13004 format acceptable for use as a minimum standard.
This spreadsheet features 2 buttons to activate/hide the relevant format;
please see notes in row 1 for instructions. Current Specified Process Controls: Recommendations Action results
Planned Completion
AS13004 min. std.:
Classification
Responsibility
1.
1. The
The AS13004
AS13004 Standard
Standard hashas 23
23 columns
columns which
which illustrate
illustrate the
the minimum
minimum PFMEA
PFMEA
Potential requirements
requirements
Effect(s)
Failure -
of to
to comply
comply with with Current Process Current Process Actual
the
the Aerospace
Aerospace (SAE)
(SAE) Standard.
Standard. Column
Column 'H'
'H' will
will need
need to
to be
be visible
visible /
/ unhidden
unhidden before
before use.
use.
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Op Seq Potential Failure Potential Cause(s) of
Date
Step Function Requirement External Customer Controls Controls RPNi Recommended Action Actions Taken Completion RPNr
Number Mode Failure
(product / system (Prevention) (Detection) Date
level) and Internal
2.
2. The
The RRPS
RRPS PFMEA
PFMEA template
template has
has additional
additional columns
columns to
to drive
drive activity
activity and
and capture
capture data
data that
that represents
represents best
Process (SQCDP) best
known
known Lean
Lean practice.
practice. 8 MCC 0 8 0
Column
Column 'H'
'H' should
should be
be hidden
hidden when
when using
using the
the RRPS
RRPS PFMEA
PFMEA template
template format.
format. 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
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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 02/07/2019

This spreadsheet features 2 buttons to activate/hide the relevant format; Page 7 of 43
Planned Completion
AS13004 min. std.:
Classification
1.
1. The
The AS13004
AS13004 Standard
Standard hashas 23
23 columns
columns which
which illustrate
illustrate the
the minimum PFMEA requirements to
to comply
comply with
Responsibility
minimum PFMEA
Effect(s)
Failure -
of with Current Process Current Process Actual
the
the Aerospace
Aerospace (SAE) Standard.
(SAE) Standard. Column 'H'
Column 'H' will need to be visible
will need to be visible / unhidden
/ unhidden before
before use. use.
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
Number Mode Failure
level) and Internal
2.
2. The
The RRPS
RRPS PFMEA
PFMEA template
template has
has additional
additional columns
columns to
to drive
drive activity
activity and
and capture
capture data
data that
that represents
represents best
known
known Lean
Lean practice.
practice. 0 0 0
Column
Column 'H'
'H' should
should be
be hidden
hidden when
when using
using the
the RRPS
RRPS PFMEA
PFMEA template
template format.
format. 0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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
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0 0 0
0 0 0
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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
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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

Planned Completion
AS13004 min. std.:
Classification
1.
1. The
The AS13004
AS13004 Standard
Standard hashas 23
23 columns
columns which
which illustrate
illustrate the
to comply
comply with
Responsibility
minimum PFMEA
Effect(s)
Failure -
the
the Aerospace
/ unhidden before
before use. use.
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
Number Mode Failure
level) and Internal
2.
2. The
The RRPS
RRPS PFMEA
PFMEA template
template has
has additional
additional columns
columns to
to drive
drive activity
activity and
and capture
capture data
data that
that represents
represents best
known
known Lean
Lean practice.
practice. 0 0 0
Column
Column 'H'
'H' should
should be
be hidden
hidden when
when using
using the
the RRPS
RRPS PFMEA
PFMEA template
template format.
format. 0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Planned Completion
AS13004 min. std.:
Classification
1.
1. The
The AS13004
AS13004 Standard
Standard hashas 23
23 columns
columns which
which illustrate
illustrate the
to comply
comply with
Responsibility
minimum PFMEA
Effect(s)
Failure -
the
the Aerospace
/ unhidden before
before use. use.
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
Number Mode Failure
level) and Internal
2.
2. The
The RRPS
RRPS PFMEA
PFMEA template
template has
has additional
additional columns
columns to
to drive
drive activity
activity and
and capture
capture data
data that
that represents
represents best
known
known Lean
Lean practice.
practice. 0 0 0
Column
Column 'H'
'H' should
should be
be hidden
hidden when
when using
using the
the RRPS
RRPS PFMEA
PFMEA template
template format.
format. 0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0

Planned Completion
AS13004 min. std.:
Classification
1.
1. The
The AS13004
AS13004 Standard
Standard hashas 23
23 columns
columns which
which illustrate
illustrate the
to comply
comply with
Responsibility
minimum PFMEA
Effect(s)
Failure -
the
the Aerospace
/ unhidden before
before use. use.
OCCr
OCCi
SEVr
DETr
SEVi
DETi
Date
Number Mode Failure
level) and Internal
2.
2. The
The RRPS
RRPS PFMEA
PFMEA template
template has
has additional
additional columns
columns to
to drive
drive activity
activity and
and capture
capture data
data that
that represents
represents best
known
known Lean
Lean practice.
practice. 0 0 0
Column
Column 'H'
'H' should
should be
be hidden
hidden when
when using
using the
the RRPS
RRPS PFMEA
PFMEA template
template format.
format. 0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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 43
Version: 13

Please read before using.
Process Location: PFMEA 'Process / Manufacturing Method Owner': Date originated: Other relevant / supporting information:
PFMEA RPN Reduction History Sheet

Product Details / Part nos: Process Details: Dates Revised: Revised by: Issue #
The following spreadsheet serves as an Risk Archive to record the change history of the
PFMEA risks and redundant lines in the PFMEA.
How to use:
1. Ensure you are using the correct template type (AS13004 or RRPS Lean best practice)
before moving data to ensure correct presence or absence of column 'H'.
2. Cut and paste the original / existing line information from the PFMEA template Current Specified Process Controls: Recommendations Action results
3. Paste in time-series order to provide a historical record ofAS13004 previous existing conditions
Planned Completion
min. std.:
Classification
and RPN values
Responsibility
Potential Effect(s) of
Failure - Current Process Current Process Actual
OCCr
4.Number
Update
Step the PFMEA template with the new condition data.
OCCi
SEVr
DETr
SEVi
DETi
Date
Function Requirement External Customer Controls Controls RPNi Recommended Action Actions Taken Completion RPNr
Mode Failure
level) and Internal
Process (SQCDP)
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
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0 0 0

How to use:
1. Ensure you are using the correct template type (AS13004 or RRPS Lean best practice) Page 12 of 43

Planned Completion
min. std.:
Classification
and RPN values
Responsibility
OCCr
4.Number
Update
OCCi
SEVr
DETr
SEVi
DETi
Date
Mode Failure
level) and Internal
Process (SQCDP)
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
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How to use:

Planned Completion
min. std.:
Classification
and RPN values
Responsibility
OCCr
4.Number
Update
OCCi
SEVr
DETr
SEVi
DETi
Date
Mode Failure
level) and Internal
Process (SQCDP)
0 0 0
0 0 0
0 0 0
0 0 0
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0 0 0

How to use:

Planned Completion
min. std.:
Classification
and RPN values
Responsibility
OCCr
4.Number
Update
OCCi
SEVr
DETr
SEVi
DETi
Date
Mode Failure
level) and Internal
Process (SQCDP)
0 0 0
0 0 0
0 0 0
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How to use:

Planned Completion
min. std.:
Classification
and RPN values
Responsibility
OCCr
4.Number
Update
OCCi
SEVr
DETr
SEVi
DETi
Date
Mode Failure
level) and Internal
Process (SQCDP)
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RRPS Process Failure Mode and Effects Analysis Rankings GUIDELINES
SEVERITY OCCURRENCE DETECTION Other DETECTION examples
Criteria : Severity of Effect on Criteria : Severity of Effect on

Criteria: Occurrence of Cause
Rank Effect
Product Rank Effect
Process Likelihood of Failure (Incidents per 1000 items /
products)
Rank
Opportunity for
Detection
Criteria:
Likelihood of Detection by Process Control
Rank Likelihood of detection
(Customer Effect) (Manuf. / Assy) Prevention/Detection Criteria Detection Reliability Typical Detection
Potentially hazardous failure without No controls exist, or current controls will not
≥ 100 per 1000 pieces or cannot detect the failure or defect
warning. Failure potentially affects safe May endanger operator (machine or No current process control; cannot detect or is not
10 10 Very high 10 No Detection Opportunity 10 Almost impossible No known controls available occurrence. < 1% In-service
operation of the product or causes assembly) without warning measured,verified, analysed or confirmed Defective parts will be shipped to the
≥ 1 in 10
regulatory non-compliance. Customer.
Failure to meet safety
Failure to meet safety and
and/or regulatory
or regulatory requirements
requirements
Potentially hazardous failure with

warning. Failure potentially affects safe ≥ 50 per 1000 pieces
May endanger operator (machine or Not Likely to Detect at any Failure Mode and / or error (cause) is not easily
9 operation of the product, causes 9 9 9 Very remote No current checks made Customer
assembly) with warning Stage detected (eg. random audits) Limited control measures with a poor chance
regulatory non-compliance or results in a ≥ 1 in 20
of detecting every failure or defect
significant reduction in safety margins. occurrence.
(e.g. random visual checks) 1 - 50%
Defects may be 'subtle' or 'difficult' to identify
Product is not operational; safety not and can readily go undetected and be passed
100% of product may have to be ≥ 20 per 1000 pieces to the Customer
compromised. Failure causes major High Problem detection post- Failure Mode detection post-processing by operator
8 8 Major Disruption scrapped. Line shutdown or stop 8 8 Remote Random visual inspection, single inspector Subsequent operation/Customer
customer dissatisfaction and processing through visual / tactile / audible means
ship. ≥ 1 in 50
inconvenience.
Loss or degradation of
Primary Function
Operability severely affected; primary A portion of the production run may Failure Mode detection in-station by operator
≥ 10 per 1000 pieces
functions/systems may be degraded. have to be scrapped. Deviation from Problem detection at through visual / tactile / audible means, or post- Patrol inspection. Gauge R&R unknown.
7 7 Significant Disruption 7 7 Very low
Failure causes high degree of customer primary process including decreased Source processing through use of attribute gauging Multiple visual inspection
≥ 1 in 100
dissatisfaction. line speed or added manpower (go/no-go, manual torque check / break-back etc.)
Some controls exist but are not effective for
detecting every failure or defect in good time.
50 - 90% Subsequent Operation
Defects may be non-obvious and some
Operability significantly degraded; Failure Mode detection post-processing by operator passed on to subsequent operations.
100% of the production run may ≥ 2 per 1000 pieces
secondary systems may be inoperable. Problem detection post- through use of variable gauging or in-station by Recorded audit of parts/process output.
6 6 have to be reworked off line and 6 6 Low Gauge R&R poor (>30%)
Failure causes significant customer processing operator through use of attribute gauging (go/no-
accepted ≥ 1 in 500
dissatisfaction. go, manual torque check / break-back etc.)
Loss or degradation of
secondary function
Failure Mode or error (cause) detection in-station
Moderate effect on operability; secondary
by operator through variable gauging or by
systems may be degraded. Product A proportion of the production run ≥ 0.5 per 1000 pieces
Problem detection at automated controls in-station will detect SPC chart on non-capable operation. Gauge
5 secondary systems do not conform to 5 may have to be reworked off line and Moderate 5 5 Moderate
Source discrepant part and notify operator (light / R&R average (20-25%).
operational requirements. Failure causes accepted ≥ 1 in 2,000
buzzer / other). Gauging performed on set-up and Controls have a reasonable chance of
customer dissatisfaction.
first-off check (for set-ups only) detecting the existence of the failure or
Moderate Disruption defect. Same operation/Subsequent
90 - 95%
If the defect is not detected at the operation, operation
it is likely to be detected at a subsequent
Moderate effect on operability. Product operation.
does not conform, but all systems fully 100% of the production run may ≥ 0.1 per 1000 pieces Failure Mode detection post-processing by
Problem detection post- SPC chart on capable operation. Gauge R&R
4 operational. Failure causes some 4 have to be reworked in station before 4 automated controls that will detect discrepant part 4 Moderately high average (15-20 %)
processing
customer dissatisfaction noticed by most it is processed ≥ 1 in 10,000 and lock part to prevent further processing
(> 75%) customers.
Minor effect on operability. Minor product Failure Mode detection 'in-station' by automated
Annoyance A proportion of the production run ≥ 0.01 per 1000 pieces 100% checks using mistake proofed variable
non-conformance. Failure causes minor Problem detection at controls that will detect discrepant part and
3 3 may have to be reworked in station 3 3 High or attribute gauging, reasonable Gauge R&R 95 - 98%
customer dissatisfaction noticed by many Source automatically lock part in-station to prevent (10-15%) Failures can sometimes be prevented.
before it proceeds ≥ 1 in 100,000 Control measures are highly effective with a
(50%) customers. further processing
good chance of early detection of the failure
Low mode or defect.
Same operation
Subsequent operations are protected from
Slight effect on operability. Product does
≥ 0.001 per 1000 pieces Error (cause) detection 'in-station' by automated Measurement processes have good gauge accepting discrepant parts.
not conform. Failure causes slight Slight inconvenience to process, Error detection and / or
2 2 Minor Disruption 2 controls that will detect error and prevent non- 2 Very high R&R (<10%). 100% mistake proofed checks > 98%
customer annoyance noticed by most operation or operator problem prevention in place using variable data
≥ 1 in 1,000,000 conformance being produced
discerning (< 25%) customers.
Effective error prevention controls

Error (cause) prevention as a result of fixture Reliable detection controls are known with
Detection not applicable; (e.g. error-proofing of the design/process
same or similar processes. Measurement
Failure is eliminated through design, machine design or part / component / (Poka Yoke), or alarms will prevent the failure
1 No effect No discernible effect on product operation. 1 No effect No discernible effect Very low 1 Error Prevention (before 1 Almost certain processes have excellent gauge R&R (<5%)
mode or defect from occuring.
> 99.9% Before failure
preventive control assembly design. Non-conformance prevented and are mistake proofed. 100% checks using
any failure) Detection will prevent ther next step from
through error-proofed process / product design variable data
being performed)
'Process Failure Mode,
Cause and Effect' reference lists
The following spreadsheets list failure modes identified to date within PFMEAs for a range of manufacturing processes. The contents
areThe
notfollowing spreadsheets
comprehensive, more list failure modes
a collection identified
of 'starting to date
points' within
to assist thePFMEAs for a range
'thinking-way of manufacturing
and approach' processes.
to the PFMEA The Also
process. contents
are notare
included comprehensive, more a collection
a number of possible of 'starting
causes, possible points'
effects, to assist
possible the 'thinking-way
detection and methods
and prevention approach'for
toreference.
the PFMEAThis
process. Also
lists are
included
provided forare a number of possible
cross-checking purposescauses, possible
and should not effects, possible
be considered detection andfor
a replacement prevention methodsteam
a cross-functional for reference. Thisalists
carrying-out are
formal
provided
PFMEA for cross-checking
activity purposes
using a 'go-look-see' and should not be considered a replacement for a cross-functional team carrying-out a formal
approach.
PFMEA activity using a 'go-look-see' approach.
The intention is to update and add to this list when new failure modes are identified that are deemed useful to share, or when
The intention
improved is to update
definitions and add
are available forto this listconditions
existing when newalready
failurestated.
modes Your
are identified thatmay
suggestions arewell
deemed useful
provide to share, detail
appropriate or whenwhere
improved
spaces definitions
currently exist inare
theavailable for existing
worksheets, so please conditions
propose already stated.
new content andYour suggestions
updates based may wellown
on your provide appropriate
team's experiencedetail
wherewhere
youspaces
feel itcurrently exist intothe
is appropriate do worksheets,
so, so that we somay
please propose
share new content
the knowledge and updates
throughout based on your own team's experience where
the Company.
you feel it is appropriate to do so, so that we may share the knowledge throughout the Company.
For further information, please contact Mark Fall (RRPS Core Team) - 49180.
For further information, please contact Mark Fall (RRPS Core Team) - 49180.
Note: This document is for the use of Rolls-Royce employees only
Note: This document is for the use of Rolls-Royce employees only
© 2016 Rolls-Royce plc

The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is
supplied without the express written consent of Rolls-Royce plc.
This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not
be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.
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
When complete please e-mail this sheet to: mark.fall@rolls-royce.com (RRPS Team - Quality Operating System module co-ordinator)
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 timing Use automated 'Speedy Zero Point' or 'Erowa'
Fixture not correctly positioned
machine table and secure in correct position Process delay. position 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:
Lift component on to machine Component dropped Injury to operator and/or damage to part suction cups damaged or
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 Probe tooling prior to cutting
Select correct tool Wrong tool selected 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 Warning if probed dimension out of Check probing with fixture in a series of
Probe fixture location probed Time wasted Probe touches on wrong part of 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 and
Analyse defect data Defect data not analysed defects - risk of escapes No process in place to analyse defect data improvement process
No action being taken to address
Analyse defect data Defect data not analysed defects - risk of escapes Data logged but not passed on for analysis
Warning if coolant flow/pressure

Confirm coolant flow Lack of coolant Poor surface finish Blocked nozzle Regular check of coolant nozzle
goes below set levels
Confirm coolant flow Lack of coolant Poor surface finish Worn pump Warning if coolant flow/pressure Regular maintance checks on
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
Confirm coolant flow Coolant temperature incorrect Poor surface finish Temperature control system failed Warning if temperature goes out of function monitored and machine
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 Wrong Wheel Used Poor Quality of Polished Part Unclear Identification on Wheels ID & Colour Code Already on
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
Set correct Spindle Speed Set Incorrect Spindle Speed Poor Quality of Polished Part Incorrect Speed Readout Use of Technical Instructions and
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 Wheel Not correctly Dressed Poor Quality of Polished Part Worn dressing stone used
Abrasive Stone
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
bare hand
Visual inspection
to carry out the cleaning process
JES221
Fitter training to dispose the

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

Preparation of faying surface equipments used for equipments and store incharge ensures
for electrical bonding as per Cleaning of faying surface Improper cleaning Visual inspection
JES221 cleaning. the continuous availability of cleaning
i.e.Wipes/Gloves. equipments
Non conformance. Delay in
process as the contaminated
Preparation of faying surface faying surface need re Poor lighting facility, fitter
cleaning may not notice the
for electrical bonding as per Cleaning of faying surface Improper cleaning
contamination present on
Visual inspection Periodic illumination audit
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

for electrical bonding as per Cleaning of faying surface Cleaning residue on faying agent/wet wipes not Visual inspection continuous availability of approved
JES221 surface available on the bay cleaning equipments/agent
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 surface completed the cleaning Visual inspection
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 surface be removed by re cleaning equipment
Visual inspection
availability of cleaning equipments
JES221
Poor electrical conductivity
Preparation of faying surface Cleaning residue on faying during test, need rework. Cleaning SOPs are approved by the
for electrical bonding as per Cleaning of faying surface surface Hence delay in process Inadequate work instruction Visual inspection
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
JES221 available on the bay cleaning equipments/agent
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
Preparation of faying surface Non conformance. Delay in 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 process as the mating faces entire area / extra periphery Visual inspection
JES221 on the faying surface fitter training on cleaning process
to be re cleaned again
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
JES221
Preparation of faying surface Inappropriate

Excess material removed / JES 221 specifies the correct
for electrical bonding as per Cleaning of faying surface Damage on faying surface abrasion/sanding technique Visual inspection
abrasion/sanding technique to be used
JES221 used
Non conformance. Delay in
Preparation of faying surface process as the faying surface
for electrical bonding as per Cleaning of faying surface Excess material removed / to be repaired Poor condition of cleaning Visual inspection Store incharge ensures that continuous
JES221 Damage on faying surface equipment availability of cleaning equipments
Potential scrap of part due to
Preparation of faying surface excess material removal Store incharge ensures that continuous
for electrical bonding as per Cleaning of faying surface Excess material removed / Approved abrasion material Visual inspection availability of approved cleaning
JES221 Damage on faying surface May deteriorate the life of not available equipments
the joint
Preparation of faying surface
for electrical bonding as per Cleaning of faying surface Excess material removed / Inadequate work instruction Visual inspection Cleaning SOP's are approved by the
JES221 Damage on faying surface authorised department
Preparation of faying surface

Damage/Surface scratch on No instruction to select the
for electrical bonding as per Cleaning of faying surface faying surface Garnet paper grade
Visual inspection None
JES221
Delay in process as the faying
surface to be repaired to
Preparation of faying surface Damage/Surface scratch on achieve the required surface Store incharge ensures that continuous
for electrical bonding as per Cleaning of faying surface finish Worn out Garnet paper used Visual inspection availability of garnet papers and fitter
JES221 faying surface 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 faying surface
Inadequate work instruction Visual inspection
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
brush not available
Visual inspection continuous availability of swarf removal
JES221 brush
Preparation of faying surface JES 221 instructs to remove the swarf

for electrical bonding as per Cleaning of faying surface Swarfs not removed Fitter missed to remove the Visual inspection inorder to achieve the clean surface
JES221 swarf after polishing
Contamination on the faying
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 Swarf trapped in Blanking plug/Masking tape PL and store incharge ensures the
for electrical bonding as per Cleaning of faying surface holes/Threaded surface not available
Visual inspection continuous availability of blanking
JES221 Applies less clamping 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 holes/Threaded surface not used
Visual inspection Fitter training on the cleaning process
JES221 Potential FOD entry to open
holes
Preparation of faying surface Non availability of safety PL issues safety equipments to
for electrical bonding as per Cleaning of faying surface None
JES221 equipments individual fitters and they maintain it
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
JES221 data sheet safety data sheet
Safety equipments not used
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)

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Process Failure Mode and Effects Analysis (PFMEA)

RRPS 'How to Compile a Failure General FMEA Guidance

Name Representing 1-Jan-00

Process Flow Diagram Template

KEY PRODUCT KEY CONTROL

KEY PRODUCT KEY CONTROL

Process Failure Mode and Effects Analysis (PFMEA)

RRPS PFMEA Template Printed 02/07/2019

RRPS PFMEA Template Printed 02/07/2019

RRPS PFMEA Template Printed 02/07/2019

RRPS PFMEA Template Printed 02/07/2019

RRPS PFMEA Template Printed 02/07/2019

Process Failure Mode and Effects Analysis (PFMEA)

PFMEA RPN Reduction History Sheet

RRPS PFMEA Template Printed 02/07/2019

before moving data to ensure correct presence or absence of column 'H'.

RRPS PFMEA Template Printed 02/07/2019

before moving data to ensure correct presence or absence of column 'H'.

RRPS PFMEA Template Printed 02/07/2019

before moving data to ensure correct presence or absence of column 'H'.

RRPS PFMEA Template Printed 02/07/2019

before moving data to ensure correct presence or absence of column 'H'.

RRPS PFMEA Template Printed 02/07/2019

SEVERITY OCCURRENCE DETECTION Other DETECTION examples

Criteria : Severity of Effect on Criteria : Severity of Effect on

Potentially hazardous failure with

Effective error prevention controls

© 2016 Rolls-Royce plc

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

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

Component loaded incorrectly

Production Delays, part non- Probe part and/or fixture to verify

Improve legibility or input using bar

Damage to tooling and/or non- Use tooling chip to read offsets

No clear visual standard for

Warning if coolant flow/pressure

Wrong diamond roll used as no checks completed against

Moisture in optics causing poor

Design head such that incorrect

Correctly dress component Component over-dressed Non-conformance Poor lighting in area

Correctly dress component Component over-dressed Non-conformance Instructions not explicit