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Process Failure Mode Effects Analysis

Item/Part#: Rev: Customer: Supplier: Christopher Tool & Mfg. Co. * SEV, OCC, & DET scoring per the tables provided in WPQR-9102, unless otherwise approved by Woodward. Resulting Action(s) Item / Function / Process Description SAWING-Cut blanks 5.937 1/64 long. HEAT TREATHarden, Temper and Stress Relieve Hardness: 30-36 Rc ----------------------Certs Required CNC TURNING CENTER WORKTurn the blank from the right side per CTM T-4836 sheet 1: Face to cleanup only. Center drill #3 MAX as shown. Hold all lengths near mean size for mfg. Inspect runouts: All diameters concentric within .002 T.I.R. 30 CNC TURNING CENTER WORKTurn the blank from the right side per CTM T-4836 sheet 2: Center drill as shown--#4 max. See SS-81. Inspect runout between centers: All diameters concentric within .002 T.I.R. Parts do not meet CTM in-process drawing requirements. Parts will not meet customer requirements. Programming is incorrect. Tools are not setup correctly. Tool breakage. Operators are expected to gage and adjust tooling as needed, plus a 1st. Piece is required to pass our inspection department. Correct program, adjust or replace tooling. S E V C l Potential Cause(s) a / Mechanism(s) of Failure s s Saw is not set-up correctly. Saw malfunction. Oven malfunction. O C C D E T R P N Responsibility & Target Action(s) Taken Completion Date S E V O C C D E T R P N 3595-1038 6 Process Owner: Process: FMEA Team: FMEA #: FMEA Rev: FMEA Date: Prepared by: 3595-1038

Op / Ref #

ID #

Potential Failure Mode

Potential Effect(s) of Failure

Current Controls Prevention

Current Controls Detection

Recommended Action(s)

Blanks are cut undersized. Parts do not meet customer drawing requirements per CTM P.O.

Parts will not be usable for this part. Parts will be reworked or approved by customer.

Measure parts after saw cutting. Certification required.

Adjust saw. Change blade. Anneal and reharden.

10

20

Parts do not meet CTM in-process drawing requirements.

Parts will not meet customer requirements.

Programming is incorrect. Tools are not setup correctly. Tool breakage.

Operators are expected to gage and adjust tooling as needed, plus a 1st. Piece is required to pass our inspection department. 0

Correct program, adjust or replace tooling.

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O.D. GRINDINGLap grinding centers 100% for mfg. Rough grind the O.D. of the (2) Splines to cleanup only. Leave .005 g/s per side for mfg.

Parts do not meet traveler requirement.

The splines will be undersized.

Machine malfuntion, operator did not check parts.

Visual, and spline gage.

Adjust grinder.

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50

DEBURRINGRemove burrs and break sharp edges. See drawing notes.

Part still has burrs or the edges have exceeded the drawing requirements.

Rework parts.

Operator did not see or feel burrs, plus was not able to hold customer tolerances. Inspector was distracted or does not comprehend the dimension.

Visual, and inspection. 0

60

INSPECTION, IN PROCESS-InProcess Inspect prior to outside processes. Verify part count. Verify that all preceding operations have been completed and are signed off.

Inspector did not Rework parts. check dimension Possibly scrap correctly or did not parts. understand the requirement.

Better lighting and magnifying lens for operator. Plus being able to understand and hold customer requirements. Additional blueprint or use of precision gages training.

70

SPLINING & GEAR Spline is CUTTING-Finish undersized. shape and inspect the (2) Involute Splines per Woodward Governor drawing #3595-1038 and drawing notes 8 & 9. Hold concentricity between centers within .001 T.I.R. Gaging requirements per Woodward SS-201 rev. V. ----------------------Certs Required RECEIVING INSPECTIONInspect incoming parts to verify the part count and the vendor compliance to the requirements of the previous operation purchase order. Visually inspect all parts for handling damage (nicks and dings).

Scrap parts.

Incorrect set-up of hob.

Certifications required.

Inspection of parts.

Replace hob.

80

Part count is Short parts, or incorrect. Parts do scrap parts. not meet compliances to the P.O.

Lost or scrapped parts from vendor. Subcontractor did not check parts.

Count and inspect parts to traveler.

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DEBURRINGRemove burrs and break sharp edges. See drawing notes.

Part still has burrs or the edges have exceeded the drawing requirements.

Rework parts.

Operator did not see or feel burrs, plus was not able to hold customer tolerances.

Visual, and inspection. 0

Better lighting and magnifying lens for operator. Plus being able to understand and hold customer requirements. Anneal and reharden.

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100

110

HEAT TREATCore Harden per Woodward Governor drawing 3595-1038, note #12, IAW SP-908 rev. B-B. Core Hardness: 4450 Rc Do not nitride. -----------------Certs Required RECEIVING INSPECTIONInspect incoming parts to verify the part count and the vendor compliance to the requirements of the previous operation purchase order. Visually inspect all parts for handling damage (nicks and dings).

Parts do not meet customer drawing requirements.

Parts will be reworked or approved by customer.

Oven malfunction.

Certification required.

Part count is Short parts, or incorrect. Parts do scrap parts. not meet compliances to the P.O.

Lost or scrapped parts from vendor. Subcontractor did not check parts.

Count and inspect parts to traveler.

120

STRAIGHTENING- Parts do not meet Lap centers 100%. runout Note: Inspect the requirements. parts between centers, and check the true position of the pitch diameters of both splines using gage pins. Use the spline gages. Determine if parts require straightening and record results. Check runout of the finished splines between centers. Maximum runout to be within .001 T.I.R. Also inspect the runout of the datum -A- flange. Straighten and Stress relieve any straightened parts as follows: NOTE: STRESS RELIEF IS REQUIRED.

Rework parts.

Center lap is misaligned, or broken stone. Needs to be straightened.

Measure and record results 100%.

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O.D. GRINDING***Allow for .005 g/s on the right side face of the large flange.*** Green grind from the left side: Finish grind the LEFT end face. Green grind the datum -A- face, leaving .002 g/s per side. Green grind the spline O.D. leaving .002 g/s per side. Do not grind the O.D. groove or the .320 diameters.

Parts are undersized to the traveler requirements.

Scrap parts.

Machine Malfunction.

Visual and inspect.

Re-dress wheel and change set-up.

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140

O.D. GRINDING- Parts are ***Allow for .002 undersized to the g/s on the datum -A- traveler face.*** requirements. Green grind right side diameters: Finish grind the RIGHT end face. Do not grind the existing .350 diameter. Green grind the .3163, Spline O.D and .47525 diameters leaving .002 g/s per side. Leave .002 g/s on the shoulders and chamfers. Green grind the right side of the large flange leaving .002 g/s. (Allow for .002 g/s on datum -A-).

Scrap parts.

Machine Malfunction.

Visual and inspect.

Re-dress wheel and change set-up.

150

O.D. GRINDING***Allow for .002 g/s on the datum -Aface.*** Finish grind the .373/.371 diameter groove, concentric to -Band -C- within .002. Hold 32 Ra finish.

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EDM MACHINING- Holes are out of EDM angular holes position and as required per oversized. drawing note #11. ***Allow for .002 g/s on datum -Aface.*** Qualification required per SP1084.

Re-work or scrap.

Machine malfunction.

Inspect dimensions.

Change settings or electrodes.

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170

DEBURRINGPart still has burrs Remove burrs and or the edges have break sharp edges. exceeded the drawing requirements. NITRIDE-Nitride per Woodward Governor drawing 3595-1038, including drawing notes #7 & #12, IAW SP-908 rev. BB. Core Hardness: 4450 Rc Case Hardness: 90 HR15N Final Case Depth: .006-.015 Recommended Applied Case Depth: .012-.020 Max stock removal after nitriding: .005 Max permissible White Layer: .0004 Inspect Case Depth per drawing note #21. -----------------Certs Required Parts do not meet custom drawing requirements including correct areas to be masked.

Rework parts.

Operator did not see or feel burrs, plus was not able to hold customer tolerances. Atmosphere of application is contaminated.

Visual, and inspection. 0

Better lighting and magnifying lens for operator. Plus being able to understand and hold customer requirements. Monitor settings and inspect.

180

Parts may or maynot be useable pending customer approval.

Hardness check for correct depth and visual of correct areas.

190

O.D. GRINDING- Dimensions are O.D. grind to undersized. remove the excess stock and finish grind the .320 diameters x 2 places to the left of the flange. Finish grind datum A- shoulder. Leave .0005 max lapping stock. Hold best surface finish possible.

Scrap.

Machine malfunction, or incorrect wheel.

Visual and inspect.

Change settings or wheel and re-dress.

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O.D. GRINDINGGrind from the LEFT side: Finish grind the Spline major diameter. Finish grind the .470/.472 diameter.

Dimensions are undersized.

Scrap.

Machine malfunction, or incorrect wheel.

Visual and inspect.

Change settings or wheel and re-dress.

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210

O.D. GRINDING- Dimensions are From the right side: undersized. Remove the excess stock and finish grind the major diameter of the .3125-24 UNFJ-3A thread. Finish grind the .030 X 45 chamfer.

Scrap.

Machine malfunction, or incorrect wheel.

Visual and inspect.

Change settings or wheel and re-dress.

220

O.D. GRINDINGFinish grind all diameters on the right side. Leave .0002 max. lapping stock on the .3163/.3158 and .47525/.47475 diameters. Hold best microfinish possible (8 Ra max, 2 Ra required).

Dimensions are undersized.

Scrap.

Machine malfunction, or incorrect wheel.

Visual and inspect.

Change settings or wheel and re-dress.

230

O.D. GRINDINGFrom the left end: Finish grind the .228/.226 Shear Section diameter.

Dimensions are undersized.

Scrap.

Machine malfunction, or incorrect wheel.

Visual and inspect.

Change settings or wheel and re-dress.

240

DEBURRINGPart still has burrs Remove burrs and or the edges have break sharp edges. exceeded the drawing requirements. THREAD GRINDING-Finish grind the .312524 UNFJ-3A Thread per Woodward Governor specification SS130 rev. CG. Parts do not meet CTM P.O. requirements per drawing.

Rework parts.

Operator did not see or feel burrs, plus was not able to hold customer tolerances. Incorrect set-up. Machine malfunction.

Visual, and inspection. 0

Better lighting and magnifying lens for operator. Plus being able to understand and hold customer requirements.

250

Rework or scrap

Thread gages.

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SURFACE LAPLap Splines if required to accept Ring Gages.

N/A if already accepted. 0

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270

WASH PARTSParts are dirty, Wash all parts in clean Zep Dyna 143 solvent, drain and blow dry with clean shop air. Visually inspect parts inside and out for cleanliness. Dip in MIL-C-15074 fingerprint neutralizer and Oil parts to prevent rusting.

Rework.

Used a different cleaning solvent.

Visual

Improve training and directions on traveler.

280

INSPECTION, IN PROCESS-InProcess Inspect prior to outside processes. Verify part count. Verify that all preceding operations have been completed and are signed off.In-Process Inspect prior to outside processes.

Inspector did not Rework parts. check dimension Possibly scrap correctly or did not parts. understand the requirement.

Inspector was distracted or does not comprehend the dimension.

Additional blueprint or use of precision gages training.

290

SURFACE LAPParts are out of Finish lap the tolerance. datum -A- shoulder to attain .000025 flatness and 2 Ra microfinish per the requirements of Woodward Governor drawing 3595-1038 and drawing notes #13 and #15. Also lap the opposite shoulder to satisfy drawing requirements. Ring Lap the .47525/.47475 [-B] diameter and the .3163/.3158 diameter to meet the 2 Ra drawing requirement.

Rework

Incorrect lapping compound or procedure.

Measure flatness and microfinish.

Monitor and inspect .

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RECEIVING INSPECTIONInspect incoming parts to verify the part count and the vendor compliance to the requirements of the previous operation purchase order. Visually inspect all parts for handling damage (nicks and dings).

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310

LASER MARKING- Incorrect marking Laser mark on the or location. noted area as required per drawing note #10 Mark as follows: 66503-3595-1038 4

Rework

Operator misinterpreted the location or entered wrong numbers/letters into the machine.

Visual and approval by different person.

Improve training and notes in files.

320

INSPECTION, IN PROCESS-InProcess Inspect prior to outside processes. Verify part count. Verify that all preceding operations have been completed and are signed off.

Inspector did not Rework parts. check dimension Possibly scrap correctly or did not parts. understand the requirement.

Inspector was distracted or does not comprehend the dimension.

Additional blueprint or use of precision gages training.

330

MISC. COATINGS- Coating is Brush Coat noted inadequate or area only, with the wrong location. required material, per drawing notes #18 and #19. Material: Corrosion Preventative film per WoodwardGovernor SP-949 rev. Y (Sandstrom 9AV-35 or alternates). ---------------------Certs Required

Rework

Rust or discoloration on part.

Visual.

Replace outdated coating.

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RECEIVING INSPECTIONInspect incoming parts to verify the part count and the vendor compliance to the requirements of the previous operation purchase order. Visually inspect all parts for handling damage (nicks and dings).

Part count is Short parts, or incorrect. Parts do scrap parts. not meet compliances to CTM P.O.

Lost or scrapped parts from vendor.

Count and inspect parts to traveler.

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350

INSPECTION, FINAL-Final Inspect complete per drawing and the requirements of the Customer Purchase Order. PRE-SHIPPINGINSPECTION-Prior to packing, when all parts are complete, inspect this traveler to verify all operations have been signed off and all part counts are correct. Visually inspect the entire lot for foreign objects (chips/dirt inside and out), the correct marking, handling nicks and general appearance.

Inspector did not Out of tolerance check dimension part gets to correctly or did not customer. understand the requirement.

Inspector was distracted or does not comprehend the dimension.

Documentation of all dimensions per customer requirements and CTM AQL .

Implement SPC monitoring throughout the manufacturing process.

360

Incorrect quantity, dirty or nicked parts, operations are not signed off.

Rework

An operation was not completed. Parts were not cleaned properly.

Visual.

Standart checklist of criteria before packing.

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PACKAGE PARTS- Not properly Dip in Preserative packaged for Oil and drain. handling. Place in **VCI** plastic bags and heat seal. Package in protective containers as required. Pack containers in an appropriate box with all necessary certifications and inspection reports. Label package and attach shipping carrier label. Place package on the proper cart to be picked-up by the shipping carrier.

Parts may become nicked or broken and possible scrap.

Incorrect packaging.

Traveler sign-off.

Improve traveler instructions for proper packaging.

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e Mode Effects Analysis

3595-1038

Resulting Action(s)

Status

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