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QSEQSE Quality Systems Engineering
Core Team: Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis,
08/19/06 © 2000/2006 All Rights Reserved Quality Systems Engineering @ 810-499-1015Printed on
Pipe Fixture
Part Numbers & Rev Level: 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465(R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3),465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3),454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3),465465465 (R3), 454545 (R3), 465465465 (R3) , 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3),454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3)
QSE suggests putting all Header information in this field so the no header view can be printed using lesspages per printout.
Model:Key Date:Responsible Engineer:
546876413 - 165468469465468Part Number:
123456Flow Number:
9/27/035/4/049/14/05
MasterRevision
Date History
5/4/03Master Original Date:
ControlledControlledControlled
MasterRevisionStatus
1.11.21.3
MasterRevision
LevelJim BimJackson MississippiApril Somebody
PersonResponsible
Controlled1.3
Status:Revision:
Prototype Pre launch ProductionPrototype Pre-launch Production
123456FMEA Number: Controlled1.3
123456Control Plan Number: Controlled1.3
QSEQuality Systems Engineering
QSE
Sev
Occ
Det
User types info of choice
Operation DescriptionCharacteristics
Product Process
Specificationand/or Tolerances
PotentialFailure
Mode(s)Potential Effects of
Failure
PotentialCause(s)
Mechanism(s)of Failures
Current Process ControlsPrevention / Detection
IntPutAnything
GD&T
Pp
Ppk
Cp
CpkRPN
Class Risk
Function IDProcess ID
Op ID
Row NoPCID
CHARACTERISTICS FAILURE WORKSHEET
Jack Joseph 810-499-1015
Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis,
11/17/03Brighton2003B-4589Model Year(s) Vehicle(s):
Core Team:
Responsible Engineer:
Key Date:
05/27/05
Sandra Werwega
09/03/05Original Date: Revision Date:
Prepared By:
1 2Page of
7778FMEA Number:
EC StatusIVEC Level 09/15/05EC Date
Part Name:
Part Number:
Title Page
546876413 - 165468469465468
Counter703900 Final RPNInitial RPN
Supplier Audits.Tags verify FIFO.Receiving / Incoming
Material Verification
Operator mustInsure MaterialLabel is correct.
Missing, Wrongor UnreadableLabel
Incorrect Label OnContainer, PRR Written
Wrong partsshipped
*3 3 63
Op005Part IDcondition
71a 000-0000-000Receiving11
PutAnything
APurchasing(Providessupplier withcorrect specs).
A
Training in PartLoading. Tagsverify FIFO.
Receiving / IncomingMaterial
Part Placed inProper Positionusing Due Care.
Hopper Jams Damage Parts ScrapParts
ImproperLoading of Part
3 2 48
Op005000-0000-000
82a Put AnythingReceiving Inspection22
PutAnything
LPMaterialHandling /Non-ConformingProcedure
A
Training in PartLoading.Position Part On Pallet
Material HandlerMust Use Caution
Damaged Part Impairs OperationCannot Mount Part,Damage Part, ScrapParts.
Forks NotAdjustedProperly DuringTransport
6 3 144
Op010Part Condition
83a Storage Locations ?Transfer33
PutAnything
HPVisual Inspection
B
Training, SWIDrill Hole On Front Side
5.680 - 7.433 Off Location No Assembly, Rework Wrong CNCProgram
5 1 15
Op011Hole Location
34a Hole No 401Step 1 Drill44
PutAnything
LN Gage 2 Partsafter every ToolChange
C
Training, SWIDrill Hole On Front Side
0.0025 Out of Round Leaks, SafetyIssue,Rework, ImpairsNext Operation
ImproperMachine Setup
*10 7 280
Op011
Circularity ofHole
45aStep 1 Drill55
PutAnything
HDAuto stop if theTool Holder isnot Properlyseated.
C
S.W.I. PMDrill Hole On Front Side
2.224 +/- 0.20 Diam too Wide Impairs next operation,rework, scrap part
Premature ToolWear
PQC10 3 150
Op011
First PassDiam of Hole
56aStep 1 Drill66
PutAnything
HPAutomaticSpindle LubeSystem.
C
S.W.I. PMDrill Hole On Front Side
15.434 +/- 0.20 Depth tooShallow
Rework Impairs NextOperation Loss OfAssembly Srap Parts
Improper SpeedSetting
SC5 3 105
Op011
First PassDepth of Hole
77aStep 1 Drill77
PutAnything
HDInspect First PartAfter anyAbnormalOccurrence.
C
S.W.I. PMDrill Hole On Front Side
3.823 +/- 0.20 Diam too Wide Impairs nextoperationLoss ofAssembly Srap parts
ImproperMachine Setup
FF5 3 75
Op011
Final PassDiam of Hole
58aStep 1 Drill88
PutAnything
APGage 2@ start ofevery shiftC
S.W.I. PMDrill Hole On Front Side
Thru Depth tooShallow
Part will not Assemble,Scrap.
IncompleteCycle
5 2 20
Op011
Final PassDepth of Hole
29aStep 1 Drill99
PutAnything
LN Gage 2@ start ofevery shiftC
© 2005 All Rights Reserved Quality SystemsEngineering @ 810-499-101510/14/05 1.3 DRAFTStatus:Revision:Printed on High Risk Average Risk Low Risk
QUALITY SYSTEMS ENGINEERING QSE QSEProcess Flow Diagram
CounterUser types info of choicePut Anything
Operation DescriptionFlow
SymbolsCharacteristics
Product Process
Specification and/orTolerances
EC StatusIVEC Level 09/15/05EC Date
Brighton2003B-4589
Part Name:
Part Number:
Model Year(s) Vehicle(s):
02/02/05 09/22/05
Rob Bescoe
Sandra Werwega
Original Date:
Responsible Engineer:
Prepared By:
Revision Date:
GD&T Pp
Ppk
Cp
CpkClassRiskProcess ID
Op ID
Row NoFunction ID
PCID
112749Flow Number:Pipe Fixture
546876413 - 165468469465468
Receiving / Incoming MaterialVerification
Operator must InsureMaterial Label iscorrect.
Op005 Part IDcondition1a
Receiving *
A
000-0000-000
A
11 PutAnything
Receiving / Incoming Material
Part Placed in ProperPosition using DueCare.
Op005 000-0000-0002a
Receiving Inspection
L
Put Anything
A
22 PutAnything
Position Part On Pallet
Material Handler MustUse CautionOp010 Part Condition
3a
Transfer
H
Storage Locations ?
B
33 PutAnything
Drill Hole On Front Side
5.680 - 7.433Op011 Hole Location
4a
Step 1 Drill
L
Hole No 401
C
44 PutAnything
Drill Hole On Front Side
0.0025Op011
Circularity ofHole
5a
Step 1 Drill *
H
C
55 PutAnything
Drill Hole On Front Side
2.224 +/- 0.20Op011
First Pass Diamof Hole
6a
Step 1 Drill PQC
H
C
66 PutAnything
Drill Hole On Front Side
15.434 +/- 0.20Op011
First PassDepth of Hole
7a
Step 1 Drill SC
H
C
77 PutAnything
Drill Hole On Front Side
3.823 +/- 0.20Op011
Final PassDiam of Hole
8a
Step 1 Drill FF
A
C
88 PutAnything
Drill Hole On Front Side
ThruOp011
Final PassDepth of Hole
9a
Step 1 Drill
L
C
99 PutAnything
528a
1010
529a
1111
530a
1212
531a
1313
532a
1414
2Packaging Inspection TransferOperation ReworkStorage 10/10/05
© 2005 All Rights Reserved Quality Systems Engineering @ 810-499-1015 Controlled 1.1Status: Revision:
Printed on 1Page of
QSE QSEQUALITY SYSTEMS ENGINEERING
Process Flow Details
User types info of choicePut Anything
Operation DescriptionPicture Flow
Characteristics
Product ProcessSpecification and/or
Tolerances
EC StatusIVEC Level 09/15/05EC Date
Brighton2003B-4589
Part Name:Part Number:
Model Year(s) Vehicle(s):
02/02/05 09/22/05
Rob Bescoe
Sandra Werwega
Original Date:
Responsible Engineer:Prepared By:
Revision Date:
GD&T
PpPpk
CpCpkClass
RiskFunction IDPROCESS IDOP ID
ROW NO
PCID
112749Flow Number:Pipe Fixture546876413 - 165468469465468
Counter
Receiving / Incoming MaterialVerification
Part ID conditionOperator must InsureMaterial Label is correct.
*
Op005
1aReceivingA
11
Put Anything
A
000-0000-000
Receiving / Incoming Material 000-0000-000Part Placed in ProperPosition using Due Care.
Op005
2aReceiving InspectionA
22
Put Anything
L
Put Anything
Position Part On Pallet Part ConditionMaterial Handler Must UseCaution
Op010
3aTransferB
33
Put Anything
H
Storage Locations ?
Drill Hole On Front Side Hole Location5.680 - 7.433
Op011
4aStep 1 DrillC
44
Put Anything
L
Hole No 401
Drill Hole On Front SideCircularity ofHole
0.0025*
Op011
5aStep 1 DrillC
55
Put Anything
H
Drill Hole On Front SideFirst Pass Diamof Hole
2.224 +/- 0.20PQC
Op011
6aStep 1 DrillC
66
Put Anything
H
Drill Hole On Front SideFirst Pass Depthof Hole
15.434 +/- 0.20SC
Op011
7aStep 1 DrillC
77
Put Anything
H
Drill Hole On Front SideFinal Pass Diamof Hole
3.823 +/- 0.20FF
Op011
8aStep 1 DrillC
88
Put Anything
A
Drill Hole On Front SideFinal Pass Depthof Hole
Thru
Op011
9aStep 1 DrillC
99
Put Anything
L
528a1010
529a1111
530a1212
10/10/05
Controlled1.1
© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015
Printed on
Status:Revision:
21Page
of
QSE
Sev
Occ
Det
Sev
O c c
D e t
QUALITY SYSTEMS ENGINEERING QSE
Counter
Operation Description
PROCESS POTENTIAL FAILURE MODES AND EFFECT(S) ANALYSIS
PotentialFailure
Mode(s)Potential Effects of
Failure
PotentialCause(s)
Mechanism(s)of Failures
Current Process Controls Prevention /Detection Recommended
Actions Responsible:
Target Date Completion Date
Actions Results
Requirements
Int Final
Actions ResultsRPN RPN
Jack Joseph 810-499-1015
Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis,
11/17/03Brighton2003B-4589
EC StatusIVEC Level 09/15/05EC Date
Model Year(s) Vehicle(s):
Core Team:
Responsible Engineer:Key Date:
05/27/05
Sandra Werwega
09/03/05Original Date: Revision Date:
Prepared By:
ClassGD&TProcess ID
Op ID
Row No
7778FMEA Number:
1 3Page of
PutAnything
Part Name:
Part Number:
Pipe Fixture
546876413 - 165468469465468
Function ID703900 Final RPNInitial RPN
*Missing, Wrongor UnreadableLabel
Incorrect Label OnContainer, PRRWritten
3 Wrong partsshipped
3 Supplier Audits. Tagsverify FIFO.
7 None 3 3 7 6363
Operator must Insure MaterialLabel is correct.
Receiving / IncomingMaterial VerificationOp005
ReceivingA
PutAnything
Purchasing (Providessupplier with correctspecs).A
11
Hopper Jams Damage Parts ScrapParts
3 ImproperLoading of Part
2 Training in PartLoading. Tags verifyFIFO.
8 ScheduleTraining in JobProcedures.ImplementPreventiveMaintenance.
Trainingcompleted2-1-2004. PostedPM Schedule.
3 2 5 3048
Part Placed in Proper Positionusing Due Care.
Receiving / IncomingMaterial
ProcessEngineer
06/20/05 07/01/05
Op005No
Receiving InspectionL
PutAnything
Material Handling /Non-ConformingProcedure
P
A22
100%
Damaged Part Impairs OperationCannot Mount Part,Damage Part, ScrapParts.
6 Forks NotAdjustedProperly DuringTransport
3 Training in PartLoading.
8 Revise VisualAids & ScheduleTraining .Implementmarking tags
5 4 6 120144
Material Handler Must Use Caution
Position Part On Pallet Supervisor -Henry / 222
02/15/05 02/20/05
Op010No
TransferH
PutAnything
Visual Inspection
P
B33
22
10%
Off Location No Assembly,Rework
5 Wrong CNCProgram
1 Training, SWI 3 None 5 1 3 1515
5.680 - 7.433
Drill Hole On Front Side ProcessEngineerOp011
Step 1 DrillL
PutAnything
Gage 2 Parts after everyTool Change
N
C44
35
*Out of Round Leaks, SafetyIssue,Rework,Impairs NextOperation
10 ImproperMachine Setup
7 Training, SWI 4 Go/No Go Gage 2Parts @ EachSetup. ImplementPreventiveMaintenance.
Posted PMSchedule andimplementedgauging 2 partsper shift
10 6 4 240280
0.0025
Drill Hole On Front Side ProcessEngineer
08/02/05
Op011Yes
Step 1 DrillH
PutAnything
Auto stop if the ToolHolder is not Properlyseated.
D
C55
44
30%
PQCDiam too Wide Impairs nextoperation, rework,scrap part
10 Premature ToolWear
3 S.W.I. PM 5 Go/No Go Gage 2Parts per shift.ImplementPreventiveMaintenance.
Posted PMSchedule andimplementedgauging twoparts per shift
10 2 4 80150
2.224 +/- 0.20
Drill Hole On Front Side ProcessEngineer
06/02/05 08/04/05
Op011No
Step 1 DrillH
PutAnything
Automatic Spindle LubeSystem.
N
C66
100%
SCDepth tooShallow
Rework Impairs NextOperation Loss OfAssembly Srap Parts
5 Improper SpeedSetting
3 S.W.I. PM 7 Go/No Go Gage 2Parts per shift.ImplementPreventiveMaintenance.
5 3 5 75105
15.434 +/- 0.20
Drill Hole On Front Side ProcessEngineer
08/15/05
Op011Yes
Step 1 DrillH
PutAnything
Inspect First Part Afterany AbnormalOccurrence.
D
C77
31
60%
© 2005 All Rights Reserved - QualitySystems Engineering @ 810-499-101510/10/05 1.3 DRAFTStatus:Revision:Printed on High Risk Average Risk Low Risk
User types info of choice
Operation DescriptionCharacteristics
Product Process
Specification and/orTolerances
Machine,Device, Jigs,Tools for Mfgr
Control MethodsSample Sizeand Frequency Concern No
Responsible:Evaluation
Measurement &Technique
PutAnything
Reaction No
Pp
Ppk
Cp
CpkGD&T Risk
Special
Class
Quality Systems Engineering QSE QSEPROCESS CONTROL PLAN
Function IDPROCESS ID
OP ID
ROW NO
Key Contact Phone:
Jack Pieron - 1-810-499-1015
?
?
06/27/05
07/03/05
?
EC StatusIVEC Level 09/15/05EC Date
Core Team:
PartNumber:
Part Description:
Latest Change Level:
Key Contact:
Supplier Plant Appr Date: Supplier Phone:Cus Eng Approval Date:Cus Quality Appr Date:
Other Approval Date:
Original Date:
Revision Date:
Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, MerryHurt, Mary Davis,
Supplier / Plant: Supplier Code:
PCID
112749Control Plan Number:
Pipe Fixture
546876413 - 165468469465468
Prototype Pre launch ProductionPrototype Pre-launch Production
Receiving / IncomingMaterial Verification
Part ID conditionAudit 4 Samplesper lot.
AutomaticConveyor
Colored Tags - LogSheet
*In ProcessInstructions
TemplateOp005
Receiving 1A RecievingInspector
Put Anything A
000-0000-000 Operator must InsureMaterial Label is correct.
005
A11
Receiving / IncomingMaterial
000-0000-000100% On GoingAutomatic
ConveyorColored Tags - LogSheet
In ProcessInstructions
#45895Op005
Receiving Inspection 2A
# 6778
Operator
Put AnythingL
Put Anything Part Placed in ProperPosition using Due Care. 006A
22
Position Part On Pallet Part Condition100% On GoingAutomatic
ConveyorEnter on Log SheetIn Process
Instructions
#45795Op010
Transfer 3A
789
Operator
Put AnythingH
Storage Locations ? Material Handler Must UseCaution 006B
33
Drill Hole On Front Side Hole LocationGage 2 Parts afterevery Tool Change
MachiningCenter #1
X & R Bar ChartPlug Gage
#272549Op011
Step 1 Drill 4A Operator
Put AnythingL
Hole No 401 5.680 - 7.433005C
44
Drill Hole On Front SideCircularity ofHole
100% Set-upMachiningCenter #1
X & R Bar Chart*Plug Gage
#272549Op011
Step 1 Drill 5A ProductionOperator
Put Anything H
0.0025C
55
Drill Hole On Front SideFirst Pass Diamof Hole
1 Part per ShiftChange
MachiningCenter #1
X & R Bar ChartPQCPlug Gage
#272549Op011
Step 1 Drill 6A ProductionOperator
Put Anything H
2.224 +/- 0.20C
66
Drill Hole On Front SideFirst Pass Depthof Hole
2 @ the beginningand end of eachlot.
MachiningCenter #1
X & R Bar ChartSCPlug Gage
#272549Op011
Step 1 Drill 7A Process
Put Anything H
15.434 +/- 0.20C
77
Drill Hole On Front SideFinal Pass Diamof Hole
Gage 2 Parts perShift
MachiningCenter #1
X & R Bar ChartFFPlug Gage
#272549Op011
Step 1 Drill 8A Process
Put Anything A
3.823 +/- 0.20C
88
Drill Hole On Front SideFinal Pass Depthof Hole
2 @ start of everyshift
MachiningCenter #1
X & R Bar ChartPlug Gage
#272549Op011
Step 1 Drill 9A Process
Put AnythingL
ThruC
99
10/10/05
1.2 Controlled © 2005 All Rights Reserved - QualitySystems Engineering @ 810-499-1015
Printed on Status:Revision:21Page
ofHigh Risk Average Risk Low Risk
QSE QSE
INTERNAL GEAR
USER TYPES COMPANY NAME
ReactionPlan Number Reaction Description
Reaction Plans
005 QS-9000 Requirements Procedure must be setup for the control of Non conformingProduct (Element 4.13). Must be identified and in specified area (Element 4.8Product Identification & Traceability). Supervisor contacts supplier, is heldaccountable (have a corrective action in place Element 4.14).
ReceivingInspectionLow
010 If new material is unacceptable notify supervisor or setup person. Cease operationuntil suspect parts are removed or are being sorted. If parts are in the systeminform the supervisor so that they can be contained. Supervisor will determine acourse of action based on the test results. Non conforming parts are separated andreturned to supplier.
ReceivingInspectionHigh
011 Operator reports serious concerns to Team Leader, who accesses the problem todetermine course of action. The team leader appoints a problem solving team tothe problem for evaluation and recommendations. It is the responsibility of theTeam Leader to implement recommended actions and insure action results arerecorded on Process FMEA.
Sub-AssemblyLow
012 Operator stops the machine and notifies supervisor of suspect part. Supervisorcontacts preventive maintenance team leader to access the problem and makerecommendation.
Sub-AssemblyAverage
Printed on: 09/26/2005 1Page 1of© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015
Part Number: 546876413 - 165468469465468Part Description: Pipe FixtureQUALITY SYSTEMS ENGINEERING
QSE
GD&T
QSE
Control PlanProcess FMEAControl Plan Process Flow, Control PlanAll Documents
Process Overview
OperationDescription
CharacteristicsProduct Process
Machine,Device, Jigs,Tools for Mfgr
Specificationand/or
Tolerances
PotentialFailure
Mode(s)
PotentialEffects of
Failure
Potential Cause(s)Mechanism(s) of
FailuresCurrent Process ControlsPrevention / Detection Control Methods
Sample Size and Frequency Concern No
Responsible:
Reaction No RPNInt
Final
Pp
Ppk
Cp
CpkClass
Function IDProcess ID
Row No
Op ID
PCIDGage Name & Number
PutAnythingUser types info of choice
Receiving /IncomingMaterialVerification
Operator mustInsure MaterialLabel is correct.
* Missing,Wrong orUnreadableLabel
63IncorrectLabel OnContainer,PRR Written
Wrong partsshipped
SupplierAudits. Tagsverify FIFO.
RecievingInspector
63Op005
AutomaticConveyor
In Process Instructions
Audit 4 Samples per lot. Colored Tags - Log Sheet
Part ID condition1A
000-0000-000Receiving
A
1Template1 A
005Put
Anything
Purchasing(Providessupplier withcorrect specs).
Receiving /IncomingMaterial
Part Placed inProper Positionusing Due Care.
Hopper Jams 48Damage PartsScrap Parts
Improper Loadingof Part
Training inPart Loading.Tags verifyFIFO.
Operator
30Op005
AutomaticConveyor
In Process Instructions
100% On GoingColored Tags - Log Sheet
000-0000-0002A
Put AnythingReceivingInspection
A
2
# 6778#458952 L
P
006
PutAnything
MaterialHandling /Non-Conforming Procedure
Position PartOn Pallet
Material HandlerMust UseCaution
DamagedPart
144ImpairsOperationCannot MountPart, DamagePart, ScrapParts.
Forks NotAdjusted ProperlyDuring Transport
Training inPart Loading.
Operator
120Op010
AutomaticConveyor
In Process Instructions
100% On GoingEnter on Log Sheet
Part Condition3A
Storage Locations ?Transfer
B
3
789#457953 H
P
006
PutAnything
VisualInspection
Drill Hole OnFront Side
5.680 - 7.433 Off Location 15No Assembly,Rework
Wrong CNCProgram
Training, SWI Operator
15Op011
MachiningCenter #1
Plug Gage
Gage 2 Parts after every ToolChange
X & R Bar ChartHole Location
4AHole No 401Step 1 Drill
C
4#2725494 L
N
005
PutAnything
Gage 2 Partsafter everyTool Change
Drill Hole OnFront Side
0.0025* Out of Round 280Leaks, SafetyIssue,Rework,Impairs NextOperation
Improper MachineSetup
Training, SWI ProductionOperator
240Op011
MachiningCenter #1
Plug Gage
100% Set-upX & R Bar Chart
Circularity of Hole5A
Step 1 Drill
C
5#2725495 H
DPut
Anything
Auto stop ifthe ToolHolder is notProperlyseated.
Drill Hole OnFront Side
First Pass Diam ofHole
2.224 +/- 0.20PQC Diam tooWide
150Impairs nextoperation,rework, scrappart
Premature ToolWear
S.W.I. PM ProductionOperator
80Op011
MachiningCenter #1
Plug Gage
1 Part per Shift ChangeX & R Bar Chart
6AStep 1 Drill
C
6#2725496 H
N Put
Anything
AutomaticSpindle LubeSystem.
Drill Hole OnFront Side
First Pass Depth ofHole
15.434 +/- 0.20SC Depth tooShallow
105ReworkImpairs NextOperationLoss OfAssemblySrap Parts
Improper SpeedSetting
S.W.I. PM ProcessEngineer
75Op011
MachiningCenter #1
Plug Gage
2 @ the beginning and end of eachlot.
X & R Bar Chart
7AStep 1 Drill
C
7#2725497 H
DPut
Anything
Inspect FirstPart After anyAbnormalOccurrence.
Drill Hole OnFront Side
3.823 +/- 0.20FF Diam tooWide
75Impairs nextoperationLossof AssemblySrap parts
Improper MachineSetup
S.W.I. PM ProcessEngineer
60Op011
MachiningCenter #1
Plug Gage
Gage 2 Parts per ShiftX & R Bar Chart
Final Pass Diam ofHole8A
Step 1 Drill
C
8#2725498 A
PPut
Anything
Gage 2@ startof every shift
10/10/05
1.2Controlled3:08:31 AM 10/10/05Modified
© 2005 All Rights Reserved - Quality SystemsEngineering @ 810-499-1015
Status: Revision:
Printed on 1Pageof
High Risk Average Risk Low Risk2
This icon will takeuser back to thisscreen. Make sureyour target value iscorrect beforerunning RPN
User must select report and click the preview button to see this report, this is anautomatic summary report. This report is a useful tool when making a graph of thetotals per operations. This report should be printed per month and the totals keptseparate. Later the team can compare the totals per month, year etc. showing processimprovement results overtime.
This icon willsort Final RPN’sfrom Highest toLowest.
User can go to this form (layout) to see details of severity, occurrence and detection.Good report format for editing and identifying risk . Special reports can be created byuser, all other reports will reflect these sorts.
User can click on icons to see reports in this form (layout) and/or run other reports oftheir choice. A nice tracking tool for sorting by causes or characteristics.
This is an automatic RPN Report showing only the top five, giving the team the highestrisk is per process. Before clicking the icon ”Top 5 RPN’s” user must click the “FindAll”and the “Clear Title” buttons. The “Top 5 RPN’s can be seen in all documents. Click theSortSet button to perform sorts of five records.
Top 5 RPN’s
RPN
Sort
40ENTER
Target
RPN
09/20/05
This icon will take user to thechart file user is able to link anychart to this file for commonreporting. Default charts are inthis file, user must have excel touse them.
RPN
Overviewof Failures
RiskManagement
RISK EVALUATION REPORTS
Current RPN Report Title:Total RPN's per Process ID
QSE
© 2005 All Rights Reserved - QualitySystems Engineering @ 810-499-1015
RPN REPORT DEFINITIONS
40
9
360
678
834
-156
360
678
318
Target
Final RPN
Difference
Initial RPN Total
Final RPN Total
Ideal RPN
Count of All RPN's
Ideal RPN
Difference Between Ideal and Actual
Printed on
Difference
TARGET
Automatic reporting gives user choice of reports, user must select report and click thepreview button to see the report (1) Subtotals RPN per operation number and includes agrand total. (2) Subtotals RPN per Process ID number and includes a grand total. It willshow the weakest and strongest RPN’s per process. The RPN reporting documentshave a “Clear Title” button so user can Sort/Find and print reports of their choice.
ChoiceTotal RPN’s
ChoiceSummary
QSEQSE RPN SPECIAL RPN REPORTS
QUALITY SYSTEMS ENGINEERING
ECN Status 225IVECN Level 09/15/05ECN Date
Brighton2003B-4589Model Year(s) Vehicle(s):
02/02/05 09/22/05
Rob Bescoe
Sandra Werwega
112749Flow Number:
Original Date:
Responsible Engineer:
Prepared By:
Revision Date:
Effects
Causes
Recommended Actions
Responsible: Actions TakenCompletion
Target Date
IntFinalRPN
40
3
120
465
529
-64
120
465
345
Target
Final RPN
DifferenceDifference
Initial RPN Total
Final RPN Total
Ideal RPN
Count of All RPN's
Ideal RPN
Function Description FailureMode
Process IDOP ID
REPORT ON ALL RPN'S ABOVE 100
ROW NO
Part Name:Part Number:
Pipe Fixture546876413 - 165468469465468
Op010
Position Part On Pallet
Damaged Part
144
Supervisor - Henry / 222
Revise Visual Aids & Schedule Training .Implement - Gauging2 parts per shift. Feb 20, 2005
120Forks Not Adjusted ProperlyDuring Transport
Feb 15, 2005
No
10%
Impairs Operation Cannot MountPart, Damage Part, Scrap Parts.
Transfer
B
31
Op011
Drill Hole On Front Side
Out of Round
280
Process Engineer
Go/No Go Gage 2 Parts @ Each Setup.Implement Preventive Maintenance.
240Improper Machine SetupAug 2, 2005
Yes
40%
Posted PMSchedule andimplementedgauging 2 partsper shift
Leaks, Safety Issue,Rework,Impairs Next Operation
Step 1 Drill
C
52
Op011
Drill Hole On Front Side
Depth too Shallow
105
Process Engineer
Go/No Go Gage 2 Parts per shift.Implement Preventive Maintenance.
105Improper Speed SettingAug 15, 2005
Yes
60%
Rework Impairs Next OperationLoss Of Assembly Srap Parts
Step 1 Drill
C
73
465TOTAL FINAL
REPORT ON ALL RPN'S ABOVE 100 529
09/20/05
© 2005 All Rights Reserved Quality Systems Engineering@ 810-499-1015 1
1Page
ofHigh Risk Average Risk Low RiskPrinted on
RPN TOTALS PER OPERATION ID
QSE QSEQuality Systems Engineering
S O DS O DSpecialOperation
DescriptionPotential Failure
Mode(s)Potential Cause(s)Mechanism(s) of
Failures Responsible: Recommended Actions
Initial Final FinalTarget Date
Completion
Total ActualRPN's
Total IdealRPN's
Difference Ideal /Actual678 31840 360Target
InitialRPN
RPN
Sandra WerwegaPrepared By:
Jack Joseph 810-499-1015
7778FMEA Number:
RPN Risk Management, RPN Details
Percent
Responsible Engineer:
ROW NO
PROCESS
OP ID
112749
Part Name:Part Number:
Pipe Fixture
546876413 - 165468469465468
Control Plan Number:
Op005Receiving / IncomingMaterial Verification
Missing, Wrong orUnreadable Label
None 48Wrong parts shipped3 2 8
723 3 8
Receiving
A1
1
Op005Receiving / IncomingMaterial
Hopper Jams Process Engineer Schedule Training in Job Procedures.Implement Preventive Maintenance.
Jul 1, 2005
30Improper Loading of Part Jun 20, 2005
No3 2 5
483 2 8
100%
Receiving Inspection
A22
Op005 78120Op010
Position Part On PalletDamaged Part Supervisor - Henry /
222Revise Visual Aids & ScheduleTraining . Implement - Gauging2 parts per shift. Feb 20, 2005
120Forks Not Adjusted ProperlyDuring Transport Feb 15, 2005
No5 4 6
1446 3 8
10%
Transfer
B3
3
Op010 120144Op011
Drill Hole On FrontSide
Off Location Process Engineer None 15Wrong CNC Program5 1 3
155 1 3
Step 1 Drill
C44
Op011Drill Hole On FrontSide
Out of Round Process Engineer Go/No Go Gage 2 Parts @ Each Setup.Implement Preventive Maintenance. 240Improper Machine Setup Aug 2, 2005
Yes10 6 4
28010 7 4
40%
Step 1 Drill
C5
5
Op011Drill Hole On FrontSide
Diam too Wide Process Engineer Go/No Go Gage 2 Parts per shift.Implement Preventive Maintenance.
Aug 4, 2005
40Premature Tool Wear Jun 2, 2005
No5 2 4
755 3 5
100%
Step 1 Drill
C6
6
Op011Drill Hole On FrontSide
Depth too Shallow Process Engineer Go/No Go Gage 2 Parts per shift.Implement Preventive Maintenance. 105Improper Speed Setting Aug 15, 2005
Yes5 3 7
1055 3 7
60%
Step 1 Drill
C7
7
Op011Drill Hole On FrontSide
Diam too Wide Process Engineer -Rob BescoeEXT: 276
Implement Preventive Maintenance.
Aug 19, 2005
60Improper Machine Setup May 17, 2005
No5 3 4
755 3 5
100%
Step 1 Drill
C8
8
Op011Drill Hole On FrontSide
Depth too Shallow Process Engineer None 20Incomplete Cycle5 2 2
205 2 2
N/A
Step 1 Drill
C99
Op011 480570
9/20/2005© 2005 All Rights Reserved - Quality Systems
Engineering @ 810-499-1015Draft1.3Printed on
Status:Revision: 21Page
ofHigh Risk Average Risk Low Risk
QSE QSEQuality Systems Engineering
Monday, September 19, 2005
RPN Totals per Operation ID
75
ECL# 225IIIECL: 03/02/03ECN Date:
02/02/03 09/22/03Rob Bescoe
Sandra Werwega
Original Date:Responsible Engineer:
Prepared By:
Revision Date:
Target
InitialRPN
FinalRPN
DifferenceIdeal / Actual
Operation DescriptionProcessID
TotalRPN's
TotalRPN's
Summary of RPN’s
7778FMEA Number:
Part Name:Part Number:
Pipe Fixture546876413 - 165468469465468
Op005 781202Receiving / Incoming Material
A
Op010 1201441Position Part On Pallet
B
OP011 4805706 C
6788349 3675GRAND TOTALS
09/19/05© 2004 All Rights Reserved - Quality
Systems Engineering @ 810-499-1015Printed on
QSE QSE
TOTAL RPN'S PER OPERATION
Risk Priority Measurements
Project Totals
QUALITY SYSTEMS ENGINEERING INC.
High Risk Priority Average Risk Low Risk
0
50
100
150
200
250
300
350
400
450
Pipe Fixture Door Fixture Quarter Panel Fixture Rear Door Fixture Luggage Fixture0
100
200
300
400
500
600
700
OP010 OP020 OP030 OP040 OP050 OP060
0
50
100
150
200
250
300
350
400
450
Part 1 Part 2 Part 3 Part 4 Part 5
0
50
100
150
200
250
300
350
10 20 30 40 50 60 70 80 90 100
Num
ber o
f Fai
lure
Mod
es
Risk ReportingRisk Reporting per Operation
© 2004All Rights Reserved - Quality Systems Engineering 1-810-499-1015
QSE
Flows, FMEA’s,
Control Plans
Thank you!
For viewing the QSE FMEA APQP Application.For more information
contact QSE @ 352-597-1197
© All rights reserved 2000/2005. Quality Systems Engineering. No part of this material may be reproduced
or utilized (in any form or by any means), electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, for any purpose (training) without prior
written permission from Sandra Werwega.
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