Failure Mode and Effects Analysis - Report
Failure Mode and Effects Analysis - Report
Supplier/Plant ...:
. Cirteq Limited/Keighley
Supplier code:
Core team ..........:
Control plan ....
: 00007190_077
Step Process No. Characteristic Failures Effect Severity Classificati onCause of failure
10 Coil ring & 150 Appearance attributes Visual defect Part will not function or will fail 6 Miss-blanked
blank profile in service holes
150 Appearance attributes Visual defect Part will not function or will fail 6 Rolling marks
in service
setting
1 Beam width Undersize Part will not function correctly 7 Incorrect turks
setting
135 Burr height Above top limit Damage to housing or 6 Tool blunt
202 Dish Above top limit Part leaves groove in service 7 Incorrect setting
147 Flatness Above top limit Part will not assemble 6 Incorrect setting
18 Outside diameter Undersize Part will not function correctly 7 Incorrect setting
22 Gap width loaded Above top limit Part will not function correctly 7 Incorrect setting
69 Wing variation Above top limit Part will not function correctly 7 Incorrect setting
150 Appearance attributes Sticking parts Jamming on auto assembly. 5 Salt residue
188 Atmosphere gas flow Low hardness Internal scrappage/rework cost. 8 Loss of
atmosphere
188 Atmosphere gas flow Low surface hardness, Part will not function or will fail 7 Loss of
decarburisation in service atmosphere
291 Feed method Distorted parts Jamming on auto assembly. 5 Incorrect feed
pattern
291 Feed method Low hardness - Slack quenched Part will not function or will fail 8 Excessive
in service section size
291 Feed method Low hardness - Slack quenched Part will not function or will fail 8 Incorrect wiring
in service up method
291 Feed method Low hardness - Slack quenched Part will not function or will fail 8 Incorrect feed
in service pattern
291 Feed method Low hardness - Slack quenched Part will not function or will fail 8 Parts snagging
Occurrence Controls Prevention Main Controls Detection Detection RPN AP Responsibility Action proposed/taken
2 SOP0111 Every 30 minutes Visual 6 72 L MIBA Update SOP0111 to include
check SPC In process failure mode.
inspection
2 First off verification. Every 30 minutes Visual 6 72 L
Work instruction check SPC In process
inspection
2 SOP0111 Every 30 minutes Visual 6 24 L MIBA Update SOP0111 to include
check SPC In process failure mode.
inspection
2 First off verification. Every 30 minutes Visual 6 24 L
Work instruction
inspection
3 First off verification. Every 1 hour OGP 5 90 L
Work instruction machine SPC In process
inspection
3 First off verification. Every 1 hour OGP 5 105 M
Work instruction machine SPC In process
inspection
3 First off verification. Every 30 minutes Flat 4 72 L
Work instruction Micrometer SPC In
process inspection
3 First off verification. Every 30 minutes 5 105 M
Work instruction
SPC In process
inspection
3 First off verification. Every 30 minutes 5 90 L
Work instruction
SPC In process
inspection
3 First off verification. Every 30 minutes Caliper 4 72 L
Work instruction SPC In process
inspection
3 First off verification. Every 30 minutes Caliper 4 84 L
Work instruction SPC In process
inspection
3 First off verification. Every 30 minutes 5 90 L
Work instruction
recorded
3 First off verification. Every 1 hour OGP 5 105 M
Work instruction machine SPC In process
inspection
3 First off verification. Every 1 hour OGP 5 90 L
Work instruction
inspection
3 First off verification. Every 1 hour OGP 5 90 L
Work instruction machine SPC In process
inspection
3 First off verification. Every 30 minutes Bore 5 90 L
Work instruction Gauge SPC In process
inspection
3 First off verification. Every 1 hour OGP 5 90 L
Work instruction
inspection
3 First off verification. Every 30 minutes Flat 4 72 L
Work instruction
process inspection
3 First off verification. Every 30 minutes Flat 4 84 L
Work instruction Micrometer SPC In
process inspection
3 First off verification. Every 1 hour OGP 5 105 M
Work instruction machine SPC In process
inspection
2 Competence checks. Continuous Visual check 6 84 M
Training. Layered audits. Not recorded
2 SOP110. SOP111 Each batch Visual check 7 112 M TS Verify feed method at first off &
SPC Last Off
SOP0110
2 SOP110. Route card Each batch Visual check 7 112 M TS Verify feed method at first off &
SPC Last Off
SOP0110
2 SOP110. SOP111 Each batch Visual check 7 112 M MIBA New cause of failure
SPC Last Off
Action date
28/07/2020
28/07/2020
28/07/2020
06/09/2019
06/09/2019
06/09/2019
28/07/2020
Step Process No. Characteristic Failures Effect Severity Classificati onCause of failure
291 Feed method Low hardness - Under soaked Part will not function or will fail 8 Incorrect wiring
in service up method
291 Feed method Low hardness - Under soaked Part will not function or will fail 8 Incorrect feed
in service pattern
79 Feed rate Low hardness - Under soaked Part will not function or will fail 8 Overfeeding of
in service parts
189 Furnace Belt Speed High hardness Part will fail on assembly or in 9 Insufficient time
service. in salt
189 Furnace Belt Speed Low hardness Internal Scrappage/rework costs 8 Belt condition
service.
26 Hardness High hardness Parts may fail on assembly or 9 Failure to
comply with
service. procedures
26 Hardness High hardness Parts may fail on assembly or 9 Lack of training
service.
26 Hardness High hardness Parts may fail on assembly or 9 Incorrect start up
service.
26 Hardness High hardness Parts may fail on assembly or 9 Instrument
reading
service. incorrectly
26 Hardness High hardness Parts may fail on assembly or 9 Incorrect
service. Maintenance
26 Hardness High hardness Parts may fail on assembly or 9 Unauthorised
service.
area
26 Hardness High hardness Parts may fail on assembly or 9 Instrument out of
calibration
service.
26 Hardness High hardness Parts may fail on assembly or 9 Incorrect
procedures
service.
26 Hardness Low hardness Customer receives out of 8 Unauthorised
area
service.
26 Hardness Low hardness Customer receives out of 8 Burner condition
service.
26 Hardness Low hardness Customer receives out of 8 Instrument failure
service.
26 Hardness Low hardness Customer receives out of 8 Lack of training
service.
26 Hardness Low hardness - Slack quenched Part will not function or will fail 8 Wrong Furnance
in service used
26 Hardness Low hardness - Slack quenched Part will not function or will fail 8 Incorrect
in service procedures
26 Hardness Low hardness - Slack quenched Part will not function or will fail 8 Failure to
in service comply with
procedures
26 Hardness Low hardness - Slack quenched Part will not function or will fail 8 Incorrect
in service
Maintenance
26 Hardness Low hardness - Slack quenched Part will not function or will fail 8 Poor quench
in service conditions
26 Hardness Low hardness - Slack Part will not function or will fail 8 Lack of
in service Maintenance
build up
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Incorrect
in service
Maintenance
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Instrument out of
in service calibration
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Instrument
in service reading
incorrectly
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Incorrect
in service procedures
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Incorrect start up
in service
Occurrence Controls Prevention Main Controls Detection Detection RPN AP Responsibility Action proposed/taken
2 SOP110. SOP111 Each batch Visual check 7 112 M TS Verify feed method at first off &
SPC Last Off
SOP0110
2 SOP110. Route card Each batch Visual check 7 112 M TS Verify feed method at first off &
SPC Last Off
SOP0110
2 SCADA monitorning and Each load Process 6 96 M WI-09-01 now includes reaction
control system. Feed Instrumentation Operator plan for deviation
method defined Check List
loose/wired stacks.
2 SCADA monitoring and Continuous Process 3 54 M WI-09-01 now includes reaction
control system. Control Instrumentation Heat plan for deviation
of belt speed and salt
level
2 Maintenance checks. Continuous Process 3 48 L
Maintenance schedule.
06/09/2019
Step Process No. Characteristic Failures Effect Severity Classificati onCause of failure
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Wrong Furnance
in service used
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Power cut
in service
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Failure to
in service comply with
procedures
26 Hardness Low hardness - Under soaked Part will not function or will fail 8 Lack of
in service Maitenance
brickwork
26 Hardness Low hardness-Slack quenched Part will not function or will fail 8 Lack of
due to trap zones in service Maintenance
197 Temperature zone 4 High hardness Parts may fail on assembly or 9 Thermocouple
in service. position
197 Temperature zone 4 High hardness Parts may fail on assembly or 9 Thermocouple
in service. inaccuracy
197 Temperature zone 4 Low hardness Part will not function or will fail 8 Thermocouple
in service inaccuracy
197 Temperature zone 4 Low hardness Part will not function or will fail 8 Thermocouple
in service position
197 Temperature zone 4 Low hardness - Slack quenched Part will not function or will fail 8 Low end zone
in service temperature
187 Oxygen potential Low surface hardness, Part will not function or will fail 7 Oxidising
decarburisation in service conditions in
furnace
or in belt
190 Quench bath belt speed Low hardness - Slack quenched Part will not function or will fail 8 Belt condition
in service
131 Salt Bath temperature High hardness Parts may fail on assembly or 9 Salt temperature
in service. too low
131 Salt Bath temperature Low hardness Part will not function or will fail 8 Salt temperature
in service too high
131 Salt Bath temperature Low hardness - Under soaked Part will not function or will fail 8 Low
in service austenatising
temperature
296 Material micro-structure Carbon depletion Part will wear of fatigue 7 Oxidising
prematurely conditions in
furnace
296 Material micro-structure Incorrect Structure Part will not function or will fail 9 Wrong Furnance
in service used
296 Material micro-structure Low surface hardness, Part will not function or will fail 7 Incorrect
decarburisation in service
Maintenance
296 Material micro-structure Low surface hardness, Part will not function or will fail 7 Incorrect
decarburisation in service procedures
296 Material micro-structure Low surface hardness, Part will not function or will fail 7 Burner condition
decarburisation in service
296 Material micro-structure Low surface hardness, Part will not function or will fail 7 Incorrect start up
decarburisation in service
296 Material micro-structure Low surface hardness, Part will not function or will fail 7 Instrument
decarburisation in service reading
incorrectly
296 Material micro-structure Low surface hardness, Part will not function or will fail 7 Power cut
decarburisation in service
296 Material micro-structure Low surface hardness, Part will not function or will fail 7 Instrument out of
decarburisation in service calibration
30 Shot blast 150 Appearance attributes Mixed parts Jamming on auto-assembly 5 Mixing of parts,
stragglers
150 Appearance attributes Scale on surface Failure of system in service 6 Insufficient
150 Appearance attributes Scale on surface Failure of system in service 6 Low blast
pressure
40 Phosphate & 150 Appearance attributes Contamination Jamming on auto-assembly 5 Excessive dirt
oil
processes
150 Appearance attributes Corroded prior to oiling Premature corrosion 5 in process
corrosion
150 Appearance attributes Excessive oil Jamming on auto-assembly 5 Oil
150 Appearance attributes Excessive oil Jamming on auto-assembly 5 High oil strength
Occurrence Controls Prevention Main Controls Detection Detection RPN AP Responsibility Action proposed/taken
2 Route card. Control plan. Every 1 hour Rockwell 5 80 M
hardness tester SPC In
process inspection
2 None Every 1 hour Rockwell 5 80 M
hardness tester SPC In
process inspection
2 Competence checks. Every 1 hour Rockwell 5 80 M
Training. Layered audits. hardness tester SPC In
process inspection
2 Maitenance schedule Every 1 hour Rockwell 5 80 M
hardness tester SPC In
process inspection
2 Maintenance schedule Every 1 hour Rockwell 5 80 M
hardness tester SPC In
process inspection
1 CQI-9. TUS Study Continuous Process 3 27 L
Instrumentation SCADA
records
1 CQI-9. TUS Study Continuous Process 3 27 L
Instrumentation SCADA
records
1 CQI-9. TUS Study Continuous Process 3 24 L
Instrumentation SCADA
records
1 CQI-9. TUS Study Continuous Process 3 24 L
Instrumentation SCADA
records
2 SCADA mornitoring and Continuous Process 3 48 L Failure mode added
cotrol system Instrumentation SCADA
records
2 CO2 and carbon Every 4 hours Process 5 70 M WI-09-01 now includes reaction
potential monitoring. Instrumentation Process plan for deviation
Control of atmosphere records
gas flow and eductor
pressure.
2 CO2 and carbon Every 4 hours Process 5 50 L
potential monitoring Instrumentation Process
records
2 SCADA monitoring and Continuous Process 3 48 L WI-09-01 now includes reaction
cotrol system.Controlled Instrumentation SCADA plan for deviation
feed method rate. records
Monitoring of belt
conditions.
2 Maintenance checks. Continuous Process 3 48 L
Maintenance schedule. Instrumentation SCADA
records
2 SCADA monitoring and Continuous Process 3 54 M WI-09-01 now includes reaction
control system. Instrumentation SCADA plan for deviation
Temperature control & records
monitoring.
2 SCADA monitoring and Continuous Process 3 48 L WI-09-01 now includes reaction
control system. Instrumentation SCADA plan for deviation
Temperature control & records
monitoring.
2 SCADA monitoring and Continuous Process 3 48 L WI-09-01 now includes reaction
control sysyem. Zoned Instrumentation SCADA plan for deviation
temperature contols CQI- records
09. Temperature survays
& STATS
2 CO2 and carbon Every 8 hours Optical 5 70 M
potential monitoring. microscope Process
Hourly structure checks. records
2 Route card. Control plan. Every 8 hours Optical 5 90 H
microscope Process
records
2 WI-09-23 Every 8 hours Optical 5 70 M
microscope Process
records
1 Procedure review. Every 8 hours Optical 5 35 L
Training Matrix Review. microscope Process
Furnance Controller records
2 Maintenance checks. Every 8 hours Optical 5 70 M
Maintenance schedule. microscope Process
records
1 WI-17-03 & WI-17-08 Every 8 hours Optical 5 35 L
microscope Process
records
1 Calibration schedule. Every 8 hours Optical 5 35 L
Calibration contract. CQI- microscope Process
9 records
2 None Every 8 hours Optical 5 70 M
microscope Process
records
1 Calibration schedule. Every 8 hours Optical 5 35 L
Calibration contract microscope Process
records
3 Work Instruction. Each load Visual check 8 120 L
Visual check
3 Control plan. Work Each load Visual check 8 144 L
Instruction. Visual check
3 Control plan. Work Each load Visual check 8 144 L
Instruction. Visual check
3 Constant filtration of Each load Visual check 7 105 L
protective oil. SPC Last Off
file
386 Revalidation & Fault detection Incorrect functional testing Part will fail on assembly or in 6 C/Plan Inspector error
(where applicable) service or use of
equipment
386 Revalidation & Fault detection Incorrect measurement (where Part will fail on assembly or in 6 C/Plan Inspector error
applicable) service or use of
equipment
386 Revalidation & Fault detection Parts not inspected (where Part will fail on assembly or in 7 C/Plan Parts have
applicable) service missed
inspection
operation
50 100% 18 Outside diameter Non-functional parts Part will not function or will fail 8 Incorrect
Function test in service overgauge
& shrink wrap
18 Outside diameter Non-functional parts Part will not function or will fail 8 Parts twisting on
in service gauging pole
18 Outside diameter Non-functional parts Part will not function or will fail 8 Incorrect bung
in service size
18 Outside diameter Non-functional parts Part will not function or will fail 8 Incorrect gauge
in service
248 Free outside diameter Non-functional parts Part will not function or will fail 8 Incorrect gauge
in service
248 Free outside diameter Non-functional parts Part will not function or will fail 8 Incorrect bung
in service size
248 Free outside diameter Non-functional parts Part will not function or will fail 8 Incorrect
in service overgauge
248 Free outside diameter Non-functional parts Part will not function or will fail 8 Parts twisting on
in service gauging pole
parts
36 Labeling requirement Incorrect labelling Customer receives wrong parts 4 Incorrect labels
printed
295 Packing characteristics Incorrect quantities Customer receives short 2 Incorrect setting
delivery of electronic
Occurrence Controls Prevention Main Controls Detection Detection RPN AP Responsibility Action proposed/taken
3 Oil condition checks Each load Visual check 7 105 L
SPC Last Off
2 SCADA control and Each load Visual check 7 70 L
SPC Last Off
2 Oil condition checks Each load Visual check 7 70 L T. Speller Oil & phos % raised
SPC Last Off
2 Solution analysis. Weekly Each load Visual check 7 70 L T. Speller Oil & phos % raised
salt spray test. SPC Last Off
3 Tumble system operator Each load Visual check 7 105 L
spreading of parts. SPC Last Off
18/02/2019
18/02/2019