A Component-oriented Process Failure Risk Analysis Method (Ver. 5) by Professor Paul G.

Ranky, PhD, NJIT/MERC

Product Name and Appearance Before Process

Process ID

Name of Organization Responsible for the Process

PFRA Study ID Number

Date of This Study (mm/dd/yy)

7/26/16

Process Code
Engineering Release Date of Process Methodology

Other Organizations Involved in the Process

Orignal Date of This Study

7/26/16

Type of Product Processed

Subcontractors, process Plants Effected

Product Serial Number and Optional Image Map

Revision Number
Comments

EM 636 - Assignment 4

Product Group Classifier

Engineering Release Date of the Product

List / Identify the Parts / Components Retrieved in

Each Process Step

Process
Time

Describe the Process for Each Process Step and

Optionally Illustrate the State of the Device/ Part/
Subassembly/ Object AFTER the Process is
Complete

Examples of Risky Processes in Ranky Videos

Specify the Tool(s) Used in Each Process Step

Specify the Fixtures / Clamps Used in Each

Process Step

1
2

[sec]
Dropped the hair dryer

Used my hands and a screw driver to re-assemble

broken dryer

Used my hands; no special fixtures were required

240

Process
Cost
15.00
[USD]
1.00

Accumulated
Process Cost

The PFRA Team Describes / Illustrates the Potential Process Failure

Mode and the Effect; the Risk of Failure
Proc.ID

[USD]
1.00

ID 1.1
ID 1.2
ID 1.3
ID 2.1

Tree/Branch Clean-up/Removal: Self-contained Vehicle

where decomposed tree/branches can be stored instead
of being thrown into the air that cause air pollution

Closing Under-Construction Site: Following Proper

Safety Procedure

Laborers Working on Construction Site: Following PPE

Hazardous Transfer of Materials On-Site: Properly

secured pallets

Human Hand, Tree/Branch Removal Vehicle

Clamps on Robotic Arm to pick up tree/branches Tree/Branches, Container in the Back of Vehicle

3600

15.00

16.00

ID 2.2
ID 2.3

Human Hands, Signs, Construction Tape, Tarp

No special fixtures required

Human Decision, Proper Equipment

No special fixtures required

Human Hand, Vehicle/Fork Lift, Pallets

Be sure to set up temporary alternative pedestrian

walkway, cover possible debris, tape-off area under
construction
Gloves, Helmet, Safety Vest, Safety Glasses, etc.

The Vehicle/Forklift must have the pallet stabilized

Fork Lift/Robotic Arm of Vehicle to pick up pallets and all materials on top of it must be securely
with materials
fastened

900

3.75

19.75

300

1.25

21.00

ID 3.1
ID 3.2
ID 4.1
ID 5.1

360

1.50

22.50

ID 5.2
ID 5.3

Quality Checking all Materials that will be Used: Assure

zero degradation or cracks

Human Eye and Hand, Vision System in

Warehouse

Vision System and Human

Construction Site Clean-up for Scraps and Waste: The

Sustainably Green Way

Human Hands, Recycling Bins, Biodegradable

Garbage Bags, On-site Storage Containers

No special fixtures required

Procurement of Materials: Contracting Strategies on

Sustainable Projects

Human Decision, Procurement Department

No special fixtures required

Cameras, Material handling in Receiving Area of

Warehouse
Use on-site storage for back filling of garbage in one
central location (recycling bins and biodegradable
garbage bags). Have stations clearly identified.
Establish and require recycled content thresholds for
materials and have them readily available. Require
documentation on recycled content and source
materials locally.

200

0.83

23.33

ID 6.1
ID 6.2

1800

7.50

30.83

ID 7.1

10800

45.00

75.83

ID 8.1

ID 9.1
10

Use of Incorrect Material: Checking Routine Checklist

Human Eye, Checklist

No special fixtures required

1500

6.25

82.08

ID 9.2
ID 9.3

11

Construction Worker No-Show: New Construction

Worker

12

Cement Mixer Vehicle Unresponsive: Replacement

Cement Mixer Ready

Human Decision, HR, Project Manager

No special fixtures required

If the worker called out before hand, project manager

should have found a replacement by planning ahead
accordingly.

600

2.50

84.58

Human Decision, Cement Mixer Vehicle, Telephone

No special fixtures required

Call for Immediate Assistance from Mechanic. If

unable to fix vehicle within an allotted time, order for
a replacement vehicle to come.

14400

60.00

144.58

ID 10.1
ID 11.1
ID 11.2

 Copyright by Paul G. Ranky, 1992-2002

This PFRA Study was Prepared By

Alodie Vargas

PFRA Team

Alodie Vargas and Dr. Paul G. Ranky

Responsible Organization/ Department

Comments

The PFRA Team Describes / Illustrates the Potential Process Failure

Mode and the Effect; the Risk of Failure

Safety, and risk-based green engineering design

RPN (Risk
Priority
Number)

Severity
Rating

Detection
Rating

Occurrence
Rating

(1-10)

(1-10)

(1-10)

8
5

3
1

4
2

96
10

36

90

ON / OFF switch separated in Vehicle: risk of electrical failure!

36

Saw inside of vehicle does not decompose tree/branches fully: risk

of damaging machinery

10

250

Area not covered: risk of debris and air pollution

144

Area not taped off: risk of injury to human

Risk of Personal Injury
Vehicle/Forklift not holding on to pallet securely: risk of damaging
material by letting it drop
Vehicle/Forklift not holding on to pallet properly: risk of causing
injury to human or property
ON / OFF switch separated in Vehicle: risk of electrical failure!
Unable to identify appropriate package/damage in delivery: risk of
using damaged or wrong material

48

10

250

168

Failure Mode(s) and Effect(s)

Heating element separated: risk of burning my hands!
Handle disintegrated: risk of electrical shock!
ON / OFF switch separated: risk of electrical failure!
Robotic Arm not clasping tree/branch tight enough: risk of causing
injury to human or property.

Max. RPN

Tooling
Factor

Clamping/
Fixturing
Factor

Skill Factor

Any Other
Factor You
Define

Accumulated
RPN

Risk
Associated

96.00

Low

216

36

120

96

250

144

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

250.00

144.00

HIGH

Low

250

1.00

1.00

1.00

1.00

250.00

HIGH

216

1.00

1.00

1.00

1.00

216.00

HIGH

120

1.00

1.00

1.00

1.00

120.00

Low

200

1.00

1.00

1.00

1.00

200.00

Low

0
8

Using un-sustainable materials for construction: risk of aiding

pollution and causing harm to environment

Wrong material to be returned: risk of impacting project timeline

200

200

216

Wrong material needed for another project: risk of impeding

another project

168

Less personnel: risk of getting project completed on time

Cement not ready to be used: risk of not building

10

5
6

6
4

200

180

216

180

1.00

1.00

1.00

200.00

Unit and system failure!

Danger of electrical shock!

Unit cannot be turned ON / OFF

Unit and system failure!

System failure!

Unit cannot grab tree/branches

Unit and system failure!

Unit cannot be turned ON / OFF

System failure!

Unit cannot decompose tree/branches

Air Pollution

Unit and system failure!

Environmental Violation

Possible Human Injury

Safety Violation

Possible Human Injury

Safety Violation

Materials cannot be transferred

Safety Violation

Possible Human Injury

Unit cannot be turned ON / OFF

Safety Violation
System failure!

Cost Impact
Integrity of Construction

Direct measurable effect: loss!

Safety Violation

Air/Water/Waste Pollution

Environmental Violation

Air/Water/Waste Pollution

Environmental Violation

Time Impact

Direct measurable effect: loss!

Cost/Time Impact

Direct measurable effect: loss!

Cost/Time Impact

Direct measurable effect: loss!

Time Impact

Direct measurable effect: loss!

Integrity of Construction

Safety Violation

Time Impact

Direct measurable effect: loss!

Low

1.00

1.00

1.00

1.00

1.00

1.00

1.00

1.00

216.00

180.00

HIGH

Low

240
240

Unable to perform construction: risk of impacting project timeline

1.00

Unit cannot heat: serious hazard!

180

Use of wrong material already installed: risk construction integrity

The Effect of Each Process Step Failure

Risk on Other Parts (I.e. components/
objects)

0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100% 0.1-2,1=100%

Incorrectly disposing of materials: risk of aiding pollution and

causing harm to environment

The Effect of Each Process Step Failure

Risk on Other Processes

1.00

1.00

1.00

160

1.00

240.00

HIGH

Detection Mode

Recommended Corrective Action(s)

Corrective Action(s) Taken and Date (mm/

dd/yr)

Accumulated RPN for Each Failure Mode

RPN for Each Failure Mode

Visual inspection

Attempt re-assembly

Assembled and tested OK!

Visual inspection
Visual inspection

Attempt re-assembly
Attempt re-assembly

Assembled and tested OK

Assembled and tested OK

Visual inspection

Attempt re-assembly

Assembled and tested OK!

Visual inspection

Assembled and tested OK!

Visual inspection

Attempt re-assembly
Attempt to remove tree/branch, and reassemble. Make sure the machine warranty
information is in place.
Attempt re-assembly

Visual inspection

Attempt re-assembly

Assembled and tested OK!

Visual inspection

Attempt re-assembly

Immediate action needed

Visual inspection

Attempt re-assembly

Immediate action needed

Visual inspection
Visual inspection

Attempt re-assembly
Attempt re-assembly

Immediate action needed

Logistics/Receiving Department
Visual inspection

Design and deliver proper operator training

Design and deliver proper operator training

Visual inspection

Attempt to recycle and deliver proper clean-up

training
Immediate action needed

System-Self Inspection

Procurement Department

Visual inspection
Visual inspection
Project Manager

Project Manager/HR
Visual inspection
Visual inspection

Check recyclable documentation, return

unused materials to vendors consider
replaceable sustainable material
Return material, determine where it belongs,
retrieve correct material. Design and deliver
proper training on what to check on the
checklist, how to complete it, and when to
check it.
Check if material can still be used, if not, reassemble with correct material.
Check with project manager on which material
this material may be needed on and return to
warehouse immediately.
Check if construction worker is repeat offender
of missing work. If so, HR shall set up a
meeting and set up disciplinary action.
Design and deliver proper training on how to
check if Cement Mixer is working properly and
how to check if cement is completely mixed.
Attempt re-cementing once cement is
completely mixed.

Immediate action needed

Assembled and tested OK!

Immediate action needed

Immediate action needed
Immediate action needed

Immediate action needed

Immediate action needed
Immediate action needed

75

150

225

300

65

130

195

260