Sample FMEA

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Process Failure Mode Effects AnalysisItem/Part#: 3595-1038 Process Owner: FMEA #: 3595-1038

Rev: 6 Process: FMEA Rev:Customer:

FMEA Team:FMEA Date:

Supplier: Christopher Tool & Mfg. Co. Prepared by:

* SEV, OCC, & DET scoring per the tables provided in WPQR-9102, unless otherwise approved by Woodward.

Resulting Action(s)

ID # Action(s) Taken

50 0

10 Oven malfunction.

20

0 0

30

0 0

Op / Ref #

Item / Function / Process

DescriptionPotential Failure

ModePotential Effect(s)

of FailureSEV

Class

Potential Cause(s) / Mechanism(s) of

Failure

OCC

Current Controls Prevention

Current Controls Detection

DET

RPN

Recommended Action(s)

Responsibility & Target Completion

Date

SEV

OCC

DET

RPN

SAWING-Cut blanks 5.937 ± 1/64 long.

Blanks are cut undersized.

Parts will not be usable for this part.

Saw is not set-up correctly. Saw malfunction.

Measure parts after saw cutting.

Adjust saw. Change blade.

HEAT TREAT-Harden, Temper and Stress RelieveHardness: 30-36 Rc-----------------------Certs Required

Parts do not meet customer drawing requirements per CTM P.O.

Parts will be reworked or approved by customer.

Certification required.

Anneal and reharden.

CNC TURNING CENTER WORK-Turn 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.

Parts do not meet CTM in-process drawing requirements.

Parts will not meet customer requirements.

Programming is incorrect. Tools are not set-up 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.

CNC TURNING CENTER WORK-Turn 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 set-up 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.

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40

0

Adjust grinder.

0

50 Rework parts.

0 0

60

0 0

70 Scrap parts. Inspection of parts.

0

Replace hob.

0

80

0 0

O.D. GRINDING-Lap 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.

DEBURRING-Remove burrs and break sharp edges.See drawing notes.

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

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

Visual, and inspection.

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

INSPECTION, IN PROCESS-In-Process Inspect prior to outside processes.

Verify part count.Verify that all preceding operations have been completed and are signed off.

Inspector did not check dimension correctly or did not understand the requirement.

Rework parts. Possibly scrap parts.

Inspector was distracted or does not comprehend the dimension.

Additional blueprint or use of precision gages training.

SPLINING & GEAR CUTTING-Finish 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

Spline is undersized.

Incorrect set-up of hob.

Certifications required.

RECEIVING INSPECTION-Inspect 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 incorrect. Parts do not meet compliances to the P.O.

Short parts, or scrap parts.

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

Count and inspect parts to traveler.

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90 Rework parts.

0 0

100 Oven malfunction.

0

110

0 0

120 Rework parts.

0 0

DEBURRING-Remove burrs and break sharp edges.See drawing notes.





HEAT TREAT-Core Harden per Woodward Governor drawing 3595-1038, note #12, IAW SP-908 rev. B-B.Core Hardness: 44-50 RcDo not nitride.------------------Certs Required

Parts do not meet customer drawing requirements.

Parts will be reworked or approved by customer.

Certification required.

Anneal and reharden.


Part count is incorrect. Parts do not meet compliances to the P.O.


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


STRAIGHTENING-Lap centers 100%.Note: Inspect the 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.

Straightening shall be accomplished at 400°± 25°F followed by stress

Parts do not meet runout requirements.

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

Measure and record results 100%.

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130 Scrap parts. Visual and inspect.

0 0

140 Scrap parts. Visual and inspect.

0 0

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 Ø.320 diameters.

Parts are undersized to the traveler requirements.

Machine Malfunction.

Re-dress wheel and change set-up.

O.D. GRINDING-***Allow for .002 g/s on the datum -A- face.***Green grind right side diameters:

Finish grind the RIGHT end face.Do not grind the existing Ø.350 diameter.

Green grind the Ø.3163, Spline O.D and Ø.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-).

Parts are undersized to the traveler requirements.

Machine Malfunction.

Re-dress wheel and change set-up.

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150

0 0

160 Re-work or scrap.

0 0

170 Rework parts.

0 0

180

0 0

O.D. GRINDING-***Allow for .002 g/s on the datum -A- face.***

Finish grind the Ø.373/.371 diameter groove, concentric to -B- and -C- within .002.Hold 32 Ra finish.

EDM MACHINING-EDM angular holes as required per drawing note #11.

***Allow for .002 g/s on datum -A- face.***

Qualification required per SP-1084.

Holes are out of position and oversized.

Machine malfunction.

Inspect dimensions.

Change settings or electrodes.

DEBURRING-Remove burrs and break sharp edges.





NITRIDE-Nitride per Woodward Governor drawing 3595-1038, including drawing notes #7 & #12, IAW SP-908 rev. B-B.

Core Hardness: 44-50 RcCase Hardness: 90 HR15NFinal Case Depth: .006-.015Recommended Applied Case Depth: .012-.020Max stock removal after nitriding: .005Max permissible White Layer: .0004Inspect Case Depth per drawing note #21.------------------Certs Required

Parts do not meet custom drawing requirements including correct areas to be masked.

Parts may or maynot be useable pending customer approval.

Atmosphere of application is contaminated.

Hardness check for correct depth and visual of correct areas.

Monitor settings and inspect.

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190 Scrap. Visual and inspect.

0 0


0 0


0 0


0 0


0 0

O.D. GRINDING-O.D. grind to remove the excess stock and finish grind the Ø.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.

Dimensions are undersized.

Machine malfunction, or incorrect wheel.

Change settings or wheel and re-dress.

O.D. GRINDING-Grind from the LEFT side:

Finish grind the Spline major diameter.Finish grind the Ø.470/.472 diameter.




O.D. GRINDING-From the right side:

Remove the excess stock and finish grind the major diameter of the Ø.3125-24 UNFJ-3A thread.Finish grind the .030 X 45° chamfer.




O.D. GRINDING-Finish grind all diameters on the right side.

Leave .0002 max. lapping stock on the Ø.3163/.3158 and Ø.47525/.47475 diameters.Hold best microfinish possible (8 Ra max, 2 Ra required).




O.D. GRINDING-From the left end:

Finish grind the Ø.228/.226 Shear Section diameter.




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240 Rework parts.

0 0

250 Rework or scrap Thread gages.

0 0

260

0 0

270 Parts are dirty, Rework. Visual

0 0

280

0 0

DEBURRING-Remove burrs and break sharp edges.





THREAD GRINDING-Finish grind the Ø.3125-24 UNFJ-3A Thread per Woodward Governor specification SS-130 rev. CG.

Parts do not meet CTM P.O. requirements per drawing.

Incorrect set-up. Machine malfunction.

SURFACE LAP-Lap Splines if required to accept Ring Gages.

N/A if already accepted.

WASH PARTS-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.

Used a different cleaning solvent.

Improve training and directions on traveler.


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





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290 Rework

0

Monitor and inspect .

0

300

0 0

310 Rework

0 0

SURFACE LAP-Finish lap the 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 Ø.47525/.47475 [-B-] diameter and the Ø.3163/.3158 diameter to meet the 2 Ra drawing requirement.

Parts are out of tolerance.

Incorrect lapping compound or procedure.

Measure flatness and microfinish.


LASER MARKING-Laser mark on the noted area as required per drawing note #10

Mark as follows:

66503-3595-1038 4

Incorrect marking or location.

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

Visual and approval by different person.

Improve training and notes in files.

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320

0 0

330 Rework Visual.

0 0

340

0 0

350

0 0


Verify part count.Verify that all preceding operations have been completed and are signed off.





MISC. COATINGS-Brush Coat noted area only, with the required material, per drawing notes #18 and #19.

Material: Corrosion Preventative film per Woodward-Governor SP-949 rev. Y (Sandstrom 9AV-35 or alternates).----------------------Certs Required

Coating is inadequate or wrong location.

Rust or discoloration on part.

Replace outdated coating.

RECEIVING INSPECTION-Inspect 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 incorrect. Parts do not meet compliances to CTM P.O.


Lost or scrapped parts from vendor.


INSPECTION, FINAL-Final Inspect complete per drawing and the requirements of the Customer Purchase Order.


Out of tolerance part gets to customer.


Documentation of all dimensions per customer requirements and CTM AQL .

Implement SPC monitoring throughout the manufacturing process.

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360 Rework Visual.

370 Traveler sign-off.

0 0

PRE-SHIPPING-INSPECTION-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.

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

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

Standart checklist of criteria before packing.

PACKAGE PARTS-Dip in Preserative Oil and drain.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.

Not properly packaged for handling.

Parts may become nicked or broken and possible scrap.

Incorrect packaging.

Improve traveler instructions for proper packaging.

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Process Failure Mode Effects Analysis3595-1038

Resulting Action(s)

Status

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Sample FMEA

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