Afolawemi Afolabi

 IE 673-001

 Pack ID IE673-Fall 2008-70-18

 Assignment A4 

NJIT ID:-210-85-220

 Class taken: Live

Authorship Statement: I pledge that all works was accomplished by me.

LIST OF CONTENTS:

1.      Project Objective

2.      Applied Methodology

3.      Project Management & Collaboration

4.     PFRA at Fola Quality Plastic Toys

5.      Executive Summary

6.      Further Work Needed/Proposed

7.      References & Bibliography

8.      Templates & Tools Used

 Fola Quality Plastic Toys

 1.      Project Objective

The objective is to enable all the collaborating parties (companies) to come together and deliberate on each and every stage of the Plastic toys development. Representative will be required for the main processes to enable them figure out any possible failure. Also employee will be given the relevant and proper training to enable them identify trends that will help in finding the origin of any given problem.

By doing this it can offer the following advantages to the customers:

1.Highly Reliable and Durable PLASTIC TOYS.

2.Cost Effective PLASTIC TOYS to Maintain.

3.Providing ALL TIME SUPPORT for the Customer

2.      Applied Methodology

With the aid of the product failure risk analysis (PFRA) will determine the possibility of processes that might be at risk of failure. This great tool PFRA does not just help to identify the risks but also helps to acts on them at a very early stage. PFRA is a Team Oriented Problem solving Method that is essentially aimed at minimizing dissatisfaction and financial loss for the process related failure risk. PFRA is applied during the planning stages of a process, and then updated on a regular basis to document changes. This in turns helps FQPT to make wise decisions on so many areas of its business which are not limited to employee morale and finances.

There are seven steps to follow this  methodology which are as follows:

1.Define scope, function and purpose: It means to define the system or sub-system, or any product, or process (including service) design to be analyzed.

2.Identify potential risks and failure modes, and their effects: Using the PFRA analysis determining the failure much ahead.

3.Prioritize potential failures: This means that all faults should be ranked and critical quality, or cost, or safety related faults should be located and eliminated by the cross-functional team as early as possible.

4.Select and manage subsequent actions: This aspect of PFRA means, that in cases in which the risk of potential failures is high, following the basic TQM principles, an immediate control plan must be devised and subsequent actions should be taken to control the situation.

5.Observe and learn.

6.Document the process: The team along the way store the PFRA contained information in a widely accessible format (preferably, both electronically, such as the spreadsheet and optionally on paper based media) for the current as well as for future Teams working on the product.

7.Enter the values into the PFRA / DFRA spreadsheet on a relative scale.

These rating (values) are determined by three factors:

1.Severity

2.Detection

3.Occurrence

The product of these rating values gives a number, called the Risk Priority Number (RPN), which can be used as a measure of the degree of failure risk. Severity rating is set between 1 and 10 with ‘1’ being least severe and 10 being most severe. Detection; ‘1’ is assigned if it is almost certain that the failure mode will be detected and ‘10’, if it is almost impossible that the process controls will detect the failure mode.Occurrence; ‘1’, indicates almost impossible and 10, indicates it is almost certain.

3. PROJECT MANAGEMENT & COLLABORATION

Fola Quality Plastic Toys has planned to achieve its goals with the collaboration of four different following companies. 

Collaborating Companies

 FQPT is a virtual company that is collaborating with

1. Rockwell Automation- is the leading global provider of industrial automation power, control and information solutions that help manufacturers achieve a competitive advantage for their businesses.

2. AKRO-MILS® Buckhorn™- this is one of the world’s largest packaging company, product handling and storage organization. They provide quality products for storage to their customers; they have different sizes of packaging product that are reusable and also help in plastic packaging systems. Their role would be to issue the address of SERVICEABILITY (ALL TIME SUPPORT) and TRACKING.

3. Somero Matson Group LLC- this is leading company that is a expansion joint manufacturer for concrete slab flooring. Provide the different kinds of equipment to customers that a fix a problem.

4. Russ Berrie and Company, Inc., a leader in the infant, juvenile, and gift industries, and its wholly-owned subsidiaries design, develop, and distribute a variety of innovative gift, infant, and juvenile products to specialty and mass market retailers worldwide.

FQPT places a very high priority on the reliability of all its processes and systems. Hence, it continues to strive very hard to ensure that the demand for high quality is the center of focus at all times. FQPT constantly ensures that its actions are reliable thereby concentrating on achieving quality even at the developmental stage of its productions systems.

4. PFRA at Fola Quality Plastic Toys

           Fola Quality Plastic Toys team in collaboration with other companies, has performed Process Failure Risk Analysis (PFRA) at their premises to improve the overall quality of processes involved in the making plastic toys analyzing the processes and their failure risks. PFRA is applied during the early planning stages of a process, and then updated on a regular basis as the document changes. PFRA is a Team Oriented Problem Solving (TOPS) method, aimed at minimizing dissatisfaction, and financial loss for process related failure risks. The quality of a product relates to how well the product serves the needs of the customer; as perceived by the customer. The following is the PFRA spreadsheet developed by using templates provided by Prof. Paul G. Ranky.  

PFRA is applied for the following 15 steps listed.

                                                                    PFRA Spreadsheet— FOLA QUALITY PLASTIC TOYS

        The team has analyzed each and every process-step carefully to identify potential failure modes and their effects. All the tools, fixtures/clamps that are used and all the parts that are retrieved from process-step, are listed in the spreadsheet along with the execution time of each process, cost incurred on executing each process. Moreover, each failure mode is rated between 1-10 in terms of its severity level, likelihood of its detection and probability of its occurrence. Likewise, the type of factors that might involve in the failure mode is also rated between 1-10. In the end, the effects of each process failure risk on other processes, parts and product characteristics are listed. 

Analysis.RPN (Risk Priority Number) & accumulated RPN calculations has helped in prioritizing potential failures by determining overall risk of each failure. From our spreadsheet, we found that 5 process failures namely Research & Development, Safety, ISO 9000 , Product warranty, Appearance, were marked as ‘high’, meaning the overall risk of each of those process failures were high. Upon observation, it can be seen that PFRA calculated that the highest failure and risk lay with the process step of ISO 9000 and Appearance. These two have an accumulated RPN of 288. So these steps need immediate attention and corrective measures to avoid disappointment of the customers. Corrective measures in terms of using superior engineering knowledge and safety/protecting materials were applied to reduce the risk.

       Research & Developement (RPN of 216),  Safety (RPN of 216) these also correspond to customer disappointment so utmost care is taken next to the above mentioned RPN. Later, the company would focus on the lesser risky steps of the process i.e. this is done by addressing the step with the next highest RPN. That is the re-wiring of the units. Other processes such as Quality Testing, Technical Specification, which have low RPN Should not be neglected for the quality purpose. Hence, this analysis facilitates information required to decide upon actions leading to reduce the risk, by reducing likelihood of occurrence and improving controls for detecting the failure. Even though Suggested actions are also highlighted in the spreadsheet for eliminating and/or minimizing potential failures. 

6. EXECUTIVE SUMMARY

 To execute the project, the whole process was modeled with the help of CIMpgr process modeling tool. To understand fully, all the system processes and variables were identified. And to cater different levels of management, three layers of process models with different magnitude of details were presented. To integrate the processes with product, Component Oriented Requirements Analysis (CORA) is used.

FQPT, is always aiming at having a very effective systems that functions very well. This is very paramount in our system. In all the cases that we use the Process Failure Requirement Analysis (PFRA), there must be an improvement in methods. This is highly important and relevant steps in anticipating what might go wrong on any process. We would constantly focus on improvement on the desired finished product. PFRA will continue to be the practice of enhancing a good process.

7. FURTHER WORK NEEDED/ PROPOSED

                    The continuing improvements and further product development suggests new research and more study. In addition, a shift to  will help in seeking future solutions and improvements for the coming years.

8. REFERENCES & BIBLIOGRAPHY

- Research Supplements provided by Prof. Paul G. Ranky

- e-Learning Pack, prepared by Prof. Paul G. Ranky

- CIMware USA website, http://cimwareukandusa.com

- The Most Resourceful Encyclopedia on Internet, http://www.wikipedia.org

9.TEMPLATES & TOOLS USED

- Microsoft Excel 2007