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NAME: KISHORE PADIGIREDDY

EMAIL: kp399@njit.edu
IE655 CONCURRENT ENGINEERING
E-LEARNING PACK: IE655-FALL 2015-32-12
PROFESSOR: PAUL G RANKY
Statement of Work: The below assignment has been done solely by
Kishore Padigireddy.
Content
Introduction and objectives of the project
A Brief Description of the Methodologies applied
The Main Body of the Project
FMEA/ DFRA
Analysis of PFRA
Potential Failure Modes for Images_1684 to 1704
Ranky-Weibull Calculator
Collaborative Companies
Social Networking Articles
Summary
Further Work Needed/Proposed
References
Self-Assessment
Introduction and Objective:
There are many aspects in this world that are yet to be discovered and
researched upon. Looking at the future there is going to be a great demand
for many more new generation machinery that can perform not only just
programmed work but also be able to self program them, that is, the
machines got to be intelligent artificially. Yes, this is what exactly our
company ROBOFUSION Inc. is all about.
Our company aims to build extremely intelligent robotic system for the
future. Looking at the current perspective of this particular area there arent
many companies who have actually set foot into this business as it involves a
great deal of research than business at present. Robofusion Inc. aims at
designing and manufacturing intelligent robots for electronic,
telecommunication and industrial sectors for high-speed picking and

packaging applications. The company operates under segments that include


power products, power systems, automation products, process automation
and robotics. Robofusion is the leading supplier of robots-also providing
robotic software, peripheral equipments, modular manufacturing cells and
service for task as simple as welding to complicated task such as handling,
assembly, painting and finishing, picking, packing, pelletizing and machine
tending. Robofusion offers complete capability in robotic solutions and
supports its customers in manufacturing all over the world. The company
provides practical assistance in the implementation of automation projects.
Methodologies Applied:
The methodologies applied by Robofusion Inc. for gaining a better edge
over the
Competitors in the market and to promote the company towards new goals
and milestones are:
1. To make use of a Product Lifecycle Management (PLM).
2. Failure Mode Effects Analysis (FMEA) is a methodology, which
focuses on lowering cost of product development by monitoring and
detecting failure modes.
3. Implementing Concurrent engineering for the entire process.
4. Our company focuses on less energy consumption, lubricant
consumption and durability in order to minimize lifecycle, cost and
increase cost efficiency.
5. Process Failure Risk Analysis (PFRA) is a tool which FMEA to
analyze processes and their development. PFRA recognizes
potentially risky processes and analyzed data created with PFRA
helps to create corrective actions.
6. Maintain high standards quality for the product manufacturing.
7. Develop\Maintain good customer relationship.
8. Ranky-Weibull calculator is statistical method, which helps to study
product's reliability over its product life cycle.
9. Reduce the overall cost of the product and the services.
MAIN BODY OF THE PROJECT:

FMEA/DFRA:
PFRA is a Team Oriented Problem Solving (TOPS) method, aimed at
minimizing dissatisfaction and financial loss or process related failure risks.
PFRA is applied during the planning stages of a process, and then updated
on a regular basis to document changes. The PFRA spreadsheet is attached
below.
Analysis of PFRA Spreadsheet:
From the PFRA spreadsheet, processes having high failure potential have
been analyzed. The highest RPN is the wiring process (RPN: 399.38) and
the second one is the assembly of the body (RPN: 396.58). A product works
properly only if the wiring is done accurately without any short-circuiting,
which results in high voltage or high current. Frequent inspection should be
performed on the type of wires used for the electrical connectivity of the
product, so that no damage is occurred after the product is reached out to the
customers, which may result in customer dissatisfaction. The second
potential risk is the assembly or installation of the body, which is also
important factor in manufacturing a product. The assembly section is where
all the parts are embedded together to get the desired product. The product
will not last long if the assembly of the parts is not done accurately. It may
cause more time and cost to rectify that small error and rebuilt or reassembly of the whole process is not an easy task. One of the corrective
actions is re-assembly of the whole product, even though it will costs more
than estimated. Immediate action will be taken if there is any mismatch
during the assembly phase of the product manufactured.

Potential Failure Modes Images:

IMG_1684: It is an image of an underwater camera. The failures modes


recognized here are rusty metal body parts (nuts, screw, and washer). This

part doesnt satisfy its function as a water-resistant part, as it is corrosive and


not eco friendly. Material with high water resistant should be selected to
avoid the potential failures.
IMG _1685:The image illustrates the glass of the underwater camera, which
appears to be damaged due to poor customer care or poor material
selection. The glass material should be changed and high durable glass
should be used to avoid this type of failure.
IMG _1688: This is the back view of the camera water-resistive housing.
Shows signs of water damage, tear and wear due to usage and rust collected
on the metallic parts.
IMG _1689:The image illustrates a glass cover that is damaged due to
customer handling. Scratches are present on the body part of the camera,
which does not give a good look on the camera.
IMG _1692:The image is a inside view of the camera. The inner part is
more spacious and nothing productive is present apart from the lens. The
design team could have built without wasting that much space or could have
used it productively by placing some more elements inside it.
IMG _1693:The image shows a screw that is used to clamp the handle with
the glass cover. This part is rusted and perhaps it was a choice of bad
material selection. Some other material, which withstands corrosion, could
have been used.
IMG _1695:The Image illustrates lighting equipment used in under-water
photography. Clearly, it shows lack of engineering approach due to
mounting of the screw in an unsecured manner. When it does not tighten
enough, it will cause direct damage to the lighting equipment.
IMG _1696:The Image illustrates the screw compartment of the waterresistive part. It seems that the screws are not inserted properly. Failed
assembly has resulted in the product failure.
IMG_1697: Same as Image 1696, The Image illustrates the screw
compartment of the water-resistive part. It seems that the screws are not
inserted properly. Failed assembly has resulted in the product failure.

IMG_1698: This Image shows poor choice of material used for this part. It
shows how bad design, leaded by bad planning and selection could influence
the final product.
IMG_1699: The Image shows a defective connector, which used low quality
material. The plastic part has completely broken off. The connector is not
properly designed and a proper design during the design phase could have
helped the product.
IMG_1701: This is the side view of the Image 1699.The tube has been worn
out due to regular usage and cannot be used further more. The lifetime of the
tube material is not what it should be, so poor material selection has also
taken place.
IMG_1702: The Image shows a battery cover .The material used for the
battery cover is not safe and may tear under high water pressure. There will
be hazardous influence on the environment if the battery is exposed to the
water.
IMG _1703: The Image shows an electrical connection that has failed. The
material used as the insulator between the pins has broken and cracked off.
The design is faulty and the material chosen was not correct for the
application. This battery connector, located under the battery has a very
weak base. It could easily break during the regular under-water activities.
IMG_1704:The Image is the same as battery connector having weak leads,
which are water sensitive. It shows poor quality in design and it will not
work properly when taken underwater.
Ranky-Weibull Calculator:
The Weibull distribution is one of the statistical models that have been
created on an empirical basis. It means that its building is based on the data
set itself, which requires a good understanding of the methodology. It is
named after Waloddi Weibull who started promoting it in the 40s for the
strength of materials.
Final results were obtained
=1.81
=1.68

Beta value is greater than 1.It shows that the failure rate increases when
wires are tested under extreme conditions. Alpha measures how varied the
data is and value greater than 1 shows higher variations.
Collaborative Companies:
Safari Ltd: Safari Ltd is the only American family owned manufacturer and
distributor of educational animal, fantasy, and human figurines. Safari Ltd
toys are inspired by nature, fueling the imagination and speaking to the
innate curiosity in all of us. They had a vision to share the unique beauty of
wildlife with children and a passion to educate through the joy of play. Each
figure is designed to have museum-quality authenticity to ensure they are as
lifelike as possible. With new scientific data always emerging, this means
the products are also continually being updated.
Interroll: Interroll offers the most efficient drives, rollers, conveyor
modules and sorters as well as pallet and carton flow modules: a truly global
product platform with highest availability for individual applications.
Working as an expert team of Consultants, System Integrators and OEMs,
they turn complex tasks fast into smart, scalable solutions for airports, CEP,
food processing, warehousing & distribution and various kinds of industries.
BMW Motorrad: BMW Motorrad is the motorcycle brand of the German
company BMW. The Company manufactures a variety of engine
configurations and gear parts. These products are designed with high
precision and efficiency. The emission of carbon and its by products are very
less compared to other products resulting in a green environment.
G-Technology: G-Technology powered by Hitachi is a premium storage
solution for audio/video production, photography and the professional
content creation market. This storage device provides a high data transfer
rate making the workflow simpler, better and faster. It has been built for
professional environment where performance and reliability are paramount.

Social Networking Articles:


All Aboard Energy-Efficient Rail Transportation
The Southeastern Pennsylvania Transportation Authority (SEPTA) has
demonstrated super efficiency and significant economic benefits of rail
energy capture and deployment. Normally, an immense amount of energy is
lost during stopping or when applying brakes in a train and when train start
from their respective stations a lot of energy is also needed. Ultracapacitors
are used in the trains for braking purposes. Capturing and reusing the energy
is what capacitive energy storage is all about.
Hydrogen-Fueled Sedan:
Toyota is taking their company into the next level with the launch of Mirai
Hydrogen-Fueled sedan. Hydrogen Fueled cars are produced to reduce the
levels of carbon emissions compared to that of normal petroleum or diesel
cars. It is sold only in Belgium, Denmark, Britain and Germany where talks
are going with the local partners to setup hydrogen pumping stations. Toyota
is planning to launch more of hybrid cars in the coming future, as this will
be the next generations of cars.
Air Pollution Kills 3.3 Million worldwide
Air pollution is killing 3.3 Million people worldwide. Air pollution has
always been a serious trouble worldwide due to the emission of harmful
gases from the power plants and traffic. The Shocking fact is that agriculture
is the main cause for soot and smog deaths in Europe, Russia, Japan and
South Korea .The ammonia from the fertilizers combine with the gases that
comes out from the power plants and car exhaust to form soot particles that
are air pollution killers. The deaths will be doubled by 2050 if no action is
taken against this issue. By reducing a different air pollutant like CO2 , the
air pollution will also be reduced, thus reducing the soot and smog level.
Summary:
In this assignment, PFRA concept is analyzed and spreadsheet is created. It
helped me to understand the importance of risk analysis and the severity of
risk for each process, which is very important for development of a company
product.

Further Work Needed/Proposed:


The PFRA should be updated frequently to have a look on the processes,
which have high risk factor so that no damage occurs in the future.
References:

Paul G Ranky Concurrent Engineering 3D e-book and videos


http://www.g-technology.com
http://www.bmw-motorrad.com
http://www.interroll.us
https://www.safariltd.com

Self-Assessment:

I would give myself a 10/10; this assignment has been one great task, as it
covers various aspects. I have analyzed the PFRA spreadsheet and calculated
alpha and beta value using ranky-weibull calculator. I have completely
covered all the areas required.

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