A B C D E F G H

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A Component-oriented Process Failure Risk Analysis Method (Ver. 5) by Professor Paul G. Ranky, PhD, NJIT/MERC
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7 Product Name and Appearance Before Process Unmanned Tire Retrieval Vehicle (UTRV) PFRA Study ID Number Study 123 Process Code
Engineering Release Date of Process
8 Name of Organization Responsible for the Process GreenFocus Inc. Date of This Study (mm/dd/yy) 10/24/2008
Methodology
9 Other Organizations Involved in the Process Orignal Date of This Study 10/24/2008 Type of Product Processed
MTS, Diamond Phoenix, Dreamflyer, Nikon
10 Subcontractors, process Plants Effected no subcontrators affected Revision Number Rev. 0 Product Group Classifier
11 Product Serial Number and Optional Image Map UTRV000123 Comments Engineering Release Date of the Product
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Describe the Process for Each Process Step and Process
13 Optionally Illustrate the State of the Device/ Part/ Specify the Tool(s) Used in Each Process Specify the Fixtures / Clamps Used in Each List / Identify the Parts / Components Process
Process ID Cost
Subassembly/ Object AFTER the Process is Step Process Step Retrieved (if any) in Each Process Step Time
14 Complete 15.00
15 [sec] [USD]
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17 1 Examine the clarity of the cameras (no cracks) Adult human hand and eye Human hand none 12 0.05
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20 2 Examine the touch screen for the UTRV (no cracks) Adult human hand and eye Human hand none 15 0.06
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23 3 Examine the tire retrieval parts (no dents) Adult human hand and eye Human hand 12 0.05
24 none
25
Examine buttons that operate UTRV (buttons are
26 4 Adult human hand and eye Human hand none 15 0.06
functioning)
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29 5 Examine sensors Adult human hand and eye Human hand none 20 0.08
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32 6 0.00
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35 7 0.00
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38 8 0.00
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41 9 0.00
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44 10 0.00
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 A B C D E F G H
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47 11 0.00
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50 12 0.00
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53 13 0.00
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56 14 0.00
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59 15 0.00
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62 16 0.00
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65 17 0.00
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68 18 0.00
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71 19 0.00
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74 20 0.00
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77 21 0.00
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80 22 0.00
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83 23 0.00
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86 24 0.00
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89 25 0.00
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92 26 0.00
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 A B C D E F G H
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95 27 0.00
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98 28 0.00
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101 29 0.94859 0.00
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104 30 0.00
105
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107 31 0.00
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110 32 0.00
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113 33 0.00
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116 34 0.00
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119 35 0.00
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 I J K L M N O P Q R S T U
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2 Copyright by Paul G. Ranky, 1992-2002

3 Copyright by Paul G. Ranky, 2002 to date

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Process Code 7 2-i93 This PFRA Study was Prepared By Mingrui
Engineering Release Date of Process
8 11/11/2017 PFRA Team GreenAuto Corp.
Methodology
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Type of Product Processed Responsible Organization/ Department PFRA Association

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Product Group Classifier GreenAuto Corp. Team 1 Comments
11 Date of the Product
Engineering Release 12/12/2017
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The PFRA Team Describes / Illustrates the Potential Process Failure Other
13 RPN (Risk Clamping/
Accumulated Mode and the Effect; the Risk of Failure Tooling Factor: Accumulated
Severity RatingDetection Rating
Occurrence Rating
Priority Max. RPN Fixturing Skill Factor
Process Cost Factor Design RPN
Number) Factor
14 Proc.ID Failure Mode(s) and Effect(s) Experience
0.1- 0.1- 0.1- 0.1-
15 [USD] (1-10) (1-10) (1-10) 2,1=100% 2,1=100% 2,1=100% 2,1=100%
Requistive picture is not clear, because of the crack on the
16 ID 1.1 5 2 3 30
lens
17 0.05 ID 1.2 0 30 1.00 1.00 1.00 1.80 54.00
18 ID 1.3 0
19 ID 2.1 Panel is fuzzy, because it has a tiny crack on the screen 5 1 3 15
20 0.11 ID 2.2 0 15 1.00 1.00 1.00 1.80 27.00
21 ID 2.3 0
The retrieval parts are not functioning properly, because there
22 ID 3.1 10 7 3 210
is a dent on the parts
23 0.16 ID 3.2 0 210 1.00 1.00 1.00 1.80 378.00
24 ID 3.3 0
25 ID 4.1 Objective part is not functioning, because buttons are stuck 7 1 3 21
26 0.23 ID 4.2 0 21 1.00 1.00 1.00 1.80 37.80
27 ID 4.3 0
28 ID 5.1 False readings on the sensors 8 5 4 160
29 0.31 ID 5.2 0 160 1.00 1.00 1.00 1.00 160.00
30 ID 5.3 0
31 ID 6.1 0
32 0.31 ID 6.2 0 0 1.00 1.00 1.00 1.00 0.00
33 ID 6.3 0
34 ID 7.1 0
35 0.32 ID 7.2 0 0 1.00 1.00 1.00 1.00 0.00
36 ID 7.3 0
37 ID 8.1 0
38 0.32 ID 8.2 0 0 1.00 1.00 1.00 1.00 0.00
39 ID 8.3 0
40 ID 9.1 0
41 0.33 ID 9.2 0 0 1.00 1.00 1.00 1.00 0.00
42 ID 9.3 0
43 ID 10.1 0
44 0.33 ID 10.2 0 0 1.00 1.00 1.00 1.00 0.00
45 ID 10.3 0
 I J K L M N O P Q R S T U
46 ID 11.1 0
47 0.33 ID 11.2 0 0 1.00 1.00 1.00 1.00 0.00
48 ID 11.3 0
49 ID 12.1 0
50 0.34 ID 12.2 0 0 1.00 1.00 1.00 1.00 0.00
51 ID 12.3 0
52 ID 13.1 0
53 0.34 ID 13.2 0 0 1.00 1.00 1.00 1.00 0.00
54 ID 13.3 0
55 ID 14.1 0
56 0.35 ID 14.2 0 0 1.00 1.00 1.00 1.00 0.00
57 ID 14.3 0
58 ID 15.1 0
59 0.35 ID 15.2 0 0 1.00 1.00 1.00 1.00 0.00
60 ID 15.3 0
61 ID 16.1 0
62 0.35 ID 16.2 0 0 1.00 1.00 1.00 1.00 0.00
63 ID 16.3 0
64 ID 17.1 0
65 0.36 ID 17.2 0 0 1.00 1.00 1.00 1.00 0.00
66 ID 17.3 0
67 ID 18.1 0
68 0.36 ID 18.2 0 0 1.00 1.00 1.60 1.00 0.00
69 ID 18.3 0
70 ID 19.1 0
71 0.37 ID 19.2 0 0 1.00 1.00 1.00 1.00 0.00
72 ID 19.3 0
73 ID 20.1 0
74 0.37 ID 20.2 0 0 1.00 1.00 1.00 1.00 0.00
75 ID 20.3 0
76 ID 21.1 0
77 0.38 ID 21.2 0 0 1.00 1.00 1.00 1.00 0.00
78 ID 21.3 0
79 ID 22.1 0
80 0.38 ID 22.2 0 0 1.00 1.00 1.00 1.00 0.00
81 ID 22.3 0
82 ID 23.1 0
83 0.38 ID 23.2 0 0 1.00 1.00 1.00 1.00 0.00
84 ID 23.3 0
85 ID 24.1 0
86 0.39 ID 24.2 0 0 1.00 1.00 1.00 1.00 0.00
87 ID 24.3 0
88 ID 25.1 0
89 0.39 ID 25.2 0 0 1.00 1.00 1.00 1.00 0.00
90 ID 25.3 0
91 ID 26.1 0
92 0.40 ID 26.2 0 0 1.00 1.00 1.00 1.00 0.00
93 ID 26.3 0
 I J K L M N O P Q R S T U
94 ID 27.1 0
95 0.40 ID 27.2 0 0 1.00 1.00 1.00 1.00 0.00
96 ID 27.3 0
97 ID 28.1 0
98 0.40 ID 28.2 0 0 1.00 1.00 1.00 1.00 0.00
99 ID 28.3 0
100 ID 29.1 0
101 0.41 ID 29.2 0 0 1.00 1.00 1.00 1.00 0.00
102 ID 29.3 0
103 ID 30.1 0
104 0.41 ID 30.2 0 0 1.00 1.00 1.00 1.00 0.00
105 ID 30.3 0
106 ID 31.1 0
107 0.42 ID 31.2 0 0 1.00 1.00 1.00 1.00 0.00
108 ID 31.3 0
109 ID 32.1 0
110 0.42 ID 32.2 0 0 1.00 1.00 1.00 1.00 0.00
111 ID 32.3 0
112 ID 33.1 0
113 0.42 ID 33.2 0 0 1.00 1.00 1.00 1.00 0.00
114 ID 33.3 0
115 ID 34.1 0
116 0.43 ID 34.2 0 0 1.00 1.00 1.00 1.00 0.00
117 ID 34.3 0
118 ID 35.1 0
119 0.43 ID 35.2 0 0 1.00 1.00 1.00 1.00 0.00
120 ID 35.3 0
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 V W X Y Z AA
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13 The Effect of Each Process Step Failure

Risk The Effect of Each Process Step Failure Corrective Action(s) Taken and Date
Risk on Other Parts (I.e. components/ Detection Mode Recommended Corrective Action(s)
Associated Risk on Other Processes (mm/dd/yr)
objects)
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0 50
16 Cameras are unable to monitor relationship critical Human inspection Fix the camera lens
17 Low ID 1.1
18 ID 1.2
19 UTRV fails to have functional screen relationship critical Human inspection Fix the UTRV screen ID 1.3
20 Low ID 2.1
21 ID 2.2
22 Quality failure relationship critical Human inspection Fix the dents on the tire retrieval parts ID 2.3
23 HIGH
24 ID 3.2
25 UTRV fails to operate normally relationship critical Human inspection Fix the screen buttons ID 3.3
26 Low ID 4.1
27 ID 4.2
28 Inaccurate measures relationship critical Human inspection Fix the sensors ID 4.3
29 Low
30 ID 5.2
31 ID 5.3
32 Low ID 6.1
33 ID 6.2
34 ID 6.3
35 Low ID 7.1
36 ID 7.2
37 ID 7.3
38 Low ID 8.1
39 ID 8.2

40 ID 8.3

41 Low ID 9.1

42 ID 9.2

43 ID 9.3

44 Low ID 10.1

45 ID 10.2
ID 10.3
ID 11.1
ID 11.2
ID 11.3
ID 12.1
ID 12.2
ID 12.3
ID 13.1
 ID 7.3
ID 8.1
ID 8.2
ID 8.3
ID 9.1
ID 9.2
ID 9.3
ID 10.1
ID 10.2
V W X Y Z AA
46 ID 10.3

47 Low ID 11.1

48 ID 11.2

49 ID 11.3

50 Low ID 12.1

51 ID 12.2

52 ID 12.3

53 Low ID 13.1

54 ID 13.2

55 ID 13.3

56 Low ID 14.1

57 ID 14.2

58 ID 14.3
ID 15.1
59 Low
ID 15.2
60
ID 15.3
61
ID 16.1
62 Low
ID 16.2
63
ID 16.3
64
ID 17.1
65 Low
ID 17.2
66
ID 17.3
67
ID 18.1
68 Low
ID 18.2
69
ID 18.3
70
ID 19.1
71 Low
ID 19.2
72
ID 19.3
73
ID 20.1
74 Low
ID 20.2
75
ID 20.3
76
ID 21.1
77 Low
ID 21.2
78
ID 21.3
79
ID 22.1
80 Low
ID 22.2
81
ID 22.3
82
ID 23.1
83 Low
ID 23.2
84
ID 23.3
85
ID 24.1
86 Low
ID 24.2
87
ID 24.3
88
ID 25.1
89 Low
ID 25.2
90
ID 25.3
91
ID 26.1
92 Low
ID 26.2
93
ID 26.3
ID 27.1
ID 27.2
ID 27.3
ID 28.1
ID 28.2
ID 28.3
ID 29.1
 ID 20.2
ID 20.3
ID 21.1
ID 21.2
ID 21.3
ID 22.1
ID 22.2
ID 22.3
ID 23.1
ID 23.2
ID 23.3
ID 24.1
ID 24.2
ID 24.3
ID 25.1
ID 25.2
ID 25.3
ID 26.1
ID 26.2
V W X Y Z AA
ID 26.3
94
ID 27.1
95 Low
ID 27.2
96
ID 27.3
97
ID 28.1
98 Low
ID 28.2
99
ID 28.3
100
ID 29.1
101 Low
ID 29.2
102
ID 29.3
103
ID 30.1
104 Low
ID 30.2
105
ID 30.3
106
ID 31.1
107 Low
ID 31.2
108
ID 31.3
109
ID 32.1
110 Low
ID 32.2
111
ID 32.3
112
ID 33.1
113 Low
ID 33.2
114
ID 33.3
115
ID 34.1
116 Low
ID 34.2
117
ID 34.3
118
ID 35.1
119 Low
ID 35.2
120
ID 35.3
121
 AB AC AD AE
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14 RPN for Each Failure Mode Accumulated RPN for Each Failure Mode
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0 50 100 150 200 250 0.00 50.00 100.00 150.00 200.00 250.00 300.00 350.00 400.00
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17 ID 1.1 1
18 ID 1.2
19 ID 1.3
20 ID 2.1 2
21 ID 2.2
22 ID 2.3
23 ID 3.1 3
24 ID 3.2
25 ID 3.3
26 ID 4.1 4
27 ID 4.2
28 ID 4.3
29 ID 5.1 5
30 ID 5.2
31 ID 5.3
32 ID 6.1 6
33 ID 6.2
34 ID 6.3
35 ID 7.1 7
36 ID 7.2
37 ID 7.3
38 ID 8.1 8
39 ID 8.2

40 ID 8.3

41 ID 9.1 9
42 ID 9.2

43 ID 9.3

44 ID 10.1 10
45 ID 10.2
ID 10.3
ID 11.1 11
ID 11.2
ID 11.3
ID 12.1 12
ID 12.2
ID 12.3
ID 13.1 13
 ID 7.3
ID 8.1 8
ID 8.2
ID 8.3
ID 9.1 9
ID 9.2
ID 9.3
ID 10.1 10
ID 10.2
AB AC AD AE
46 ID 10.3
47 ID 11.1 11
48 ID 11.2
49 ID 11.3
50 ID 12.1 12
51 ID 12.2
52 ID 12.3
53 ID 13.1 13
54 ID 13.2
55 ID 13.3
56 ID 14.1 14
57 ID 14.2
58 ID 14.3
59 ID 15.1 15
60 ID 15.2
61 ID 15.3
62 ID 16.1 16
63 ID 16.2
64 ID 16.3
65 ID 17.1 17
66 ID 17.2
ID 17.3
67
ID 18.1 18
68
ID 18.2
69
ID 18.3
70
ID 19.1 19
71
ID 19.2
72
ID 19.3
73
ID 20.1 20
74
ID 20.2
75
ID 20.3
76
ID 21.1 21
77
ID 21.2
78
ID 21.3
79
ID 22.1 22
80
ID 22.2
81
ID 22.3
82
ID 23.1 23
83
ID 23.2
84
ID 23.3
85
ID 24.1 24
86
ID 24.2
87
ID 24.3
88
ID 25.1 25
89
ID 25.2
90
ID 25.3
91
ID 26.1 26
92
ID 26.2
93
ID 26.3
ID 27.1 27
ID 27.2
ID 27.3
ID 28.1 28
ID 28.2
ID 28.3
ID 29.1 29
 ID 20.2
ID 20.3
ID 21.1 21
ID 21.2
ID 21.3
ID 22.1 22
ID 22.2
ID 22.3
ID 23.1 23
ID 23.2
ID 23.3
ID 24.1 24
ID 24.2
ID 24.3
ID 25.1 25
ID 25.2
ID 25.3
ID 26.1 26
ID 26.2
AB AC AD AE
ID 26.3
94
ID 27.1 27
95
ID 27.2
96
ID 27.3
97
ID 28.1 28
98
ID 28.2
99
ID 28.3
100
ID 29.1 29
101
ID 29.2
102
ID 29.3
103
ID 30.1 30
104
ID 30.2
105
ID 30.3
106
ID 31.1 31
107
ID 31.2
108
ID 31.3
109
ID 32.1 32
110
ID 32.2
111
ID 32.3
112
ID 33.1 33
113
ID 33.2
114
ID 33.3
115
ID 34.1 34
116
ID 34.2
117
ID 34.3
118
ID 35.1 35
119
ID 35.2
120
ID 35.3
121