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{"sheet":"Standard Grinding FMEA Question","index":0,"n_rows":16,"n_cols":11,"rows_kept":16,"cut":false,"hidden":false,"merged":[[16,6,16,7],[17,6,17,7],[8,0,15,0],[8,1,15,1],[8,2,15,2],[12,3,13,3],[10,6,10,7],[12,6,12,7],[13,6,13,7],[11,6,11,7],[10,4,11,4],[10,3,11,3],[14,3,15,3],[14,6,14,7],[15,6,15,7],[8,6,9,7],[8,3,9,3],[7,6,7,7],[0,0,0,7],[1,2,1,3],[1,4,1,7],[1,0,1,1],[3,0,3,1],[3,2,3,3],[2,2,2,3],[2,4,2,7],[2,0,2,1],[4,0,4,1],[4,2,5,3],[5,0,5,1],[8,4,9,4]]}
["Grinding Failure Mode and Effects \nAnalysis Standard Question Pack",null,null,null,null,null,null,null,null,null,"Method"]
["Process Details:  Grinding",null,"PFMEA Owner:",null,null,null,null,null,null,null,"Materials"]
["Grinding Standard PFMEA questions ",null,"Donka Novovic \n(Global manufacturing process Owner for Grinding)\n",null,"Version Control"]
["Process Location: ",null,"PFMEA IPT members and their functional areas: ",null,"Reason",null,"Revised","Issue",null,null,"Maintenance"]
[null,null,"David Adamson (Turbines grinding process apprentice)",null,"Initial issue",null,"2017-05-10",1]
[]
[null,null,null,null,null,null,null,null,null,null,"Environment"]
["Process Step","Identified Failure Mode","Potential Effect of Failure","Potential Cause of Failure","Possible Prevention","Detection of potential Failure Mode Cause","Possible Detection"]
["Machine tool set-up / \nWheel change / \nProcessing","Coolant nozzle collision with the grinding wheel - resulting in damaged nozzle & loss of grinding wheel form.","Non-conforming feature created.\nPotential inability to build or meet functional requirement.","Has the machine tool program logic been error-proofed to eliminate every opportunity for coolant nozzle & grinding wheel collision?\n \n1) Does the machine have capability to automatically adjust the coolant nozzle position towards the grinding wheel during processing to compensate for grinding wheel size loss?....and\n\n2) Does the machine have capability to allow manual intervention of the distance between the grinding wheel & the coolant nozzle(s) i.e. upon machine set-up, wheel change & between machining cycles?\n\nIf the machine has capabilities of (1) & (2) is the machine tool program logic capable of modifying the coolant nozzle position to a safe position if manual intervention (2) occurs?\nIf the machine tool program logic is not capable a significant product safety risk may exist & should be addressed.","Undertake machine tool software update",null,"100% feature inspection rate."]
[]
[null,null,null,"Does the machine automatically adjust the coolant nozzle position towards the grinding wheel during processing to compensate for grinding wheel size loss?","Does the machine tool programming logic ensure against coolant nozzle / grinding wheel collisions?",null,"Does the machine tool sound an alarm to alert the operator if a coolant nozzle / grinding wheel collision occurs?"]
[null,null,null,null,null,null,"Does the machine tool stop & issue an error report for operator investigation / escalation before it can be re-started if a coolant nozzle / grinding wheel collision occurs?"]
[null,null,null,"Is an operator required to manually set the distance between the grinding wheel & the coolant nozzle, post wheel change?  ","Does the operator have a procedure to follow? ",null,"Ref. PFMEA"]
[null,null,null,null,"Does the operator have a calibrated tool to measure & confirm the gap size?",null,"Ref. PFMEA"]
[null,null,null,"Is it possible for an operator to manually change the distance between the grinding wheel & the coolant nozzle?  ","Does the operator have a procedure to follow? ",null,"Ref. PFMEA"]
[null,null,null,null,"Does the operator have a calibrated tool to measure & confirm the gap size?",null,"Ref. PFMEA"]

{"sheet":"Risk Rankings - Process","index":1,"n_rows":1000,"n_cols":20,"rows_kept":1000,"cut":false,"hidden":false,"merged":[[1,10,1,11],[2,13,2,14],[1,15,1,18],[8,18,9,18],[4,16,5,16],[3,10,4,10],[4,18,5,18],[6,18,7,18],[10,16,11,16],[8,4,9,4],[7,10,8,10],[9,10,10,10],[10,17,11,17],[9,11,10,11],[11,11,12,11],[11,10,12,10],[10,4,11,4],[6,5,7,5],[6,17,7,17],[8,16,9,16],[8,17,9,17],[6,4,7,4],[6,16,7,16],[10,5,11,5],[2,1,2,2],[5,11,6,11],[7,11,8,11],[4,4,5,4],[2,8,2,9],[5,10,6,10],[4,5,5,5],[3,11,4,11],[8,5,9,5]]}
["Process Failure Mode and Effects Analysis Rankings GUIDELINES",null,null,null,null,null,null,null,null,null,null,null,null,null,null,null,null,null,"Version:",{"$f":"#REF!","v":{"$error":"#REF!"}}]
[null,null,null,null,null,null,null,null,null,null,"Other examples",null,null,null,null,"Other examples"]
["Ranking","Failure mode effect Severity",null,"External Customer related",null,"External effects, end user ","Process Equipment Impact related issues",null,"Failure cause Occurrence probability",null,"General prediction","Manufacturability",null,"Control method Detection effectiveness",null,null,"Prevention/Detection Criteria","Detection Reliability","Typical Detection","Ranking"]
[1,"Minor","Deviation within control limits and inside specifcation","Unreasonable to expect that the minor nature of this failure would cause any real effect on the product or system performance. Customer will probably not notice failure","No effect on product safety, quality, conformity","No discernable Customer effect","Failure mode has no effect on process. Variation is within normal common cause variation limits. No defects produced",null,"Remote","Not yet recorded\nCpk > 1.67\n< 1 in 1500000 failure rate\nFailure is unlikely, no failure associated with identical processes","Remote probability of failure","Process has demonstrated good capability of consistently meeting requirements",null,"Almost certain","Equipment design prevents cause occuring (eg Poka-Yoke 3-pin plug)","Reliable detection controls are known with same or similar processes. Measurement processes have excellent gauge R&R (<5%) and are mistake proofed. 100% checks using variable data","Effective error prevention controls\n(e.g. error-proofing of the design/process (Poka Yoke), or alarms will prevent the failure mode or defect from occuring.\nDetection will prevent ther next step from being performed)","> 99.9%","Before failure",1]
[2,"Very low","Deviation outside control limits, within specification","Nature of failure only causes slight customer annoyance","Minor effect on product safety, quality, conformity. Deviation may require minor on the spot treatment, intervention or rework.","Minor, but noticeable deviation from Customer expectations.\nNo impact on performance or safety.","Variation caused by failure within normal common cause variation limits. Some process adjustment needed. No defects produced",null,"Very low","1 per year\nCpk >1.50\n1 in 150000 failure rate\nOnly isolated failures associated with this and identical processes. Process in statistical control",null,null,null,"Very high","Obvious from operating equipment (eg, process shuts down)","Measurement processes have good gauge R&R (<10%). 100% mistake proofed checks in place using variable data","Failures can sometimes be prevented.\nControl measures are highly effective with a good chance of early detection of the failure mode or defect.\nSubsequent operations are protected from accepting discrepant parts.","> 98%","Same operation",2]
[3,"Low","Rework - additional time at existing operation, no extra set-up","Failure causes minor customer dissatisfaction, e.g. deterioration in their product or system performance",null,null,"Variation classified as special cause variation. Process parameter adjustment needed to maintain production. No defects produced",null,"Low","1 per 6 months\nCpk > 1.33\n1 in 15000 failure rate\nLow incidence of failures with this and identical processes. Process in statistical control at the moment but has shown instability in the past","Few failures occur/anticipated","Process should be capable of producing the part as designed",null,"High","Obvious from unaided inspection (eg, sounds alarm)","100% checks using mistake proofed variable or attribute gauging, reasonable Gauge R&R (10-15%)",null,"95 - 98%",null,3]
[4,"Moderate","Rework - repeat existing operation, extra set-up","Failure causes some customer dissatisfaction, e.g. extra effort or rework needed to use product","Recoverable impact on product safety, quality, conformity\n(e.g. minor injury, concession, tool breakdown, cycletime increase, extra inspection or rework)","Recovery action required to meet customer quality + safety expectations.","Downtime of up to 30 minutes. No defects produced",null,"Moderate","1 per three months\nCpk > 1.17\n1 in 2000 failure rate\nModerate rate of failure. Some evidence of process instability",null,null,null,"Moderately high","Obvious from unaided inspection (eg, lights lamp)","SPC chart on capable operation. Gauge R&R average (15-20 %) ","Controls have a resonable chance of detecting the existence of the failure or defect.\nIf the defect is not detected at the operation, it is likely to be detected at a subsequent operation.","90 - 95%","Same operation/Subsequent operation",4]
[5,"Significant","Rework - additional time at separate operation","Failure causes customer dissatisfaction, e.g. disrupts customer's operations or add cost",null,null,"Downtime of between 30 minutes and 1 hour or defects loss of up to 1 hours production",null,"Significant","1 per month\nCpk > 1.00\n1 in 400 failure rate\nFailure rate significant enough to cause problems","Occasional failures occur/anticipated","Manufacturing process barely capable, requires close controls",null,"Moderate ","Needs objective visual aid to identify correctly (eg, dipstick)","SPC chart on non-capable operation. Gauge R&R average (20-25%).",null,null,null,5]
[6,"Very significant","Major rework - new, separate operation, or concession","Failure causes significant customer dissatisfaction, e.g. major disruption or cost","Significant impact on  product safety, quality, conformity\n(e.g. recordable safety incident, significant scrap, major rework or repair)","Performance deterioration or loss of functionality without compromising safety.","Downtime of 1 to 3 hours or defects loss of 2 to 4 hours of production",null,"Very significant","1 per two weeks\nCpk > 0.83\n1 in 80 failure rate\nRate of failure now likely to cause disruption",null,null,null,"Low","Needs subjective visual aid to identify correctly (eg, photo)","Recorded audit of parts/process output. Gauge R&R poor (>30%)","Some controls exist but are not effective for detecting every failure or defect in good time.\nDefects may be non-obvious and some passed on to subsequent operations.","50 - 90%","Subsequent Operation",6]
[7,"High","High-cost rework - additional process operation","High degree of customer dissatisfaction due to failure such as an inoperable product or system shutdown that has a medium impact on the customer's operations",null,null,"Downtime of 4 to 7 hours or defects loss of 2 to 4 hours of production",null,"High","1 per week\nCpk > 0.67\n1 in 20 failure rate\nFailure often encountered","Failure occurs regularly","Process is not capable of consistently meeting the design requirements",null,"Very low","With condition monitoring when process running","Patrol inspection. Gauge R&R unknown. Multiple visual inspection",null,null,null,7]
[8,"Very high","Part scrapped","Major degree of customer dissatisfaction and inconvenience due to failure such as inoperable product or system shutdown that has a high impact on customer operations","Serious impact on  product safety, quality, conformity\n(e.g. HSE reportable accident, major scrap or stopped production.","Performance failures resulting in potential aircraft safety issues.\nMay contravene regulatory requirements.\nCompulsary aircraft modifications might be imposed.\n","Downtime of more than 8 hours or defects loss of more than 4 hours of production",null,"Very high","1 per two days\nCpk > 0.51\n1 in 8 failure rate\nRate of failure causes major disruption",null,null,null,"Remote","With condition monitoring when process stopped","Random visual inspection, single inspector","Limited control measures with a poor chance of detecting every failure or defect occurrence.\n(e.g. random visual checks)\nDefects may be 'subtle' or 'difficult' to identify and can readily go undetected and be passed to the Customer","1 - 50%","Subsequent operation/Customer",8]
[9,"Critical with warning","Minor HS&E hazard to personnel","Failure affects safe operation of product or service and/or regulatory non-compliance. Some warning that failure will occur, e.g. smoke or alarm signal",null,null,"Affects operator, plant or maintenance personnel. Affects safety or non-compliance with regulatory requirements",null,"Critical","1 per day\nCpk > 0.33\n1 in 3 failure rate\nRate of failure likely to shut process down","Failure is almost inevitable","Non-manufacturable",null,"Very remote","Cannot be detected at this operation","No current checks made",null,null,"Customer",9]
[10,"Critical with no warning","Major HS&E hazard to personnel","As above but with no warning","production shut down, major scrap or serious Environmental Health & Safety hazard.\n(e.g. permanent disability)","Failures will compromise aircraft safety and/or regulatory compliance without warning.\n","Affects operator, plant or maintenance personnel. Affects safety or non-compliance with regulatory requirements",null,"Constant","1 per shift or greater\nCpk < 0.33\n> 1 in 2\nClose to or at total failure",null,null,null,"Almost impossible","Cannot be detected","No known controls available","No controls exist, or current controls will not or cannot detect the failure or defect occurrence.\nDefective parts will be shipped to the Customer.","< 1%","In-service",10]
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["Password","letmein"]

{"sheet":"Transactional Risk Ranking","index":2,"n_rows":1000,"n_cols":8,"rows_kept":1000,"cut":false,"hidden":false,"merged":[[1,0,1,7],[2,9,2,11],[3,1,3,2],[3,3,3,4],[3,5,3,6]]}
[null,null,null,null,null,null,"Version:",{"$f":"#REF!","v":{"$error":"#REF!"}}]
["Failure Mode and Effects Analysis Rankings Guide for Transactional Processes"]
[]
["Ranking","Severity",null,"Occurrence",null,"Detection",null,"Ranking"]
[1,"Minor","The customer(s) of the process will not notice the effect of the failure. No impact on supplier's or customer's process","Remote","Not yet recorded\n< 1 in 1500000 failure rate\nFailure is unlikely, no failure associated with identical processes","Almost certain","Controls will always prevent failure from occuring or, if it does happen, will always detect the problem before it escapes",1]
[2,"Very low","Nature of failure only causes slight delay or minor rework. Slight customer annoyance","Very low","1 per year\n1 in 150000 failure rate\nOnly isolated failures associated with this and identical processes. ","Very high","Controls nearly always prevent or detect failure. Remote chance of escape",2]
[3,"Low","Failure causes minor problems which take a small amount of time to overcome. Some customer dissatisfaction and/or impact on their process","Low","1 per 6 months\n1 in 15000 failure rate\nLow incidence of failures with this and identical processes.","High","Mistake proofing used to try and prevent failure. 100% recorded audit of process. Small chance of escape",3]
[4,"Moderate","Failure causes problems which have a noticeable impact on business performance metrics.  Medium customer dissatisfaction, e.g. extra effort or rework needed","Moderate","1 per three months\nCpk > 1.17\n1 in 2000 failure rate\nModerate rate of failure. ","Moderately high","Failure prevention designed into system, 100% recorded audit of process. Low chance of escape.",4]
[5,"Significant","Failure causes customer dissatisfaction, e.g. disrupts customer's operations or add cost","Significant","1 per month\nCpk > 1.00\n1 in 400 failure rate\nFailure rate significant enough to cause problems","Moderate ","Failure prevention considered, 100 % checks on output, medium chance of escape",5]
[6,"Very significant","Failure causes significant customer dissatisfaction, e.g. disruption or cost","Very significant","1 per two weeks\nCpk > 0.83\n1 in 80 failure rate\nRate of failure now likely to cause disruption","Low","Prevention based on operator diligance and regular training, regular checks in place, significant chance of escape",6]
[7,"High","High degree of customer dissatisfaction due to failure such as system shutdown that has a medium impact on the customer's operations","High","1 per week\nCpk > 0.67\n1 in 20 failure rate\nFailure often encountered","Very low","Regular checks in place (not 100%). Prevention based on operator training. Failure likely to escape ",7]
[8,"Very high","Major degree of customer dissatisfaction due to impact of failure on their process - delay or extra cost incurred. Significant impact on business metrics","Very high","1 per two days\nCpk > 0.51\n1 in 8 failure rate\nRate of failure causes major disruption","Remote","Random checks in place, prevention based on operator noticing problem. Failure likely to escape.",8]
[9,"Critical with warning","Failure causes own or customer's process to stop completely with some warning","Critical","1 per day\nCpk > 0.33\n1 in 3 failure rate\nRate of failure likely to shut process down","Very remote","Random checks made at low frequency, no prevention in place. Failure highly likely to escape.",9]
[10,"Critical with no warning","Failure causes own or customer's process to stop completely without warning","Constant","1 per shift or greater\nCpk < 0.33\n> 1 in 2\nClose to or at total failure","Almost impossible","No known controls available. Failure will escape.",10]
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["password","letmein"]

{"sheet":"Comments for MC spec","index":3,"n_rows":19,"n_cols":1,"rows_kept":19,"cut":false,"hidden":false,"merged":[]}
["Add under 2.8.2 sections:"]
[]
["-          The coolant delivery nozzle must not interfere with the part, fixture or tool changer.  The machine tool program logic must be error proofed to eliminate every opportunity for coolant nozzle & grinding wheel/fixture/part collision(s)."]
["-          For grinding critical/sensitive features, under no circumstances (i.e. during machine tool set-up, wheel change or grinding cycle) should the Coolant Nozzle be able to collide with the Grinding Wheel (thus resulting in damaged nozzle & loss of grinding wheel form)."]
["-          Post machine tool pass-off, a manufacturing instruction must be implement to measure & verify a safe distance between the coolant nozzle & the grinding wheel is maintained after any manual intervention & prior to the next cycle starting."]
[]
[]
[]
["-          If the machine has Dynamic Auto-adjustment of Coolant Nozzle position from the grinding wheel (to compensate for grinding wheel size loss) then machine tool programming logic must ensure against coolant nozzle / grinding wheel collisions.  "]
["-          Post machine tool pass-off, a manufacturing instruction must be implement to measure & verify a safe distance between the coolant nozzle & the grinding wheel is maintained after any manual intervention & prior to the next cycle starting."]
[]
[]
["-          If the machine has Gradual/Periodic NC Cycle Coolant Nozzle Adjustment  Capability from the grinding wheel (to compensate for grinding wheel size loss) then the machine tool programming logic must ensure against coolant nozzle / grinding wheel collisions.   The machine tool logic must undertake a safety check immediately, after any manual intervention & prior to the next cycle starting. "]
["-          Post machine tool pass-off, a manufacturing instruction must be implement to measure & verify a safe distance between the coolant nozzle & the grinding wheel is maintained after any manual intervention & prior to the next cycle starting."]
[]
[]
[]
["-          If the machine has Manual Coolant Nozzle Adjustment Capability from the grinding wheel (to compensate for grinding wheel size loss) then during the machine tool acceptance phase the user must verify that forced coolant nozzle / grinding wheel collisions cannot damage grinding wheel significantly enough to lead to component form non-conformance.    "]
["-          Post machine tool pass-off, a manufacturing instruction must be implement to measure & verify a safe distance between the coolant nozzle & the grinding wheel is maintained after any manual intervention & prior to the next cycle starting."]