QSE Quality Systems Engineering QSE Pipe Fixture

QSEQSE Quality Systems Engineering

Core Team: Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis,

08/19/06 © 2000/2006 All Rights Reserved Quality Systems Engineering @ 810-499-1015Printed on

Pipe Fixture

Part Numbers & Rev Level: 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465(R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3),465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3),454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3),465465465 (R3), 454545 (R3), 465465465 (R3) , 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3),454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3), 454545 (R3), 465465465 (R3)

QSE suggests putting all Header information in this field so the no header view can be printed using lesspages per printout.

Model:Key Date:Responsible Engineer:

546876413 - 165468469465468Part Number:

123456Flow Number:

9/27/035/4/049/14/05

MasterRevision

Date History

5/4/03Master Original Date:

ControlledControlledControlled

MasterRevisionStatus

1.11.21.3

MasterRevision

LevelJim BimJackson MississippiApril Somebody

PersonResponsible

Controlled1.3

Status:Revision:

Prototype Pre launch ProductionPrototype Pre-launch Production

123456FMEA Number: Controlled1.3

123456Control Plan Number: Controlled1.3

Sandra Werwega

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Title page Enter header data for all documents from one place. Track revision and status history.

Sandra Werwega

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Click anywhere on screen to move through documents

QSEQuality Systems Engineering

QSE

Sev

Occ

Det

User types info of choice

Operation DescriptionCharacteristics

Product Process

Specificationand/or Tolerances

PotentialFailure

Mode(s)Potential Effects of

Failure

PotentialCause(s)

Mechanism(s)of Failures

Current Process ControlsPrevention / Detection

IntPutAnything

GD&T

Pp

Ppk

Cp

CpkRPN

Class Risk

Function IDProcess ID

Op ID

Row NoPCID

CHARACTERISTICS FAILURE WORKSHEET

Jack Joseph 810-499-1015

Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis,

11/17/03Brighton2003B-4589Model Year(s) Vehicle(s):

Core Team:

Responsible Engineer:

Key Date:

05/27/05

Sandra Werwega

09/03/05Original Date: Revision Date:

Prepared By:

1 2Page of

7778FMEA Number:

EC StatusIVEC Level 09/15/05EC Date

Part Name:

Part Number:

Title Page

546876413 - 165468469465468

Counter703900 Final RPNInitial RPN

Supplier Audits.Tags verify FIFO.Receiving / Incoming

Material Verification

Operator mustInsure MaterialLabel is correct.

Missing, Wrongor UnreadableLabel

Incorrect Label OnContainer, PRR Written

Wrong partsshipped

*3 3 63

Op005Part IDcondition

71a 000-0000-000Receiving11

PutAnything

APurchasing(Providessupplier withcorrect specs).

A

Training in PartLoading. Tagsverify FIFO.

Receiving / IncomingMaterial

Part Placed inProper Positionusing Due Care.

Hopper Jams Damage Parts ScrapParts

ImproperLoading of Part

3 2 48

Op005000-0000-000

82a Put AnythingReceiving Inspection22

PutAnything

LPMaterialHandling /Non-ConformingProcedure

A

Training in PartLoading.Position Part On Pallet

Material HandlerMust Use Caution

Damaged Part Impairs OperationCannot Mount Part,Damage Part, ScrapParts.

Forks NotAdjustedProperly DuringTransport

6 3 144

Op010Part Condition

83a Storage Locations ?Transfer33

PutAnything

HPVisual Inspection

B

Training, SWIDrill Hole On Front Side

5.680 - 7.433 Off Location No Assembly, Rework Wrong CNCProgram

5 1 15

Op011Hole Location

34a Hole No 401Step 1 Drill44

PutAnything

LN Gage 2 Partsafter every ToolChange

C

Training, SWIDrill Hole On Front Side

0.0025 Out of Round Leaks, SafetyIssue,Rework, ImpairsNext Operation

ImproperMachine Setup

*10 7 280

Op011

Circularity ofHole

45aStep 1 Drill55

PutAnything

HDAuto stop if theTool Holder isnot Properlyseated.

C

S.W.I. PMDrill Hole On Front Side

2.224 +/- 0.20 Diam too Wide Impairs next operation,rework, scrap part

Premature ToolWear

PQC10 3 150

Op011

First PassDiam of Hole

56aStep 1 Drill66

PutAnything

HPAutomaticSpindle LubeSystem.

C


15.434 +/- 0.20 Depth tooShallow

Rework Impairs NextOperation Loss OfAssembly Srap Parts

Improper SpeedSetting

SC5 3 105

Op011

First PassDepth of Hole

77aStep 1 Drill77

PutAnything

HDInspect First PartAfter anyAbnormalOccurrence.

C


3.823 +/- 0.20 Diam too Wide Impairs nextoperationLoss ofAssembly Srap parts

ImproperMachine Setup

FF5 3 75

Op011

Final PassDiam of Hole

58aStep 1 Drill88

PutAnything

APGage 2@ start ofevery shiftC


Thru Depth tooShallow

Part will not Assemble,Scrap.

IncompleteCycle

5 2 20

Op011

Final PassDepth of Hole

29aStep 1 Drill99

PutAnything

LN Gage 2@ start ofevery shiftC

© 2005 All Rights Reserved Quality SystemsEngineering @ 810-499-101510/14/05 1.3 DRAFTStatus:Revision:Printed on High Risk Average Risk Low Risk

owner

Note

Completed set by owner

owner

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First 8 columns flow backwards to the Process Flow and Forwards to all other documents.

owner

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Data entered populates the Flow, FMEA and the Control Plan.

Note

Unmarked set by

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Specification goes backwards to the Flow, forwards to the FMEA's (requirements) as well as the Control Plan and many others where it is applicable.

Sandra Werwega

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All blue text fields populate the FMEA's, up to the recommended Actions.

Sandra Werwega

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GD&T symbols popup. A simple drag and drop to place symbols in documents.

Sandra Werwega

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Class popup lets users drag and drop symbols. User is able to create symbols of choice. AIAG symbols are included.

Sandra Werwega

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Severity, Occurrence and Detection scales attachment giving user scale definitions popup. Scales are user defined and can be edited at anytime.

Sandra Werwega

Placed Image

QUALITY SYSTEMS ENGINEERING QSE QSEProcess Flow Diagram

CounterUser types info of choicePut Anything

Operation DescriptionFlow

SymbolsCharacteristics

Product Process

Specification and/orTolerances


Brighton2003B-4589

Part Name:

Part Number:

Model Year(s) Vehicle(s):

02/02/05 09/22/05

Rob Bescoe

Sandra Werwega

Original Date:


Prepared By:

Revision Date:

GD&T Pp

Ppk

Cp

CpkClassRiskProcess ID

Op ID

Row NoFunction ID

PCID

112749Flow Number:Pipe Fixture

546876413 - 165468469465468

Receiving / Incoming MaterialVerification

Operator must InsureMaterial Label iscorrect.

Op005 Part IDcondition1a

Receiving *

A

000-0000-000

A

11 PutAnything

Receiving / Incoming Material

Part Placed in ProperPosition using DueCare.

Op005 000-0000-0002a

Receiving Inspection

L

Put Anything

A

22 PutAnything

Position Part On Pallet

Material Handler MustUse CautionOp010 Part Condition

3a

Transfer

H

Storage Locations ?

B

33 PutAnything

Drill Hole On Front Side

5.680 - 7.433Op011 Hole Location

4a

Step 1 Drill

L

Hole No 401

C

44 PutAnything


0.0025Op011

Circularity ofHole

5a

Step 1 Drill *

H

C

55 PutAnything


2.224 +/- 0.20Op011

First Pass Diamof Hole

6a

Step 1 Drill PQC

H

C

66 PutAnything


15.434 +/- 0.20Op011

First PassDepth of Hole

7a

Step 1 Drill SC

H

C

77 PutAnything


3.823 +/- 0.20Op011

Final PassDiam of Hole

8a

Step 1 Drill FF

A

C

88 PutAnything


ThruOp011

Final PassDepth of Hole

9a

Step 1 Drill

L

C

99 PutAnything

528a

1010

529a

1111

530a

1212

531a

1313

532a

1414

2Packaging Inspection TransferOperation ReworkStorage 10/10/05

© 2005 All Rights Reserved Quality Systems Engineering @ 810-499-1015 Controlled 1.1Status: Revision:

Printed on 1Page of

owner

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Cut paste drag/drop symbols.

owner

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All Titles of documents, field names in headers and columns can be changed.

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Process Flow user can select from 4 layouts.

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Change symbol definitions with easy to edit drop down tables.

Sandra Werwega

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Colored text showing data flow. First two columns are common information in all documents. Can be changed in any document, changes are reflected in all documents.

QSE QSEQUALITY SYSTEMS ENGINEERING

Process Flow Details

User types info of choicePut Anything

Operation DescriptionPicture Flow

Characteristics

Product ProcessSpecification and/or

Tolerances


Brighton2003B-4589

Part Name:Part Number:


02/02/05 09/22/05

Rob Bescoe

Sandra Werwega

Original Date:

Responsible Engineer:Prepared By:

Revision Date:

GD&T

PpPpk

CpCpkClass

RiskFunction IDPROCESS IDOP ID

ROW NO

PCID

112749Flow Number:Pipe Fixture546876413 - 165468469465468

Counter

Receiving / Incoming MaterialVerification

Part ID conditionOperator must InsureMaterial Label is correct.

*

Op005

1aReceivingA

11

Put Anything

A

000-0000-000

Receiving / Incoming Material 000-0000-000Part Placed in ProperPosition using Due Care.

Op005

2aReceiving InspectionA

22

Put Anything

L

Put Anything

Position Part On Pallet Part ConditionMaterial Handler Must UseCaution

Op010

3aTransferB

33

Put Anything

H

Storage Locations ?

Drill Hole On Front Side Hole Location5.680 - 7.433

Op011

4aStep 1 DrillC

44

Put Anything

L

Hole No 401

Drill Hole On Front SideCircularity ofHole

0.0025*

Op011

5aStep 1 DrillC

55

Put Anything

H

Drill Hole On Front SideFirst Pass Diamof Hole

2.224 +/- 0.20PQC

Op011

6aStep 1 DrillC

66

Put Anything

H

Drill Hole On Front SideFirst Pass Depthof Hole

15.434 +/- 0.20SC

Op011

7aStep 1 DrillC

77

Put Anything

H

Drill Hole On Front SideFinal Pass Diamof Hole

3.823 +/- 0.20FF

Op011

8aStep 1 DrillC

88

Put Anything

A

Drill Hole On Front SideFinal Pass Depthof Hole

Thru

Op011

9aStep 1 DrillC

99

Put Anything

L

528a1010

529a1111

530a1212

10/10/05

Controlled1.1

© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015

Printed on

Status:Revision:

21Page

of

owner

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Symbol field is replaced with an object box...paste pictures,sound, Quicktime movie, link to other files or programs....users choice.

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Text has been colored showing data flow from one document to the other.

QSE

Sev

Occ

Det

Sev

O c c

D e t

QUALITY SYSTEMS ENGINEERING QSE

Counter

Operation Description

PROCESS POTENTIAL FAILURE MODES AND EFFECT(S) ANALYSIS

PotentialFailure

Mode(s)Potential Effects of

Failure

PotentialCause(s)

Mechanism(s)of Failures

Current Process Controls Prevention /Detection Recommended

Actions Responsible:

Target Date Completion Date

Actions Results

Requirements

Int Final

Actions ResultsRPN RPN


Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, Merry Hurt, Mary Davis,

11/17/03Brighton2003B-4589



Core Team:

Responsible Engineer:Key Date:

05/27/05

Sandra Werwega

09/03/05Original Date: Revision Date:

Prepared By:

ClassGD&TProcess ID

Op ID

Row No

7778FMEA Number:

1 3Page of

PutAnything

Part Name:

Part Number:

Pipe Fixture

546876413 - 165468469465468

Function ID703900 Final RPNInitial RPN

*Missing, Wrongor UnreadableLabel

Incorrect Label OnContainer, PRRWritten

3 Wrong partsshipped

3 Supplier Audits. Tagsverify FIFO.

7 None 3 3 7 6363

Operator must Insure MaterialLabel is correct.

Receiving / IncomingMaterial VerificationOp005

ReceivingA

PutAnything

Purchasing (Providessupplier with correctspecs).A

11

Hopper Jams Damage Parts ScrapParts

3 ImproperLoading of Part

2 Training in PartLoading. Tags verifyFIFO.

8 ScheduleTraining in JobProcedures.ImplementPreventiveMaintenance.

Trainingcompleted2-1-2004. PostedPM Schedule.

3 2 5 3048

Part Placed in Proper Positionusing Due Care.


ProcessEngineer

06/20/05 07/01/05

Op005No

Receiving InspectionL

PutAnything

Material Handling /Non-ConformingProcedure

P

A22

100%

Damaged Part Impairs OperationCannot Mount Part,Damage Part, ScrapParts.

6 Forks NotAdjustedProperly DuringTransport

3 Training in PartLoading.

8 Revise VisualAids & ScheduleTraining .Implementmarking tags

5 4 6 120144

Material Handler Must Use Caution

Position Part On Pallet Supervisor -Henry / 222

02/15/05 02/20/05

Op010No

TransferH

PutAnything

Visual Inspection

P

B33

22

10%

Off Location No Assembly,Rework

5 Wrong CNCProgram

1 Training, SWI 3 None 5 1 3 1515

5.680 - 7.433

Drill Hole On Front Side ProcessEngineerOp011

Step 1 DrillL

PutAnything

Gage 2 Parts after everyTool Change

N

C44

35

*Out of Round Leaks, SafetyIssue,Rework,Impairs NextOperation

10 ImproperMachine Setup

7 Training, SWI 4 Go/No Go Gage 2Parts @ EachSetup. ImplementPreventiveMaintenance.

Posted PMSchedule andimplementedgauging 2 partsper shift

10 6 4 240280

0.0025

Drill Hole On Front Side ProcessEngineer

08/02/05

Op011Yes

Step 1 DrillH

PutAnything

Auto stop if the ToolHolder is not Properlyseated.

D

C55

44

30%

PQCDiam too Wide Impairs nextoperation, rework,scrap part

10 Premature ToolWear

3 S.W.I. PM 5 Go/No Go Gage 2Parts per shift.ImplementPreventiveMaintenance.

Posted PMSchedule andimplementedgauging twoparts per shift

10 2 4 80150

2.224 +/- 0.20


06/02/05 08/04/05

Op011No

Step 1 DrillH

PutAnything

Automatic Spindle LubeSystem.

N

C66

100%

SCDepth tooShallow

Rework Impairs NextOperation Loss OfAssembly Srap Parts

5 Improper SpeedSetting

3 S.W.I. PM 7 Go/No Go Gage 2Parts per shift.ImplementPreventiveMaintenance.

5 3 5 75105

15.434 +/- 0.20


08/15/05

Op011Yes

Step 1 DrillH

PutAnything

Inspect First Part Afterany AbnormalOccurrence.

D

C77

31

60%

© 2005 All Rights Reserved - QualitySystems Engineering @ 810-499-101510/10/05 1.3 DRAFTStatus:Revision:Printed on High Risk Average Risk Low Risk

owner

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Running totals of initial and final RPN's

owner

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Calculates initial and final RPN

owner

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User selects from drop down for Severity, Occurrence and Detection ratings.

owner

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Select from drop down of percent complete

owner

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1 2 3 4 5 6 7 8 9 10

Text Box

Sandra Werwega

Text Box

AIAG Process FMEA scales are included as well as option for user defined scales.

Sandra Werwega

Text Box

Characteristic Failure Worksheet populates the FMEA up to the recommended Actions.

User types info of choice

Operation DescriptionCharacteristics

Product Process

Specification and/orTolerances

Machine,Device, Jigs,Tools for Mfgr

Control MethodsSample Sizeand Frequency Concern No

Responsible:Evaluation

Measurement &Technique

PutAnything

Reaction No

Pp

Ppk

Cp

CpkGD&T Risk

Special

Class

Quality Systems Engineering QSE QSEPROCESS CONTROL PLAN

Function IDPROCESS ID

OP ID

ROW NO

Key Contact Phone:

Jack Pieron - 1-810-499-1015

?

?

06/27/05

07/03/05

?


Core Team:

PartNumber:

Part Description:

Latest Change Level:

Key Contact:

Supplier Plant Appr Date: Supplier Phone:Cus Eng Approval Date:Cus Quality Appr Date:

Other Approval Date:

Original Date:

Revision Date:

Chris Werwega, Jack Joseph, Joan Burger, Laura Pieron, Nic Burger, MerryHurt, Mary Davis,

Supplier / Plant: Supplier Code:

PCID

112749Control Plan Number:

Pipe Fixture

546876413 - 165468469465468

Prototype Pre launch ProductionPrototype Pre-launch Production

Receiving / IncomingMaterial Verification

Part ID conditionAudit 4 Samplesper lot.

AutomaticConveyor

Colored Tags - LogSheet

*In ProcessInstructions

TemplateOp005

Receiving 1A RecievingInspector

Put Anything A

000-0000-000 Operator must InsureMaterial Label is correct.

005

A11


000-0000-000100% On GoingAutomatic

ConveyorColored Tags - LogSheet

In ProcessInstructions

#45895Op005

Receiving Inspection 2A

# 6778

Operator

Put AnythingL

Put Anything Part Placed in ProperPosition using Due Care. 006A

22

Position Part On Pallet Part Condition100% On GoingAutomatic

ConveyorEnter on Log SheetIn Process

Instructions

#45795Op010

Transfer 3A

789

Operator

Put AnythingH

Storage Locations ? Material Handler Must UseCaution 006B

33

Drill Hole On Front Side Hole LocationGage 2 Parts afterevery Tool Change

MachiningCenter #1

X & R Bar ChartPlug Gage

#272549Op011

Step 1 Drill 4A Operator

Put AnythingL

Hole No 401 5.680 - 7.433005C

44

Drill Hole On Front SideCircularity ofHole

100% Set-upMachiningCenter #1

X & R Bar Chart*Plug Gage

#272549Op011

Step 1 Drill 5A ProductionOperator

Put Anything H

0.0025C

55

Drill Hole On Front SideFirst Pass Diamof Hole

1 Part per ShiftChange

MachiningCenter #1

X & R Bar ChartPQCPlug Gage

#272549Op011

Step 1 Drill 6A ProductionOperator

Put Anything H

2.224 +/- 0.20C

66

Drill Hole On Front SideFirst Pass Depthof Hole

2 @ the beginningand end of eachlot.

MachiningCenter #1

X & R Bar ChartSCPlug Gage

#272549Op011

Step 1 Drill 7A Process

Put Anything H

15.434 +/- 0.20C

77

Drill Hole On Front SideFinal Pass Diamof Hole

Gage 2 Parts perShift

MachiningCenter #1

X & R Bar ChartFFPlug Gage

#272549Op011


Put Anything A

3.823 +/- 0.20C

88

Drill Hole On Front SideFinal Pass Depthof Hole

2 @ start of everyshift

MachiningCenter #1

X & R Bar ChartPlug Gage

#272549Op011


Put AnythingL

ThruC

99

10/10/05

1.2 Controlled © 2005 All Rights Reserved - QualitySystems Engineering @ 810-499-1015

Printed on Status:Revision:21Page

ofHigh Risk Average Risk Low Risk

Note

Accepted set by

Text Box

Control Plan is populated up to the Evaluation Measurement (Gage & Number) when the Characteristics Worksheet is completed.

Sandra Werwega

Text Box

Print with or without Cp data.

QSE QSE

INTERNAL GEAR

USER TYPES COMPANY NAME

ReactionPlan Number Reaction Description

Reaction Plans

005 QS-9000 Requirements Procedure must be setup for the control of Non conformingProduct (Element 4.13). Must be identified and in specified area (Element 4.8Product Identification & Traceability). Supervisor contacts supplier, is heldaccountable (have a corrective action in place Element 4.14).

ReceivingInspectionLow

010 If new material is unacceptable notify supervisor or setup person. Cease operationuntil suspect parts are removed or are being sorted. If parts are in the systeminform the supervisor so that they can be contained. Supervisor will determine acourse of action based on the test results. Non conforming parts are separated andreturned to supplier.

ReceivingInspectionHigh

011 Operator reports serious concerns to Team Leader, who accesses the problem todetermine course of action. The team leader appoints a problem solving team tothe problem for evaluation and recommendations. It is the responsibility of theTeam Leader to implement recommended actions and insure action results arerecorded on Process FMEA.

Sub-AssemblyLow

012 Operator stops the machine and notifies supervisor of suspect part. Supervisorcontacts preventive maintenance team leader to access the problem and makerecommendation.

Sub-AssemblyAverage

Printed on: 09/26/2005 1Page 1of© 2005 All Rights Reserved - Quality Systems Engineering @ 810-499-1015

Text Box

Number is referenced in the last column of the Control Plan.

Sandra Werwega

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Text boxes shrink to fit

Part Number: 546876413 - 165468469465468Part Description: Pipe FixtureQUALITY SYSTEMS ENGINEERING

QSE

GD&T

QSE

Control PlanProcess FMEAControl Plan Process Flow, Control PlanAll Documents

Process Overview

OperationDescription

CharacteristicsProduct Process

Machine,Device, Jigs,Tools for Mfgr

Specificationand/or

Tolerances

PotentialFailure

Mode(s)

PotentialEffects of

Failure

Potential Cause(s)Mechanism(s) of

FailuresCurrent Process ControlsPrevention / Detection Control Methods

Sample Size and Frequency Concern No

Responsible:

Reaction No RPNInt

Final

Pp

Ppk

Cp

CpkClass

Function IDProcess ID

Row No

Op ID

PCIDGage Name & Number

PutAnythingUser types info of choice

Receiving /IncomingMaterialVerification

Operator mustInsure MaterialLabel is correct.

* Missing,Wrong orUnreadableLabel

63IncorrectLabel OnContainer,PRR Written

Wrong partsshipped

SupplierAudits. Tagsverify FIFO.

RecievingInspector

63Op005

AutomaticConveyor

In Process Instructions

Audit 4 Samples per lot. Colored Tags - Log Sheet

Part ID condition1A

000-0000-000Receiving

A

1Template1 A

005Put

Anything

Purchasing(Providessupplier withcorrect specs).

Receiving /IncomingMaterial

Part Placed inProper Positionusing Due Care.

Hopper Jams 48Damage PartsScrap Parts

Improper Loadingof Part

Training inPart Loading.Tags verifyFIFO.

Operator

30Op005

AutomaticConveyor


100% On GoingColored Tags - Log Sheet

000-0000-0002A

Put AnythingReceivingInspection

A

2

# 6778#458952 L

P

006

PutAnything

MaterialHandling /Non-Conforming Procedure

Position PartOn Pallet

Material HandlerMust UseCaution

DamagedPart

144ImpairsOperationCannot MountPart, DamagePart, ScrapParts.

Forks NotAdjusted ProperlyDuring Transport

Training inPart Loading.

Operator

120Op010

AutomaticConveyor


100% On GoingEnter on Log Sheet

Part Condition3A

Storage Locations ?Transfer

B

3

789#457953 H

P

006

PutAnything

VisualInspection

Drill Hole OnFront Side

5.680 - 7.433 Off Location 15No Assembly,Rework

Wrong CNCProgram

Training, SWI Operator

15Op011

MachiningCenter #1

Plug Gage

Gage 2 Parts after every ToolChange

X & R Bar ChartHole Location

4AHole No 401Step 1 Drill

C

4#2725494 L

N

005

PutAnything

Gage 2 Partsafter everyTool Change


0.0025* Out of Round 280Leaks, SafetyIssue,Rework,Impairs NextOperation

Improper MachineSetup

Training, SWI ProductionOperator

240Op011

MachiningCenter #1

Plug Gage

100% Set-upX & R Bar Chart

Circularity of Hole5A

Step 1 Drill

C

5#2725495 H

DPut

Anything

Auto stop ifthe ToolHolder is notProperlyseated.


First Pass Diam ofHole

2.224 +/- 0.20PQC Diam tooWide

150Impairs nextoperation,rework, scrappart

Premature ToolWear

S.W.I. PM ProductionOperator

80Op011

MachiningCenter #1

Plug Gage

1 Part per Shift ChangeX & R Bar Chart

6AStep 1 Drill

C

6#2725496 H

N Put

Anything

AutomaticSpindle LubeSystem.


First Pass Depth ofHole

15.434 +/- 0.20SC Depth tooShallow

105ReworkImpairs NextOperationLoss OfAssemblySrap Parts

Improper SpeedSetting

S.W.I. PM ProcessEngineer

75Op011

MachiningCenter #1

Plug Gage

2 @ the beginning and end of eachlot.

X & R Bar Chart

7AStep 1 Drill

C

7#2725497 H

DPut

Anything

Inspect FirstPart After anyAbnormalOccurrence.


3.823 +/- 0.20FF Diam tooWide

75Impairs nextoperationLossof AssemblySrap parts

Improper MachineSetup

S.W.I. PM ProcessEngineer

60Op011

MachiningCenter #1

Plug Gage

Gage 2 Parts per ShiftX & R Bar Chart

Final Pass Diam ofHole8A

Step 1 Drill

C

8#2725498 A

PPut

Anything

Gage 2@ startof every shift

10/10/05

1.2Controlled3:08:31 AM 10/10/05Modified

© 2005 All Rights Reserved - Quality SystemsEngineering @ 810-499-1015

Status: Revision:

Printed on 1Pageof

High Risk Average Risk Low Risk2

Text Box

A combination of all documents. All fields are populated from other documents. Information can be changed in this document...changes will be reflected in all documents.

Text Box

Process Overview has multiple views (with Header data) this is an example of the No Header view.

Text Box

Status and Revision Number are user defined.

This icon will takeuser back to thisscreen. Make sureyour target value iscorrect beforerunning RPN

User must select report and click the preview button to see this report, this is anautomatic summary report. This report is a useful tool when making a graph of thetotals per operations. This report should be printed per month and the totals keptseparate. Later the team can compare the totals per month, year etc. showing processimprovement results overtime.

This icon willsort Final RPN’sfrom Highest toLowest.

User can go to this form (layout) to see details of severity, occurrence and detection.Good report format for editing and identifying risk . Special reports can be created byuser, all other reports will reflect these sorts.

User can click on icons to see reports in this form (layout) and/or run other reports oftheir choice. A nice tracking tool for sorting by causes or characteristics.

This is an automatic RPN Report showing only the top five, giving the team the highestrisk is per process. Before clicking the icon ”Top 5 RPN’s” user must click the “FindAll”and the “Clear Title” buttons. The “Top 5 RPN’s can be seen in all documents. Click theSortSet button to perform sorts of five records.

Top 5 RPN’s

RPN

Sort

40ENTER

Target

RPN

09/20/05

This icon will take user to thechart file user is able to link anychart to this file for commonreporting. Default charts are inthis file, user must have excel touse them.

RPN

Overviewof Failures

RiskManagement

RISK EVALUATION REPORTS

Current RPN Report Title:Total RPN's per Process ID

QSE

© 2005 All Rights Reserved - QualitySystems Engineering @ 810-499-1015

RPN REPORT DEFINITIONS

40

9

360

678

834

-156

360

678

318

Target

Final RPN

Difference

Initial RPN Total

Final RPN Total

Ideal RPN

Count of All RPN's

Ideal RPN

Difference Between Ideal and Actual

Printed on

Difference

TARGET

Automatic reporting gives user choice of reports, user must select report and click thepreview button to see the report (1) Subtotals RPN per operation number and includes agrand total. (2) Subtotals RPN per Process ID number and includes a grand total. It willshow the weakest and strongest RPN’s per process. The RPN reporting documentshave a “Clear Title” button so user can Sort/Find and print reports of their choice.

ChoiceTotal RPN’s

ChoiceSummary

Target

User enters target amount all other numbers change to reflect target.

Ideal RPN

Automatically calculates Ideal RPN.

QSEQSE RPN SPECIAL RPN REPORTS

QUALITY SYSTEMS ENGINEERING

ECN Status 225IVECN Level 09/15/05ECN Date

Brighton2003B-4589Model Year(s) Vehicle(s):

02/02/05 09/22/05

Rob Bescoe

Sandra Werwega

112749Flow Number:

Original Date:


Prepared By:

Revision Date:

Effects

Causes

Recommended Actions

Responsible: Actions TakenCompletion

Target Date

IntFinalRPN

40

3

120

465

529

-64

120

465

345

Target

Final RPN

DifferenceDifference

Initial RPN Total

Final RPN Total

Ideal RPN

Count of All RPN's

Ideal RPN

Function Description FailureMode

Process IDOP ID

REPORT ON ALL RPN'S ABOVE 100

ROW NO


Pipe Fixture546876413 - 165468469465468

Op010

Position Part On Pallet

Damaged Part

144

Supervisor - Henry / 222

Revise Visual Aids & Schedule Training .Implement - Gauging2 parts per shift. Feb 20, 2005

120Forks Not Adjusted ProperlyDuring Transport

Feb 15, 2005

No

10%

Impairs Operation Cannot MountPart, Damage Part, Scrap Parts.

Transfer

B

31

Op011


Out of Round

280

Process Engineer

Go/No Go Gage 2 Parts @ Each Setup.Implement Preventive Maintenance.

240Improper Machine SetupAug 2, 2005

Yes

40%

Posted PMSchedule andimplementedgauging 2 partsper shift

Leaks, Safety Issue,Rework,Impairs Next Operation

Step 1 Drill

C

52

Op011


Depth too Shallow

105

Process Engineer

Go/No Go Gage 2 Parts per shift.Implement Preventive Maintenance.

105Improper Speed SettingAug 15, 2005

Yes

60%

Rework Impairs Next OperationLoss Of Assembly Srap Parts

Step 1 Drill

C

73

465TOTAL FINAL

REPORT ON ALL RPN'S ABOVE 100 529

09/20/05

© 2005 All Rights Reserved Quality Systems Engineering@ 810-499-1015 1

1Page

ofHigh Risk Average Risk Low RiskPrinted on

RPN TOTALS PER OPERATION ID

QSE QSEQuality Systems Engineering

S O DS O DSpecialOperation

DescriptionPotential Failure

Mode(s)Potential Cause(s)Mechanism(s) of

Failures Responsible: Recommended Actions

Initial Final FinalTarget Date

Completion

Total ActualRPN's

Total IdealRPN's

Difference Ideal /Actual678 31840 360Target

InitialRPN

RPN

Sandra WerwegaPrepared By:


7778FMEA Number:

RPN Risk Management, RPN Details

Percent


ROW NO

PROCESS

OP ID

112749


Pipe Fixture

546876413 - 165468469465468

Control Plan Number:

Op005Receiving / IncomingMaterial Verification

Missing, Wrong orUnreadable Label

None 48Wrong parts shipped3 2 8

723 3 8

Receiving

A1

1

Op005Receiving / IncomingMaterial

Hopper Jams Process Engineer Schedule Training in Job Procedures.Implement Preventive Maintenance.

Jul 1, 2005

30Improper Loading of Part Jun 20, 2005

No3 2 5

483 2 8

100%

Receiving Inspection

A22

Op005 78120Op010

Position Part On PalletDamaged Part Supervisor - Henry /

222Revise Visual Aids & ScheduleTraining . Implement - Gauging2 parts per shift. Feb 20, 2005

120Forks Not Adjusted ProperlyDuring Transport Feb 15, 2005

No5 4 6

1446 3 8

10%

Transfer

B3

3

Op010 120144Op011

Drill Hole On FrontSide

Off Location Process Engineer None 15Wrong CNC Program5 1 3

155 1 3

Step 1 Drill

C44

Op011Drill Hole On FrontSide

Out of Round Process Engineer Go/No Go Gage 2 Parts @ Each Setup.Implement Preventive Maintenance. 240Improper Machine Setup Aug 2, 2005

Yes10 6 4

28010 7 4

40%

Step 1 Drill

C5

5


Diam too Wide Process Engineer Go/No Go Gage 2 Parts per shift.Implement Preventive Maintenance.

Aug 4, 2005

40Premature Tool Wear Jun 2, 2005

No5 2 4

755 3 5

100%

Step 1 Drill

C6

6


Depth too Shallow Process Engineer Go/No Go Gage 2 Parts per shift.Implement Preventive Maintenance. 105Improper Speed Setting Aug 15, 2005

Yes5 3 7

1055 3 7

60%

Step 1 Drill

C7

7


Diam too Wide Process Engineer -Rob BescoeEXT: 276

Implement Preventive Maintenance.

Aug 19, 2005

60Improper Machine Setup May 17, 2005

No5 3 4

755 3 5

100%

Step 1 Drill

C8

8


Depth too Shallow Process Engineer None 20Incomplete Cycle5 2 2

205 2 2

N/A

Step 1 Drill

C99

Op011 480570

9/20/2005© 2005 All Rights Reserved - Quality Systems

Engineering @ 810-499-1015Draft1.3Printed on

Status:Revision: 21Page

ofHigh Risk Average Risk Low Risk

QSE QSEQuality Systems Engineering

Monday, September 19, 2005

RPN Totals per Operation ID

75

ECL# 225IIIECL: 03/02/03ECN Date:

02/02/03 09/22/03Rob Bescoe

Sandra Werwega

Original Date:Responsible Engineer:

Prepared By:

Revision Date:

Target

InitialRPN

FinalRPN

DifferenceIdeal / Actual

Operation DescriptionProcessID

TotalRPN's

TotalRPN's

Summary of RPN’s

7778FMEA Number:


Pipe Fixture546876413 - 165468469465468

Op005 781202Receiving / Incoming Material

A

Op010 1201441Position Part On Pallet

B

OP011 4805706 C

6788349 3675GRAND TOTALS

09/19/05© 2004 All Rights Reserved - Quality

Systems Engineering @ 810-499-1015Printed on

QSE QSE

TOTAL RPN'S PER OPERATION

Risk Priority Measurements

Project Totals

QUALITY SYSTEMS ENGINEERING INC.

High Risk Priority Average Risk Low Risk

0

50

100

150

200

250

300

350

400

450

Pipe Fixture Door Fixture Quarter Panel Fixture Rear Door Fixture Luggage Fixture0

100

200

300

400

500

600

700

OP010 OP020 OP030 OP040 OP050 OP060

0

50

100

150

200

250

300

350

400

450

Part 1 Part 2 Part 3 Part 4 Part 5

0

50

100

150

200

250

300

350

10 20 30 40 50 60 70 80 90 100

Num

ber o

f Fai

lure

Mod

es

Risk ReportingRisk Reporting per Operation

© 2004All Rights Reserved - Quality Systems Engineering 1-810-499-1015

QSE

Flows, FMEA’s,

Control Plans

Thank you!

For viewing the QSE FMEA APQP Application.For more information

contact QSE @ 352-597-1197

© All rights reserved 2000/2005. Quality Systems Engineering. No part of this material may be reproduced

or utilized (in any form or by any means), electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, for any purpose (training) without prior

written permission from Sandra Werwega.

Sandra Werwega

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