21
MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS Albert Sanzari System Designer and Project Engineer [email protected] July 2, 2017 EM-636 eLearning Pak ID: EM-636-Summer2017-27-32-04 Collaborating Companies: Starrag, Mitsubishi Materials, CDBP, Schmalz The following is descriptions for all elements of the three layers of the It’s Not Easy Being Green, Phase II Process Model. Data Dictionary code will be in text, images, code or a combination of all. The Process Description designation will be in parenthesis next to the name. LAYER 0 (Process) A0 (Sub process) I1A0: Parts Orders (Element) These are the orders from our Phase I part of the company requesting parts for repair of a turbine installation. I2A0: Scrap for Recycling (Element) Any material returned from repair to be sent for recycling, such as: (1) I3A0: Design Orders (Element) - Orders for turbine installations we design ourselves, for customers. I4A0: Installation Orders (Element) Orders from customers for us to install their turbines, such as: (2)

MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

  • Upload
    others

  • View
    1

  • Download
    0

Embed Size (px)

Citation preview

Page 1: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS

Albert Sanzari

System Designer and Project Engineer

[email protected]

July 2, 2017

EM-636 eLearning Pak ID: EM-636-Summer2017-27-32-04

Collaborating Companies: Starrag, Mitsubishi Materials, CDBP, Schmalz

The following is descriptions for all elements of the three layers of the It’s Not Easy Being Green, Phase II

Process Model. Data Dictionary code will be in text, images, code or a combination of all. The Process

Description designation will be in parenthesis next to the name.

LAYER 0 (Process)

A0 (Sub process)

I1A0: Parts Orders (Element) – These are the orders from our Phase I part of the company requesting parts for repair of a turbine installation. I2A0: Scrap for Recycling (Element) – Any material returned from repair to be sent for recycling, such as:

(1)

I3A0: Design Orders (Element) - Orders for turbine installations we design ourselves, for customers. I4A0: Installation Orders (Element) – Orders from customers for us to install their turbines, such as:

(2)

Page 2: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

O1A0: Manufactured Parts (Element) – Parts we make either for repair or for new turbines, such as:

(3)

O2A0: Scrap Shipped for Recycling (Element) – This is the scrapped material from I2A0: Scrap for Recycling being shipped to our partners Mitsubishi Materials, by:

(4)

O3A0: Manufactured Turbines from Orders (Element) – These are entire wind turbine towers we design from our designs, installations and manufactured parts. So O3AO=I3A0 + I4A0 + O1A0. O4A0: Installations from Orders (Element) – These are the installations from the orders I4A0.

C1A0: Training (Element) – This covers all training at all phases of the company, and is always ongoing.

C2A0: Quality Processes (Measurement AND Improvement) – Our entire Quality system, such as:

(5)

C3A0: ERP (Element) – Our entire network management system, such as:

Page 3: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

(6)

C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest quality possible. It covers all the steps to succeed in this, such as:

(7)

C5A0: Manufacturing Software (Element) – Such as:

(8)

C6A0: Budget (Element) – The budget is the monetary constraint of the entire company project. It

Page 4: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

includes smaller budgets such as materials, resources, overhead, etc. The budget is mainly controlled by accounting department (R5A1), once it’s created with the help of all upper management.

C7A0: Lean Visual (Improvement Objective) – A way of visually laying out and labeling a factory

for ease of use and order, such as:

(9) (10) (11)

C8A0: ISO Audits (Measurement AND Improvement) – Audits that are performed in house, done

to the ISO 9001 standards for our management system.

C9A0: Databases (Element) – This database stores all our procedures, work instructions, and

training Forms. This also includes all of HR records.

R1A0: Tools (Element) – Such as:

(12) (13)

Including one of our collaborators, CDGB.

R2A0: Technicians (Element) – Such as:

(14) (15)

Page 5: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

R3A0: Engineers (Element) – We have many engineers, because it takes many engineers to

succeed such as Mechanical, Industrial, Civil, and Electrical to name some:

(16)

R4A0: Manufacturing Equipment (Element) – Such as one of our collaborating companies,

Starrag:

(17) (18)

R5A0: Utilities (Element) - Such as:

(19) (20)

There is electric hookup to main grid but majority, and most times all power supplied by

solar panels

R6A0: Recycled Material (Element) – This is the material we get back from

Page 6: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

(21), one of our collaborating companies, after we end them our scrap to

recycle. This keeps our cost of material don and is the greenest way to manufacture with these

materials.

R7A0: Vacuum Equipment (Element) – This is the vacuum connections we use on our

manufacturing equipment, and our holding connections on the arms of our repair vehicles. It is

better grip and doesn’t damage the material. We get them from one of our collaborating

companies (22)

DBI_A0 (Element) – This database contains all the top level (A0) information we need saved that is

NOT in our normal top level database for control.

Page 7: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

LAYER 1 (Process)

A1 (Sub process)

I1A1: Environmental Concerns (Elements) – Such as:

(23)

(24) (25) I2A1: Designs (Element) – These could be are our own plans for manufacturing wind turbines to be Purchased and installed (if requested) by customers. I3A1: Orders (Element) – Electronic or paper copies of requests for wind turbines built, designed, and/or Installed for customers. Will contain all the Customer Requirements as well.

I4A1: Business Plan Outline (Element) – The rough draft of where the business wants to be, and how to get there. The info used for the Process Model. Such as:

(26)

Page 8: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

I5A1: Pay Options (Element) = Cash, Credit Card, Pay Pal, Personal Check (with ID), Company

Check, Money Order, Business Account.

O1A1: Environmental Concerns (Element) = I1A1 + any new concerns

O2A1: Orders (Element) = Reviewed version of I3A1

O3A1: Designs (Element) = Reviewed version of I2A1

O4A1: Business Plan Outline (Element) = Reviewed version of I4A1

O5A1: Pay Options (Element) = I5A1

C1A1: Quality Processes (Measurement AND Improvement) = C2A0

C2A1: Deadlines (Element) = Customer and internal due dates for order or process completion.

C3A1: Customer Requirements (Element) = This covers whatever parameters are needed for the

customer. Created as a template for analysis through the process, such as:

(27)

C4A1: Budget (Element) = C6A0 for A1

C5A1: Environmental Guidelines (Improvement Objectives) – Guidelines and methods the

company follows to be Green, sustainable, and environmentally safe in ALL Processes. An

example of some of our guidelines.

(28)

R1A1: Engineers (Element) = R3A0

Page 9: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

R2A1: Requirements Analysis Team (Improvement Objectives) = A team put together from

various disciplines in the company to exam and confirm the customer requirements can be met

or exceeded.

R3A1: Analysis Tools (Measurement AND Improvement) = Any software, equipment or people

that can help in the analysis process such as:

(29) (30)

R4A1: Green Facility (Element) – The facility itself is green from the design to the operation of the

building itself. It uses solar power with storage battery backup. Has a water efficiency system

throughout including manufacturing. This also includes smaller design features like a cafeteria

and the offices on the top floor with skylights for natural lighting.

R5A1: Accounting (Element) – The department that controls the budget and tracks costs, revenue,

capital and investments.

DBI_A1 (Element) – This database stores, controls and accesses all data for A1 processes.

A2 (Sub process)

I1A2: Environmental Concerns (Element) = O1A1

I2A2: Orders (Element) = O2A1

I3A2: Designs (Element) = O3A1

I4A2: Business Plan Outline (Element) = O4A1

I5A2: Pay Options (Element) = I5A1

O1A2: Environmental Concerns (Element) = I1A2 + any new concerns.

O2A2: Orders (Element) = I2A2 + any changes

O3A2: Designs (Element) = I3A2 + any changes

Page 10: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

O4A2: Pay Options (Element) = I5A1

O5A2: Customer Feedback (Measurement AND Improvement) = A form for customers to give us

detailed information on how we are doing compliments on what they like, and what they would

like to see. Example of the form:

(31)

C1A2: Quality Processes (Measurement AND Improvement) = C2A0

C2A2: Budget (Element) = C6A0 for A2

C3A2: Manufacturing Software (Element) = C5A0

C4A2: Customer Requirements (Element) = C3A1+ any changes

C5A2: Environmental Guidelines (Improvement Objectives) = C5A1 + any additionally added

guidelines

R1A2: Project time management software (Element) – MS Project. Example:

Page 11: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

(32)

R2A2: Engineers (Element) = R3A0

R3A2: Analysis Tools (Measurement AND Improvement) = R3A1

R4A2: Project Analysis Team (Measurement AND Improvement) - A team put together from

various disciplines in the company to examine the project scope, plan and create subsequent

actions to see that realization.

R5A2: Accounting (Element) = R5A1

DBI_A2 (Element) – This database stores, controls and accesses all data for A2 processes.

A3 (Sub process)

I1A3: Environmental Concerns (Element) = O1A2

I2A3: Orders (Element) = O2A2

I3A3: Designs (Element) = O3A2

I4A3: Pay Options (Element) = O4A2

I5A3: Customer Feedback (Measurement AND Improvement) = O5A2

O1A3: Environmental Concerns (Element) = I1A3 + any new concerns.

O2A3: Orders (Element) = I2A3

O3A3: Designs (Element) = I3A3 + any changes

O4A3: Pay Options (Element) = I4A3

Page 12: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

O5A3: Customer Feedback (Measurement AND Improvement) = I5A3 + any new information to

be used to improve our processes

C1A3: Quality Processes (Measurement AND Improvement) = C2A0

C2A3: Budget (Element) = C6A0 for A3

C3A3: PDM Software (Element) – Used to store and control our drawings and work procedures.

Can be accessed with read only controls for operators and technicians, and full use for

engineers and management. Such as:

(33)

C4A3: Customer Requirements (Element) = C4A2+ any changes

C5A3: Environmental Guidelines (Improvement Objectives) = C5A2 + any additionally added

guidelines

C6A3: Design Guidelines (Improvement Objectives) = These are rules for what we can and can’t

use in a design. These are based on engineer knowledge design review meetings. Examples

are maximum height a turbine tower can be, max-min size of blades, max-min speed of

rotation, etc.

R1A3: Engineers (Element) = R3A0

R2A3: Project time management software (Element) = R1A2

R3A3: Simulation Software (Improvement Objectives) = For modeling physical project designs or

layouts, also routing of installations or deliveries. Examples are Arena (34), Simio (35), etc.:

Page 13: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

(34) (35)

R4A3: Design Review Team (Improvement Objectives) - A team put together from various

disciplines in the company to review all designs to assure it can be manufactured and fits

within the design guidelines.

R5A3: Green Facility (Element) = R4A1

R6A3: Analysis Tools (Measurement AND Improvement) = R3A1

DBI_A3 (Element) – This database stores, controls and accesses all data for A3 processes.

A4 (Sub process)

I1A4: Environmental Concerns (Element) = O1A3

I2A4: Orders (Element) = O2A3

I3A4: Designs (Element) = O3A3

I4A4: Pay Options (Element) = O4A3

I5A4: Customer Feedback (Measurement AND Improvement) = O5A3

I6A4: Scrap Parts (Element) = I2A0

O1A4: Environmental Concerns (Element) = I1A4 + any additional concerns discovered

O2A4: Orders (Element) = I2A4

O3A4: Designs (Element) = I3A4 + any additions or changes

O4A4: Pay Options (Element) = I4A4

O5A4: Customer Feedback (Measurement AND Improvement) = I5A4 + any additional comments

O6A4: Scrap Parts (Element) = O2A0

Page 14: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

C1A4: Quality Processes (Measurement AND Improvement) = C2A0

C2A4: Budget (Element) = C6A0 for A4

C3A4: Manufacturing Software (Element) = C5A0

C4A4: Lean Visual (Improvement Objectives) = C7A0

C5A4: Environmental Guidelines (Improvement Objectives) = C5A3 + any additionally added

guidelines

C6A4: JIT Manufacturing (Improvement Objectives) – The manufacturing method where orders of

parts are made as needed when needed, not made ahead of time. Keeps our storage cost to a

minimum, which allows our facility to be a smaller footprint. Good for the environment and

cost. Plus TQM.

R1A4: CDGB Tools (Element) – One of our collaborating companies. Provides us all the tools to go

with the manufacturing equipment such as R1A0

R2A4: STARRAG Machines (Element) - One of our collaborating companies. Provides us with all

the manufacturing equipment for the facility such as R4A0

R3A4: Mitsubishi Recycled Materials (Element) - One of our collaborating companies. Provides us

with all the recycled material we use such R6A0. They also are who we send our scrap

material to be recycled such as O2A0

R4A4: Project time management software (Element) = R2A3

R5A4: Schmalz Vacuum Parts (Element) - One of our collaborating companies. Provides us with all

the manufacturing equipment for the facility such as R4A0

R6A4: Engineers (Element) = R3A0

R7A4: Analysis Tools (Measurement AND Improvement) = R3A1

R8A4: Green Facility (Element) = R4A1

DBI_A4 (Element) – This database stores, controls and accesses all data for A4 processes.

A5 (Sub process)

I1A5: Environmental Concerns (Element) = O1A4

I2A5: Orders (Element) = O2A4

I3A5: Designs (Element) = O3A4

Page 15: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

I4A5: Pay Options (Element) = O4A4

I5A5: Customer Feedback (Measurement AND Improvement) = O5A4

O1A5: Manufactured Parts (Element) = O1A0

O2A5: Scrap Shipped for Recycling (Element) = O2A0

O3A5: Manufactured Turbines from Orders (Element) = O3A0

O4A5: Installations from Orders (Element) = O4A0

C1A5: Quality Processes (Measurement AND Improvement) = C2A0

C2A5: 6 Sigma (Measurement AND Improvement) = C4A0

C3A5: Budget (Element) = C6A0 for A5

C4A5: Environmental Guidelines (Improvement Objectives) - Finalized guidelines from all former

iterations

C5A5: Customer Requirements (Element) - Finalized requirements from all former iterations

C6A5: Project Deadlines (Element) = C2A1

R1A5: Continuous improvement team (Measurement AND Improvement) - A team put together

from various disciplines in the company to examine all areas of the overall project, and put

together action plans to Improve their findings. This becomes a continuous exercise

throughout the project Life cycle.

R2A5: Data Analysis Software (Measurement AND Improvement) – This would be Excel, Minitab,

SAS, etc.

R3A5: Project time management software (Element) = R4A4

R4A5: Engineers (Element) = R3A0

R5A5: ISO Audits (Measurement AND Improvement) - Hiring an outside auditor to come in and

audit the company per ISO 9001:2015 standards.

R6A5: Collaborating Company Technicians (Element) – Technicians from our collaborating

companies (Starrag, CDGB, Mitsubishi Materials, Schmalz) come in and make sure all

equipment and tools are up and running right.

DBI_A5 (Element) – This database stores, controls and accesses all data for A5 processes.

Page 16: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

LAYER 2 (Sub process)

A1.1 (Sub process)

I1A1.1: Environmental Concerns (Element) = I1A1

I2A1.1: Business Plan Outline (Element) = I4A1

I3A1.1: Orders (Element) = I3A1

I4A1.1: Pay Options (Element) = I5A1

O1A1.1: Environmental Concerns (Element) – First round of comparing I2A1.1 + I3A1.1 to

I1A1.1

O2A1.1: Orders (Element) = I3A1.1

O3A1.1: Business Plan Outline (Element) = I2A1.1 + any changes from analysis

O4A1.1: Pay Options (Element) = I4A1.1

C1A1.1: TQM Manual (Improvement Objectives) = The company manual that covers the TQM

procedures and processes such As:

(36)

C2A1.1: Deadlines (Element) = C2A1

C3A1.1: Customer Requirements (Element) = C3A1

C4A1.1: Budget (Element) = C4A1

C5A1.1: Environmental Guidelines (Improvement Objectives) = C5A1

R1A1.1: Engineers (Element) = R3A0

Page 17: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

R2A1.1: Requirements Analysis Team (Improvement Objectives) = R2A1

R3A1.1: Project time management software (Element) = MS Project, such as:

(37)

R4A1.1: PFRA analysis tool (Measurement AND Improvement) – A tool called Process Failure

Risk Analysis. Example:

(38)

© Copyright by Paul G. Ranky, 1992-2002

Product Name and Appearance Before Process PFRA Study ID Number

Name of Organization Responsible for the Process Date of This Study (mm/dd/yy)

Other Organizations Involved in the Process Orignal Date of This Study

Subcontractors, process Plants Effected Revision Number

Product Serial Number and Optional Image Map Comments

Process

Cost

15.00 Proc.ID Failure Mode(s) and Effect(s)

[sec] [USD] [USD] (1-10) (1-10) (1-10)0.1-

2,1=100%

0.1-

2,1=100%

0.1-

2,1=100%

0.1-

2,1=100%ID 1.1 0

ID 1.2 0

ID 1.3 0

ID 2.1 0

ID 2.2 0

ID 2.3 0

ID 3.1 0

ID 3.2 0

ID 3.3 0

ID 4.1 0

ID 4.2 0

ID 4.3 0

ID 5.1 0

ID 5.2 0

ID 5.3 0

ID 6.1 0

ID 6.2 0

ID 6.3 0

ID 7.1 0

ID 7.2 0

ID 7.3 0

ID 8.1 0

ID 8.2 0

ID 8.3 0

ID 9.1 0

ID 9.2 0

ID 9.3 0

ID 10.1 0

ID 10.2 0

ID 10.3 0

ID 11.1 0

ID 11.2 0

ID 11.3 0

ID 12.1 0

ID 12.2 0

ID 12.3 0

ID 13.1 0

ID 13.2 0

ID 13.3 0

ID 14.1 0

ID 14.2 0

ID 14.3 0

ID 15.1 0

ID 15.2 0

ID 15.3 0

ID 16.1 0

ID 16.2 0

ID 16.3 0

ID 17.1 0

ID 17.2 0

ID 17.3 0

ID 18.1 0

ID 18.2 0

ID 18.3 0

ID 19.1 0

ID 19.2 0

ID 19.3 0

ID 20.1 0

ID 20.2 0

ID 20.3 0

ID 21.1 0

ID 21.2 0

ID 21.3 0

ID 22.1 0

ID 22.2 0

ID 22.3 0

ID 23.1 0

ID 23.2 0

ID 23.3 0

ID 24.1 0

ID 24.2 0

ID 24.3 0

ID 25.1 0

ID 25.2 0

ID 25.3 0

ID 26.1 0

ID 26.2 0

ID 26.3 0

ID 27.1 0

ID 27.2 0

ID 27.3 0

ID 28.1 0

ID 28.2 0

ID 28.3 0

ID 29.1 0

ID 29.2 0

ID 29.3 0

ID 30.1 0

ID 30.2 0

ID 30.3 0

ID 31.1 0

ID 31.2 0

ID 31.3 0

ID 32.1 0

ID 32.2 0

ID 32.3 0

ID 33.1 0

ID 33.2 0

ID 33.3 0

ID 34.1 0

ID 34.2 0

ID 34.3 0

ID 35.1 0

ID 35.2 0

ID 35.3 0

A Component-oriented Process Failure Risk Analysis Method (Ver. 5) by Professor Paul G. Ranky, PhD, NJIT/MERC

Process CodeEngineering Release Date of Process

MethodologyType of Product Processed

Product Group Classifier

This PFRA Study was Prepared By

PFRA TeamResponsible Organization/

DepartmentComments

Engineering Release Date of the Product

Low

Low

Low

Low

Low

Low

Low

Low0.00

0.00

0.00

Low

Low

Low

Low

Low

Low

Low0.00

0.00

0.00

0.00

0.00

0.00

1.00 1.00 1.00 1.00

0.00

0.00

0.00

0.00

0.00

0.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

1.00 1.00 1.00 1.00

0

0

0

0

0

00.15

0

0

0

0

0

0

0

0

00.12

0.13

0.13

0.13

0.14

0.140.00

0.00

0.09

0.09

0.10

0.10

0.10

0.11

0.11

0.120.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

35

34

33

32

31

30

29

28

27

26

25

24

23

0.00

Low

Low

Low

Low

Low

Low

Low

Low1.00 1.00 1.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

1.00 1.60 1.00

1.00 1.00 1.00

1.00

1.00 1.00 1.00

1.00 1.00 1.00

1.00

1.00

1.00 1.00 1.00

1.00 1.00 1.00

1.00 1.00

1.00

1.00

1.00

1.00

1.00

1.00

0.08

0.08

0

0

0

0

0

0

0

0

0.00

0.00

0.00

0.00

0.05

0.06

0.06

0.07

0.07

0.08

19

20

13

14

15

16

17

18

21

0.00

Low

Low

Low

Low

Low

0.00

0.00

0.00

0.00

0.00

Low

Low

Low

Low

Risk

Associated

Low

Low

Low

0.02

0.00 0.02

0.00 0.03

0.00 0.03

3

4

5

6

12

7

8

9

10

11

1

2

Process ID

Describe the Process for Each Process Step

and Optionally Illustrate the State of the

Device/ Part/ Subassembly/ Object AFTER the

Process is Complete

List / Identify the Parts / Components

Retrieved in Each Process Step

Process

Time

Specify the Fixtures / Clamps Used in

Each Process Step

Specify the Tool(s) Used in Each Process

Step

Corrective Action(s) Taken and Date

(mm/dd/yr)

The Effect of Each Process Step

Failure Risk on Other Processes

The Effect of Each Process Step

Failure Risk on Other Parts (I.e.

components/ objects)

Detection Mode Recommended Corrective Action(s)Severity

Rating

Detection

Rating

Occurrence

Rating

RPN (Risk

Priority

Number)

0

0

0

0

0

0

0

0

0

0

0

The PFRA Team Describes / Illustrates the Potential Process

Failure Mode and the Effect; the Risk of FailureAccumulated

Process Cost

0.00 0.00

Max. RPN

0

0.00 0.03

0.00 0.04

0.00 0.01

0.00 0.01

0.00 0.05

0.00 0.04

0.00 0.05

Clamping/

Fixturing

Factor

Skill

Factor

1.00 1.00 1.00

Tooling

Factor

1.00 1.00 1.00

1.00 1.00 1.00

1.00 1.00 1.00

1.00 1.00 1.00

1.00

1.00 1.00

1.00 1.00 1.00

1.00

1.00

1.00 1.00 1.00

1.00 1.00 1.00

1.00 1.00 1.00

1.00

1.00

1.00

1.00

1.00 1.00 1.00

1.00 1.00

Accumulated

RPN

1.00

0.00

0.00

0.00

0.00

0.00

0.00

1.00

1.00

0.00

0.00

0.00

0.00

0.00

0.00

Any Other

Factor You

Define

22

1.00

1.00

1.00

1.00

ID 1.1

ID 1.2

ID 1.3

ID 2.1

ID 2.2

ID 2.3

ID 3.1

ID 3.2

ID 3.3

ID 4.1

ID 4.2

ID 4.3

ID 5.1

ID 5.2

ID 5.3

ID 6.1

ID 6.2

ID 6.3

ID 7.1

ID 7.2

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

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 13.2

ID 13.3

ID 14.1

ID 14.2

ID 14.3

ID 15.1

ID 15.2

ID 15.3

ID 16.1

ID 16.2

ID 16.3

ID 17.1

ID 17.2

ID 17.3

ID 18.1

ID 18.2

ID 18.3

ID 19.1

ID 19.2

ID 19.3

ID 20.1

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

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 29.2

ID 29.3

ID 30.1

ID 30.2

ID 30.3

ID 31.1

ID 31.2

ID 31.3

ID 32.1

ID 32.2

ID 32.3

ID 33.1

ID 33.2

ID 33.3

ID 34.1

ID 34.2

ID 34.3

ID 35.1

ID 35.2

ID 35.3

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

RPN for Each Failure Mode

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

0 0 0 1 1 1

Accumulated RPN for Each Failure Mode

Page 18: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

R5A1.1: CORA Software (Measurement AND Improvement) – A tool called Component Oriented

Requirements Analysis. Example

(39)

R6A1.1: Accounting (Element) = R5A1

DBI_A1.1 (Element) – This database stores, controls and accesses all data for A1.1 processes.

A1.2 (Sub process)

I1A1.2: Environmental Concerns (Element) = O1A1.1

I2A1.2: Orders (Element) = O2A1.1

I3A1.2: Business Plan Outline (Element) = O3A1.1

I4A1.2: Pay Options (Element) = O4A1.1

© Paul G. Ranky, 2000-2002

S.No. Describe the Requirement 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

En

ter

cu

sto

mer

rati

ng

fo

r

co

mp

eti

tor

A's

pro

du

ct

En

ter

cu

sto

mer

rati

ng

fo

r

co

mp

eti

tor

C's

pro

du

ctEngineering / Software Solutions

Responding to Customer

Requirements

Object / Component Oriented Requirements Analysis

Program Template by Professor Paul G. Ranky, PhD, NJIT /

MERC, ver. 5

Target Values (List here the

parameters that specify engineering

solutions accurately. If you don't know

the range of the acceptable values,

use our Taguchi Calculator Program

for Designing an Experiment)

Customer Requirements

(Reflecting component/ object

behavior related to customer needs) Imp

ort

an

ce R

ati

ng

(1-5

)

En

ter

cu

sto

mer

rati

ng

fo

r

co

mp

eti

tor

B's

pro

du

ct

Go

al/

Qu

ali

ty P

lan

(1-5

)

En

ter

cu

sto

mer

rati

ng

fo

r

ou

r p

rod

uct

0

21

0 1 2

Our product

Competitor A's product

Competitor B's product

Competitor C's product

Page 19: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

I5A1.2: Customer Feedback (Measurement AND Improvement) – At this point, Customer

Feedback is any customer comments or information provided towards our requirements

analysis results.

I6A1.2: Designs (Element) = I2A1

O1A1.2: Environmental Concerns (Element) = I1A1.2 + any new concerns discovered during

requirements design stage.

O2A1.2: Orders (Element) = I2A1.2

O3A1.2: Business Plan Outline (Element) = I3A1.2 + any changes made during requirements

design stage.

O4A1.2: Designs (Element) = I2A1

O5A1.2: Customer Feedback (Measurement AND Improvement) = I5A1.2 + any changes from the

requirements design stage.

O6A1.2: Pay Options (Element) = I4A1.2

C1A1.2: TQM Manual (Improvement Objectives) = C1A1.1

C2A1.2: Budget (Element) = C4A1

C3A1.2: ERP (Element) = C3A0

C4A1.2: Design Guidelines (Improvement Objectives) = C6A3

C5A1.2: Customer Requirements (Element) = C3A1

C6A1.2: Deadlines (Element) = C2A1

C7A1.2: Environmental Guidelines (Improvement Objectives) = C5A1

R1A1.2: Project time management software (Element) = R3A1.1

R2A1.2: Engineers (Element) = R3A0

R3A1.2: CORA Software (Measurement AND Improvement) = R5A1.1

R4A1.2: Design Analysis Team (Improvement Objectives) - A team put together from various

disciplines in the company to analyze all designs to assure it can be manufactured and fits

within the design guidelines (C6A3).

R5A1.2: PFRA analysis tool (Measurement AND Improvement) = R4A1.1

R6A1.2: Accounting (Element) = R5A1

Page 20: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

DBI_A1.2 (Element) – This database stores, controls and accesses all data for A1.2 processes.

A1.3 (Sub process)

I1A1.3: Environmental Concerns (Element) = O1A1.2

I2A1.3: Orders (Element) = O2A1.2

I3A1.3: Business Plan Outline (Element) = O3A1.2

I4A1.3: Designs (Element) = O4A1.2

I5A1.3: Customer Feedback (Measurement AND Improvement) = O5A1.2

I6A1.3: Pay Options (Element) = O6A1.2

O1A1.3: Environmental Concerns (Element) - Final version through requirements

O2A1.3: Orders (Element) = I2A1.3

O3A1.3: Business Plan Outline (Element) - Final version through requirements

O4A1.3: Designs (Element) - Final version through requirements

O5A1.3: Customer Feedback (Measurement AND Improvement) - Final version through

requirements

O6A1.3: Pay Options (Element) = I6A1.3

C1A1.3: TQM Manual (Improvement Objectives) = C1A1.2

C2A1.3: Detailed Budget (Element) = Final version through requirements

C3A1.3: ERP (Element) = C1A1.1

C4A1.3: Specific Action Deadlines MS Project Plan (Element) = R1A1.2 with details to each sub

project through requirements process.

C5A1.3: Customer Requirements (Element) = Final version through requirements

C6A1.3: Environmental Guidelines (Improvement Objectives) = Final version through

requirements

C7A1.3: Design Guidelines (Element) = C6A3

R1A1.3: Engineers (Element) = R3A0

Page 21: MODEL DATA DICTIONARY and PROCESS DESCRIPTIONS · 2017-07-02 · (6) C4A0: 6 Sigma (Measurement AND Improvement) – We use 6 Sigma to strive for no defects, and have the highest

R2A1.3: Specific CORA Findings (Measurement AND Improvement) = R5A1.1 with final findings

at bottom of sheet

R3A1.3: Upper Management (Element) = President, vice president and managers to review all final

decisions

R4A1.3: Consultant (Measurement AND Improvement) = At this point a project consultant from the

outside is hired to look over the requirements.

R5A1.3: Green Environmental Team (Improvement Objectives) - A team put together from

various disciplines in the company to analyze all environmental issues found and ensure there

are solutions in place.

DBI_A1.3 (Element) – This database stores, controls and accesses all data for A1.3 processes.

IMAGE REFERENCES

1. Courtesy of windaction.org 2. Courtesy of siemans.com 3. Courtesy of baytmal.org

4. Courtesy of MCCI.org 5. Courtesy of edenispl.com 6. Courtesy of erpennews.com

7. Courtesy of mutifaber.com 8. Courtesy of en.wikipedia.com 9. Courtesy of inkonit.com

10. Courtesy of hellotrade.com 11. Courtesy of detectamet.com 12. Courtesy of mojix.com

13. Courtesy of cdgb.com 14. Courtesy of rjwang.com 15. Courtesy of lisrty.com

16. Courtesy of explore.com 17. Courtesy of starrag.com 18. Courtesy of starrag.com

19. Courtesy of newsday.com 20. Courtesy of cswci.com 21. Courtesy of linkedin.com

22. Courtesy of schmalz.com 23. Courtesy of cwejournal.com 24. Courtesy of wileyasiablog.com

25. Courtesy of greenfuture.com 26. Courtesy of biggerplate.com 27. Courtesy of researchgate.com

28. Courtesy of corpresponsibiity-pmiworlwide.com 29. Courtesy of xlstat.com

30. Courtesy of slideshare.net 31. Courtesy of azgreetings.com 32. Courtesy of tensix.com

33. Courtesy of directindustry.com 34. Courtesy of azgreetings.com handlingscience.com

35. Courtesy of keywordsuggest.org 36. Courtesy of slideshare.com

37. Courtesy of tensix.com 38. Courtesy of Project Management eBook, Ranky

39. Courtesy of Project Management eBook, Ranky