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Evaluation of Process Risks in Industry 4.0 Environment.
Svingerova, Michaela ; Melichar, Martin
Table 1. FMEA--severity [10]
Consequence Severity in respect of Score
the customer
Failure to meet safety Affects safe operation 10
of regulatory requirements without warning 9
Affects safe operation
after warning
Impaired or lost primary Vehicle disabled 8
function Vehicle drivable, reduced 7
power
Impaired or lost secondary Loss of comfort 6
function Reduced comfort 5
Inconvenience Noticed by 75% of customers 4
Noticed by 50% of customers 3
Noticed by 25% of customers 2
No consequence No perceptible consequence 1
Table 2. FMEA--occurrence [10]
Consequence Occurrence in respect of the customer Score
Major 100000ppm 10
Medium 50000ppm 9
20000ppm 8
10000ppm 7
Medium 2000ppm 6
500ppm 5
100ppm 4
Low 10ppm 3
1ppm 2
Very low Eliminated by prevention 1
Table 3. FMEA--identification [10]
Chance of detection Probability of identification Score
of the cause
Detection impossible Cannot be detected 10
Near impossible Low probability of detection 9
Negligible E.g. visual inspection 8
Detection of the problem in the 7
Very low workplace
Low Measurement after the operation was 6
completed by the operator
Medium Detection by operator with the 5
aid of automated tools
Medium to high Inspection with automated tools 4
and separation
High Inspection with automated tools 3
and separation
Very high Automated tools for error detection 2
Fault prevention Error prevention 1
Fig. 9. FMEA analysis--manual operator [10]
Process
Step Function Requirements
number Potential Failure
Mode
Operation Item.
1 Components Wrong part
loading into orientation
the machine
Insuficient
part position
Insufficient part
position (
missing component
extra component
2 clamping clamping clamp quality
parts
3 part assy Part damage
unloading
from the
machine
4 packaging Box Wrong Container type
Wrong number of
parts in container
Missing label
part skipped operation
condition
Step Potential Effects(s) Severity Class Potential Cause(s)/
number of Failure Mechanism(s) of
Failure
1 Improper fit Operator mistake,
to vehicle 7 Standardize working
instruction not
followed
Tooling damage, Operator mistake,
time loss Standardize working
instruction not
8 followed
Tooling damage, Operator mistake,
time loss Standardize working
8 instruction not
followed
Improper fit to Operator mistake,
vehicle 7 Standardize working
instruction not
followed
Improper fit to component inserted
vehicle twice
7
components sticked
with oil
7
2 Part may not meet parts weren't
system design 7 clamped
requirements
parts weren't
7 clamped
parts weren't
7 clamped
Part may not meet unsifficient
system design 7 clamping
requirements
unsifficient
7 clamping
3 Improper fit Falling of the part
to vehicle
6
4 Time loss, wrong Material handler
number of parts 3 mistake
Inventory Operator mistake,
discrapency 3 packaging
instruction not
followed
Lost of Operator did not
tracebility 4 print label or
forget to place
printed label on box
Improper fit operator mistake
to vehicle 7
Occurence Current Process Current Process Controls
Step Controls Detection
number Prevention
Process steps sensors control correct
1 4 description in orientation
Standardize work
instruction
Process steps pin is controling correct
description in position (sensor on end
Standardize work stop)
4 instruction, pin is
controling correct
position (sensor on
end stop)
Process steps visual control, operator
description in has to ensure position
4 Standardize work with small equipment
instruction
Process steps sensor checking right
4 description in position
Standardize work
instruction
Work instruction install sensor to control
right material thickness
3 before clamping
Work instruction install sensor to control
right material thickness
3 before clamping
operator training sensor checking right
2 4 position of clamps
operator training sensors checking right
4 position of clamps
operator training sensors checking right
4 position of clamps
operator training sensor checking right
4 position of clamps
operator training sensors checking right
4 position of clamps
Design of the holders Operator training
3 allowing easy part
2 manipulation
no control Operator training,
4 4 packaging instruction
Operator training, Discrapancy for next
4 packaging instruction station
Operator training, Reading lable on next
4 automatic printing process step
after last piece
inspection
No control 100% Touchpoint
3 inspection on another
work station
Detection R.P.N
Step
number
1 2 56
3 96
5 160
5 140
3 63
3 63
2 4 112
4 112
4 112
4 112
4 112
3
8 96
4 8 96
8 96
4 64
7 147
Fig. 10. FMEA analysis--robot [10]
3.2. Automated process
Process
Step Function Potential Failure
number Requirements Mode
Operation Item.
1 Components components Wrong part
loading into (Stamping) orientation
the machine
Insuficient part
position
Insufficient part
position (
missing
component
extra component
2 clamping clamping parts clamping quality
3 part assy Part damage
unloading
from the
machine
4 packaging Box Wrong Container
type
Wrong number of
parts in container
Missing label
part condition skipped operation
Step Potential Effect(s) of Severity Class
number Failure
1 Improper fit to vehicle
7
Tooling damage, time
loss
8
Tooling damage, time
loss 8
Improper fit to vehicle
7
Improper fit to vehicle
7
7
2 Part may not meet
system design 7
requirements
7
7
Part may not meet
system design 7
requirements
7
3 Improper fit to vehicle
5
4 Time loss, wrong
number of parts 3
Inventory discrapency
3
Lost of tracebility
4
Improper fit to vehicle
7
Step Potential Cause(s)/ Current Process
number Mechanism(s) of Occurrence Controls
Failure Prevention
1 Operator mistake, Process steps
Standardize working 2 description in
instruction not Standardize work
fo1lowed instruction
Operator mistake, Process steps
Standardize working description in
instruction not Standardize work
followed 2 instruction, pin is
controling correct
position (sensor on
end stop)
Operator mistake, Process steps
Standardize working 2 description in
instruction not Standardize work
followed instruction
Operator mistake, Process steps
Standardize working description in
instruction not 3 Standardize work
followed instruction
component inserted Work instruction
twice
2
components sticked Work instruction
with oil
2
2 parts weren't operator training
clamped 2
parts weren't operator training
clamped 3
parts weren't operator training
clamped 3
unsifficient clamping operator training
3
unsifficient clamping operator training
3
3 Falling of the part Design of the holders
2 allowing easy part
manipulation
4 Material handler no control
mistake 4
Operator mistake, Operator training,
packaging instruction 4 packaging instruction
not followed
Operator did not print Operator training,
label or forget to 4 automatic printing
place printed label after last piece
on box inspection
operator mistake No control
3
Step Current Process Controls
number Detection Detection R.P.N
1 sensors control correct
orientation 1 14
pin is controling correct
position (sensor on end
stop)
1 16
visual control, operator
has to ensure position 2 32
with small equipment
sensor checking right
position
2 42
install sensor to control
right material thickness
before clamping 2 28
install sensor to control
right material thickness
before clamping 2 28
2 sensor checking right
position of clamps 2 28
sensors checking right
position of clamps 2 42
sensors checking right
position of clamps 2 42
sensor checking right
position of clamps 2 42
sensors checking right
position of clamps 2 42
3 Operator training
3 36
4 Operator training,
packaging instruction 8 96
Discrapancy for next
station 8 96
Reading lable on next
process step 4 64
100% Touchpoint
inspection on another 7 147
work station