PROJECT TITLE:

PROJECT VOLTES
PROCESS FAILURE MODES AND EFFECTS ANALYSIS

OCCURRENCE

CRITICALITY
DETECTION
CURRENT

SEVERITY
POTENTIAL POTENTIAL CURRENT DESIGN
FAILURE DESIGN RECOMMENDED RESPONSIBLE

RPN
ITEM FUNCTION EFFECT OF CAUSE OF CONTROLS
MODE FAILURE FAILURE (PREVENTION) CONTROLS ACTION PERSON
(DETECTION) TARGET
COMPLETION COMPLETION
DATE ACTION TAKEN EFFECTIVENESS
1 Receiving of Random Receive code from Possible File cannot be Improper USB drive Close all files in the USB Make sure that the
Codes on Different SKU's Brandtone thru flash Corruption of opened ejection from the drive before Ejection. USB drive are
drive File after PC properly scanned by
Transfer. updated Antivirus
1 1 before transfering 1 1 1
the file.

2 Storage of random code Codes are segregated Possible File cannot be Improper USB drive Close all files in the USB Make sure that the
files per 1M per SKU Corruption of opened ejection from the drive before Ejection. USB drive are
File after PC properly scanned by
Transfer. updated Antivirus
1 1 before transfering
the file.
1 1 1

Checking the LED

Indicator on the
Power Adapter of
the Laptop.

3 Transfer Code file from 1. loading of promo Power Corruption of Low Battery Always check the power Checking the Battery
flash drive to Master CPU codes from flash drive Interruption File source of the laptop Gauge that can be
to Laptop using USB that might including the Power found on the lower
2.0 port ( speed 6.0 occur during Outlet, Battery, and right of the laptop
MBPS) the transfer 1 1 Power Adapter screen 1 1 1
process

2. Create Master File Mix-up of codes Error on Double copy in the Segragate the file by 6 Checking/Verificatio
of codes for 6 during merging Traceability of column or wrong in 1 folder n of the first row and
machines for checking to master file Codes position of code last row of the code
and verification 1 column in the 1 in the master file 1 1 1
purposes master file. versus individual file

4 Load Promo codes from 1. Copy Promo Codes mix-up in the Duplication of Entry of one code One transfer of file at a Checking/Verificatio before loading of Joel Agaloos NOV. 9, 2016
master CPU to printer from Master CPU to distribution of code printing file to Multiple time n of the first row and promo codes to the
CPU Printer CPU through code file in the Printer CPU last row of the code printer PC secure
flash drive using USB printer CPU in the master file printouts of all first
2.0 port versus the printer code of master file to
5 1 cpu display 1 5 5 verify the correct
location of promo
codes

2. Save the promo Program will Delay of file saving in One transfer of file at a Checking/Verificatio
code file to "E:\ not run Production different storage time n of the first row and
[computername] address last row of the code
files\Bengar Industrial in the master file
Corporation\Bengarco versus the printer
deuploader\Codes" 2 1 cpu display 1 2 2
folder
5 3. Selection of variant Wrong Printing of Human error on 1. 3 level Password Checking/Verificatio Unique Code Oct. 24, 2016
designation of wrong the selection of protection. n of the first row and Printing Roll-
code to specific designated wrong variant a. PO#+VARIANT+Last 3 last row of the code to-Roll
SKU codes result to Char of in the master file Monitoring
rejection of Filename+Machine versus the printer form use every
products Name cpu display start of each
b. Last 3 Char of roll to verify
Filename+Printer the
4 1 Number 1 4 4 designation
c. First code of file codes to its
2. Accomplish roll to roll specific SKU.
monitoring form

6 printer head assembly Printhead Assembly Clogging of Badprint, No Long duration of Apply long term a. performing the Have a documented Edgar Rubas Nov. 4, 2016 Flowchart post Nov. 7, 2016
print codes to the Nozzle Print shutdown that shutdown procedure if proper startup procedure / flowchart or compile
Packaging Material Assembly on dried out the ink on the printer machine is procedure on the to be followed. near the
the Printhead the nozzle part. idle/not use for 3 or printer Alignment of Bengar production
more days. b. staffs and written area
checking/verification procedure
3 3 of ink pressure, 2 18 9
viscosity, and
temperature

Improper Shutdown Apply proper shutdown improper shutdown Have a documented Edgar Rubas Nov. 4, 2016 Flowchart was Nov. 7, 2016
procedure after notification appear procedure / flowchart post or
machine operation on the printer to be followed. compile near
startup Alignment of Bengar the production
3 1 1 3 3 staffs and written area
procedure

Dirty Printhead Roll to roll cleanup of a. performing the Have a documented Edgar Rubas Nov. 4, 2016 Standard
printhead proper startup standard parameters parameters for
procedure on the for pure and running pure ink and
printer ink as basis of checking running ink
b. an verification posted near
checking/verification the printer
of ink pressure, machine
viscosity, and
3 3 temperature 2 18 9
c. Roll to roll Visual
checking of the
printhead

7 Printer Sensor Sensor gives signal to No detection of no print a. improper Roll to roll checkup of Visual inspection of Enhanced the roll to roll Nov. 4, 2016
the printer to print eye mark positioning of sensor positioning and printed products. No monitoring form of
sensor calibration printed code on the Bengar to capture the
b. improper setting packaging material checking of sensor
of sensor parameters and
c. unintended condition
5 movement of 5 1 25 25 Joel Agaloos
sensor positioning
during setup.
 d. dirty lens Cleaning of lens is in No printed code on Determine how often Joel Agaloos Nov. 4, 2016 Implementatio Nov. 4, 2016
place but not identify the packaging the lens become dirty n of checklist
when to clean and not material by creating checklist. with frequency
documented. Establish frequency of of cleaning
lens cleaning by and checking.
reviewing the checklist.
5 1 1 5 5

e. Swaying of film Roll to roll checkup of Visual inspection of ULP-RnD & Flexible Increase Oct. 2016 - DONE
material during sensor positioning and printed products. No Team length and
coding calibration to ensure printed code on the width of
cetered photoeye packaging material photoeye
mark of film
materials.
5 1 1 5 5

f. defective sensor Checking of Sensor Checking of LED Maintain DONE

5 1 Lifespan and accuracy trigger indicator 1 5 5 Bengar inventory of
spare sensor

8 Promo code print quality provides the correct a. mis-aligned a. off centered a. Incorrect a. No establish Visual inspection if Enhancing Process John Patrick Deveza Nov. 7, 2016 Process Nov. 7, 2016
position, size and print code print code that printhead prevention program promo code print Flowchart by (Flexible) Flowchart
readability base on may lead to Alignment b. No establish conforme to incorporating the set- enhancement
standard requiremets rejection. b. incorrect printer prevention program standard up procedure. including set-
parameters such as c. Slitting machine must up procedure
print delay, print be coordinated Have a documented Edgar Rubas
size c. maintaining the procedure / flowchart (Bengar)
c. slitting machine machine speed to 110 to be followed.
speed did not met mpm Alignment of Bengar
3 the standard 1 d. Align code position 1 3 3 staffs and written
requirement and size procedure
e. Stop machine if
codes are not OK

b. wrong B. offsized print Slitting machine a. Established Visual inspection if Maintaining 110 speed Slitting Operator Nov. 4, 2016 Set and Nov. 4, 2016
machine speed code speed did not met procedure for set-up promo code print of slitting machine (Flexible) maintain 110
the standard and start-up of roll conforme to during coding. Rolls are mpm speed of
requirement during coding. standard subjected to double slitting
set-up of the rewind if there are machine
machine and start- defects encontered. during coding.
up of each roll. Rolls are
subjected to
b. double rewind
3 5 maintaining the 1 15 15 inspection if
machine speed to 110 defects
mpm during coding. encontered.
c. Align code position
and size
d. Stop machine if
codes are not OK
9 Promo Code Printing Printing of promo 1. Printing of Duplication of Computer and maintaining the a. Counter checking 1. Flagmark will place in Bengar staff & Nov. 4, 2016
codes on packaging single code to Codes (Double Printer machine speed to 110 of the ending codes the roll after start-up Flexible Production
materials more than 1 code) communication mpm during position or/any speed personnel
pack. failure during start- production. b. Alignment adjustment made. Rolls
up or more than checking of CPU with more than 1
the recommended versus Printer's Print flagmark are subjected
speed of 110mpm count to double rewind
during production. inspection. Portion
before and after
(around 25meters) the
flagmarks must be
removed during rewind.
5 1 4 20 5 2. Code alignment
check every 10 min
through taking picture.

2. Printer power No Code printed a. Power a. Always perform The moving code on Bengar Installed UPS
interruption on the material 3 Interruption 1 power connection the printer cpu 1 3 3
checkup screen freeze

3. Ink Shortage No Code printed Lack of Ink Supply Always perform ink a. The moving code
on the material at the ink reservoir resevoir check on the printer cpu
screen freeze.
An ink alarm will
occur.
Tower Light will turn
3 1 to red. 1 3 3

4. Diluent No Code printed Lack of makeup ink Always perform makeup a. The moving code
Shortage on the material Supply at the ink resevoir check on the printer cpu
makeup ink screen freeze.
reservoir A makeup ink alarm
will occur.
Tower Light will turn
3 1 to red. 1 3 3

Wrong code Out of specified Printer delay Delay settings of printer Continous visual Code position in promo Bengar Nov. 5, 2016
position print code settings is not sync must be set on printer inpection while box check every 10 min
(outside promo position with other printer set up/start up. running using through taking picture.
box) delay settings strobescope
4 5 1 20 20

wrong promo promo code size wrong printer Delay settings of printer Visual inpection and
code size do not conforme settings of width must be set on printer measurement every
to standard set up/start up. minutes while
specification 2 1 running using 1 2 2
strobescope

Computer hang same code Environmental no establish preventive only one code Established work Bengar Nov. 5, 2016
up printed on temperature that control program printed on packaging instruction for promo
multiple packs may contribute to materials coding and handling
heating up of printer/computer and
5 processor 4 1 20 20 machine
failure/trouble.
 sudden close of same code possible mix up in no establish preventive only one code Established work Bengar Nov. 5, 2016
computer printed on system process of control program printed on packaging instruction for promo
printer program multiple packs the printer CPU materials coding and handling
5 4 1 20 20 printer/computer and
machine
failure/trouble.
shutdown of same code a. loose power a. secure power cable only one code Established work Bengar Nov. 5, 2016
printer printed on cable connector printed on packaging instruction for promo
computer multiple packs b. malfunction of b.no establish materials coding and handling
power supply preventive control printer/computer and
4 1 program 1 4 4 machine
failure/trouble.

Waste code tagging Identify Good codes wrong tagging good codes to operator established procedure No establish checking of total Bengar Nov. 14, 2106 Enhanced
from waste codes of codes be declared as mistakenly provide for proper declaration detection number of promo monitoring of
waste codes waste codes of good codes. Conduct codes per finish good bad/good
instead of good meeting and cascade to roll. codes
codes all operators and post
the procedure on the Approximately 13,076 ±
5 1 slitting section 1 5 5 70 promo code per out
 PROJECT TITLE:
PROJECT VOLTES
SYSTEM FAILURE MODES AND EFFECTS ANALYSIS

OCCURRENCE

CRITICALITY
DETECTION
CURRENT

SEVERITY
POTENTIAL POTENTIAL CURRENT DESIGN
FAILURE DESIGN RECOMMENDED RESPONSIBLE

RPN
ITEM FUNCTION EFFECT OF CAUSE OF CONTROLS
MODE FAILURE FAILURE (PREVENTION) CONTROLS ACTION PERSON
(DETECTION) TARGET
COMPLETION COMPLETION
DATE ACTION TAKEN EFFECTIVENESS
1 Inspection of rubber The purpose of a printing defect Rejection of lapses in inspection per change
roller bearings prior to roller bearing is to appear Build-up printed output, conducting job
use reduce rotational of static charge source of inspection
friction . ignition once
fuel material
and oxygen are
presence, it can 4 1 1 4 4
create fire

2 Viscom printer will execute overlapping of No printing of slitting machine maintain recommended Beacon light will lit
the printing of promo go signal from promo code overspeeding speed of slitting red light and buzzer
codes to the wrapper sensor to machine will sound
material printer 4 1 1 4 4

Printer is not in No printing of Bengar technician Always check the tower Tower beacon Enhanced the roll to roll
ready status promo code did not set the light before start up indicator monitoring form of
machine to ready Bengar to capture the
status checking Tower beacon
and printer status
Have a documented
procedure / flowchart
to be followed.
4 2 1 8 8 Alignment of Bengar Edgar Rubas 7-Nov-16
staffs and written
procedure

3 sending of "print ready for PC to recognize if PC failed to same code will loosing RS232 cable secure the rs232 visual inspection
transmission code" the printers are ready receive the be printed between PC and connection by during printing
to receive promo "print ready" repeatedly the printer tightening the screw
code transmission (duplicate code) lock on the serial
uses rs232 connection code from the connector
with speed of 20 Kbps printer 4 1 1 4 4
transmission rate

Bengar code same code will Bengar technician roll to roll check up of visual inspection
uploader be printed did not run the the Bengar code during printing
program that repeatedly Bengar code uploader program
manage the (duplicate code) uploader program
code is not 4 1 1 4 4
running
printer is not double code during printing a.maintain a. Beacon light will Code alignment check
ready to receive process another recommended speed of lit red light and every 10 min through
new code signal of sensor to slitting machine buzzer will sound taking picture.
print occurred b.end of the roll
promo code Have a documented
positioning all 6 procedure / flowchart
computer vs printer to be followed.
Alignment of Bengar
5 1 2 10 5 staffs and written Bengar 7-Nov-16
procedure

do not perform any only the Bengar tech end of the roll declare the printer area
task on the pc supervisor is allowed to promo code as a restricted area
while printing of operate the computer positioning all 6 during promo code
5 promo codes 1 and can give signal to computer vs printer 2 10 5 printing Bengar 7-Nov-16
stop the printing
 Effect Severity of effect on product & Process Rank
Failure to meet
customer
May endanger customer-supplier relationship
requirement 100% of product 5
may have to be scrapped. Line shutdown or stop ship.
Major Effect Deviation from primary process including decreased line speed or
added manpower. 4
Significant Effect
100% of production run may have to be reworked off line and accepted 3
Moderate A portion of the production run may have to be reworked in station
before it is processed 2
Minor
slight incovenience to the process, operation and in the operator 1
 Likelihood of failure Possible Failure Rate Rank
Frequent 1>1 5
Probable 1 in 2 4
Occasional 1 in 4 3
unlikely 1 in 6 2
Extremely Unlikely <1 in 8 1
Detection Criteria Ranking
Almost impossible No known control available to detect failure mode 5
Remote Remote likelihood current control will detect failure mode 4
Moderate Moderate likelihood current control will detect failure mode 3
high high likelihood current control(S) will detect failure mode 2
current control(s) almost certain to detect the fialure mode. Reliable
almost certain detection controls are known with similar process 1
 5 5 10 15 20 25 LEGEND
SEVERITY 4 4 8 12 16 20 HIGH Critical. The identified failure m
3 3 6 9 12 15 MEDIUM Moderately critical. Needs furt
2 2 4 6 8 10 LOW Not critical. The identified failu
1 1 2 3 4 5
1 2 3 4 5
OCCURRENCE
Critical. The identified failure mode requires addditional controls to mitigate or/eliminate the impact
Moderately critical. Needs further improvement on existing controls. Additional control as deem necessary
Not critical. The identified failure mode can be controlled by existing procedure and estacblished control meaasures