Page 1 of 20

Process Failure Mode Effects Analysis

Item/Part#: 3595-1038 Process Owner: FMEA #: 3595-1038
Rev: 6 Process: FMEA Rev:
Customer: FMEA Date:
FMEA Team:
Supplier: Christopher Tool & Mfg. Co. Prepared by:

* SEV, OCC, & DET scoring per the tables provided in WPQR-9102, unless otherwise approved by Woodward.
Resulting Action(s)

C
Item / Function / S l Potential Cause(s) O D R Responsibility & S O D R
Op / Potential Failure Potential Effect(s) Current Controls Current Controls Recommended
ID # Process E a / Mechanism(s) of C E P Target Completion Action(s) Taken E C E P
Ref # Mode of Failure Prevention Detection Action(s)
Description V s Failure C T N Date V C T N
s

5 SAWING-Cut Blanks are cut Parts will not be Saw is not set-up Measure parts after Adjust saw. Change
blanks 5.937 ± 1/64 undersized. usable for this part. correctly. Saw saw cutting. 0 blade. 0
long. malfunction.
10 HEAT TREAT- Parts do not meet Parts will be Oven malfunction. Certification Anneal and
Cut ends must be
Harden, Temper customer drawing reworked or required. reharden.
square to the O.D.
and Stress Relieve requirements per approved by
within .015 total.
Hardness:
Remove 30-36
burrs and CTM P.O. customer.
Rc
break sharp edges
-----------------------
on belt grinder.
Certs Required

20 CNC TURNING Parts do not meet Parts will not meet Programming is Operators are Correct program,
CENTER WORK- CTM in-process customer incorrect. expected to gage adjust or replace
Turn the blank from drawing requirements. Tools are not set- and adjust tooling tooling.
the right side per requirements. up correctly. as needed, plus a
CTM T-4836 sheet Tool breakage. 1st. Piece is
1: required to pass
Face to cleanup our inspection
only. department.
Center drill #3 MAX
as shown.
0 0
Hold all lengths
near mean size for
mfg.
Inspect runouts:
All diameters
concentric within .
002 T.I.R.

30 CNC TURNING Parts do not meet Parts will not meet Programming is Operators are Correct program,
CENTER WORK- CTM in-process customer incorrect. expected to gage adjust or replace
Turn the blank from drawing requirements. Tools are not set- and adjust tooling tooling.
the right side per requirements. up correctly. as needed, plus a
CTM T-4836 sheet Tool breakage. 1st. Piece is
2: required to pass
our inspection
Center drill as department.
shown--#4 max. 0 0
See SS-81.
Inspect runout
between centers:
All diameters
concentric within .
002 T.I.R.

4-06-3451 Rev 1 / 30-Jan-2009

40 O.D. GRINDING- Parts do not meet The splines will be Machine Visual, and spline Adjust grinder. Page 2 of 20
Lap grinding traveler undersized. malfuntion, gage.
centers 100% for requirement. operator did not
mfg. check parts.

Rough grind the

O.D. of the (2) 0 0
Splines to cleanup
only.
Leave .005 g/s per
side for mfg.

50 DEBURRING- Part still has burrs Rework parts. Operator did not Visual, and Better lighting and
Remove burrs and or the edges have see or feel burrs, inspection. magnifying lens for
break sharp edges. exceeded the plus was not able operator. Plus being
See drawing notes. drawing to hold customer 0 able to understand 0
requirements. tolerances. and hold customer
requirements.

60 INSPECTION, IN Inspector did not Rework parts. Inspector was Additional blueprint
PROCESS-In- check dimension Possibly scrap distracted or does or use of precision
Process Inspect correctly or did not parts. not comprehend gages training.
prior to outside understand the the dimension.
processes. requirement.

Verify part count. 0 0

Verify that all
preceding
operations have
been completed
and are signed off.

70 SPLINING & GEAR Spline is Scrap parts. Incorrect set-up of Certifications Inspection of parts. Replace hob.
CUTTING-Finish undersized. hob. required.
shape and inspect
the (2) Involute
Splines per
Woodward
Governor drawing
#3595-1038 and
drawing notes 8 &
9.

Hold concentricity 0 0
between centers
within .001 T.I.R.

Gaging
requirements per
Woodward SS-201
rev. V.
-----------------------
Certs Required

80 RECEIVING Part count is Short parts, or Lost or scrapped Count and inspect
INSPECTION- incorrect. Parts do scrap parts. parts from vendor. parts to traveler.
Inspect incoming not meet Subcontractor did
parts to verify the compliances to the not check parts.
part count and the P.O.
vendor compliance
to the requirements
of the previous
0 0
operation purchase
order.
Visually inspect all
parts for handling
damage (nicks and
dings).

4-06-3451 Rev 1 / 30-Jan-2009

90 DEBURRING- Part still has burrs Rework parts. Operator did not Visual, and Better lighting and Page 3 of 20
Remove burrs and or the edges have see or feel burrs, inspection. magnifying lens for
break sharp edges. exceeded the plus was not able operator. Plus being
See drawing notes. drawing to hold customer 0 able to understand 0
requirements. tolerances. and hold customer
requirements.

100 HEAT TREAT- Parts do not meet Parts will be Oven malfunction. Certification Anneal and
Core Harden per customer drawing reworked or required. reharden.
Woodward requirements. approved by
Governor drawing customer.
3595-1038, note
#12, IAW SP-908
rev. B-B. 0
Core Hardness: 44-
50 Rc
Do not nitride.
------------------
Certs Required

110 RECEIVING Part count is Short parts, or Lost or scrapped Count and inspect
INSPECTION- incorrect. Parts do scrap parts. parts from vendor. parts to traveler.
Inspect incoming not meet Subcontractor did
parts to verify the compliances to the not check parts.
part count and the P.O.
vendor compliance
to the requirements
of the previous
operation purchase 0 0
order.
Visually inspect all
parts for handling
damage (nicks and
dings).

120 STRAIGHTENING- Parts do not meet Rework parts. Center lap is Measure and
Lap centers 100%. runout misaligned, or record results
Note: Inspect the requirements. broken stone. 100%.
parts between Needs to be
centers, and check straightened.
the true position of
the pitch diameters
of both splines
using gage pins.
Use the spline
gages.
Determine if parts
require
straightening and
record results.
Check runout of the
finished splines
between centers.
Maximum runout to 0 0
be within .001 T.I.R.
Also inspect the
runout of the datum
-A- flange.
Straighten and
Stress relieve any
straightened parts
as follows:

NOTE: STRESS
RELIEF IS
REQUIRED.

Straightening shall
be accomplished at
400°± 25°F
followed by stress
relieving for 2 hours
minimum at 450°±
25°F.

Re-inspect after
stress relief.
4-06-3451 Rev 1 / 30-Jan-2009
130 O.D. GRINDING- Parts are Scrap parts. Machine Visual and inspect. Re-dress wheel and Page 4 of 20
***Allow for .005 g/s undersized to the Malfunction. change set-up.
on the right side traveler
face of the large requirements.
flange.***
Green grind from
the left side:

Finish grind the

LEFT end face.
Green grind the
datum -A- face,
leaving .002 g/s per
side.
0 0
Green grind the
spline O.D.
leaving .002 g/s per
side.

Do not grind the

O.D. groove or the
Ø.320 diameters.

140 O.D. GRINDING- Parts are Scrap parts. Machine Visual and inspect. Re-dress wheel and
***Allow for .002 g/s undersized to the Malfunction. change set-up.
on the datum -A- traveler
face.*** requirements.
Green grind right
side diameters:

Finish grind the

RIGHT end face.
Do not grind the
existing Ø.350
diameter.

Green grind the

Ø.3163, Spline O.D
and Ø.47525
diameters leaving .
002 g/s per side.
Leave .002 g/s on 0 0
the shoulders and
chamfers.

Green grind the

right side of the
large flange leaving
.002 g/s.
(Allow for .002 g/s
on datum -A-).

4-06-3451 Rev 1 / 30-Jan-2009

150 O.D. GRINDING- Page 5 of 20
***Allow for .002 g/s
on the datum -A-
face.***

Finish grind the

Ø.373/.371
diameter groove, 0 0
concentric to -B-
and -C- within .002.
Hold 32 Ra finish.

160 EDM MACHINING- Holes are out of Re-work or scrap. Machine Inspect dimensions. Change settings or
EDM angular holes position and malfunction. electrodes.
as required per oversized.
drawing note #11.

***Allow for .002 g/s

on datum -A-
face.*** 0 0
Qualification
required per SP-
1084.

170 DEBURRING- Part still has burrs Rework parts. Operator did not Visual, and Better lighting and
Remove burrs and or the edges have see or feel burrs, inspection. magnifying lens for
break sharp edges. exceeded the plus was not able operator. Plus being
drawing to hold customer 0 able to understand 0
requirements. tolerances. and hold customer
requirements.

180 NITRIDE-Nitride Parts do not meet Parts may or Atmosphere of Hardness check for Monitor settings and
per Woodward custom drawing maynot be useable application is correct depth and inspect.
Governor drawing requirements pending customer contaminated. visual of correct
3595-1038, including correct approval. areas.
including drawing areas to be
notes #7 & #12, masked.
IAW SP-908 rev. B-
B.

Core Hardness: 44-

50 Rc
Case Hardness: 90
HR15N
Final Case Depth: .
006-.015
Recommended
Applied Case
Depth: .012-.020
Max stock removal 0 0
after nitriding: .005
Max permissible
White Layer: .0004
Inspect Case Depth
per drawing note
#21.
------------------
Certs Required

4-06-3451 Rev 1 / 30-Jan-2009

190 O.D. GRINDING- Dimensions are Scrap. Machine Visual and inspect. Change settings or Page 6 of 20
O.D. grind to undersized. malfunction, or wheel and re-dress.
remove the excess incorrect wheel.
stock and finish
grind the Ø.320
diameters x 2
places to the left of
the flange.

Finish grind datum

-A- shoulder. 0 0
Leave .0005 max
lapping stock.
Hold best surface
finish possible.

200 O.D. GRINDING- Dimensions are Scrap. Machine Visual and inspect. Change settings or
Grind from the undersized. malfunction, or wheel and re-dress.
LEFT side: incorrect wheel.

Finish grind the

Spline major
diameter. 0 0
Finish grind the
Ø.470/.472
diameter.

210 O.D. GRINDING- Dimensions are Scrap. Machine Visual and inspect. Change settings or
From the right side: undersized. malfunction, or wheel and re-dress.
incorrect wheel.
Remove the excess
stock and finish
grind the major
diameter of the
Ø.3125-24 UNFJ- 0 0
3A thread.
Finish grind the .
030 X 45° chamfer.

220 O.D. GRINDING- Dimensions are Scrap. Machine Visual and inspect. Change settings or
Finish grind all undersized. malfunction, or wheel and re-dress.
diameters on the incorrect wheel.
right side.

Leave .0002 max.

lapping stock on
the Ø.3163/.3158
and
Ø.47525/.47475 0 0
diameters.
Hold best
microfinish possible
(8 Ra max, 2 Ra
required).

230 O.D. GRINDING- Dimensions are Scrap. Machine Visual and inspect. Change settings or
From the left end: undersized. malfunction, or wheel and re-dress.
incorrect wheel.
Finish grind the
Ø.228/.226 Shear 0 0
Section diameter.

4-06-3451 Rev 1 / 30-Jan-2009

240 DEBURRING- Part still has burrs Rework parts. Operator did not Visual, and Better lighting and Page 7 of 20
Remove burrs and or the edges have see or feel burrs, inspection. magnifying lens for
break sharp edges. exceeded the plus was not able operator. Plus being
drawing to hold customer 0 able to understand 0
requirements. tolerances. and hold customer
requirements.

250 THREAD Parts do not meet Rework or scrap Incorrect set-up. Thread gages.
GRINDING-Finish CTM P.O. Machine
grind the Ø.3125- requirements per malfunction.
24 UNFJ-3A drawing.
Thread per
Woodward 0 0
Governor
specification SS-
130 rev. CG.

260 SURFACE LAP- N/A if already

Lap Splines if accepted.
required to accept
Ring Gages. 0 0

270 WASH PARTS- Parts are dirty, Rework. Used a different Visual Improve training and
Wash all parts in cleaning solvent. directions on
clean Zep Dyna traveler.
143 solvent, drain
and blow dry with
clean shop air.
Visually inspect
parts inside and out
for cleanliness.
0 0
Dip in MIL-C-15074
fingerprint
neutralizer and Oil
parts to prevent
rusting.

280 INSPECTION, IN Inspector did not Rework parts. Inspector was Additional blueprint
PROCESS-In- check dimension Possibly scrap distracted or does or use of precision
Process Inspect correctly or did not parts. not comprehend gages training.
prior to outside understand the the dimension.
processes. requirement.

Verify part count.

Verify that all
preceding
operations have
been completed 0 0
and are signed
off.In-Process
Inspect prior to
outside processes.

4-06-3451 Rev 1 / 30-Jan-2009

290 SURFACE LAP- Parts are out of Rework Incorrect lapping Measure flatness Monitor and inspect . Page 8 of 20
Finish lap the tolerance. compound or and microfinish.
datum -A- shoulder procedure.
to attain .000025
flatness and 2 Ra
microfinish per the
requirements of
Woodward
Governor drawing
3595-1038 and
drawing notes #13
and #15.

Also lap the

opposite shoulder
to satisfy drawing
requirements.
0 0
Ring Lap the
Ø.47525/.47475 [-
B-] diameter and
the Ø.3163/.3158
diameter to meet
the 2 Ra drawing
requirement.

300 RECEIVING
INSPECTION-
Inspect incoming
parts to verify the
part count and the
vendor compliance
to the requirements
of the previous
operation purchase 0 0
order.
Visually inspect all
parts for handling
damage (nicks and
dings).

310 LASER MARKING- Incorrect marking Rework Operator Visual and approval Improve training and
Laser mark on the or location. misinterpreted the by different person. notes in files.
noted area as location or entered
required per wrong
drawing note #10 numbers/letters into
the machine.
Mark as follows: 0 0
66503-3595-1038
4

4-06-3451 Rev 1 / 30-Jan-2009

320 INSPECTION, IN Inspector did not Rework parts. Inspector was Additional blueprint Page 9 of 20
PROCESS-In- check dimension Possibly scrap distracted or does or use of precision
Process Inspect correctly or did not parts. not comprehend gages training.
prior to outside understand the the dimension.
processes. requirement.

Verify part count.

Verify that all
preceding 0 0
operations have
been completed
and are signed off.

330 MISC. COATINGS- Coating is Rework Rust or Visual. Replace outdated

Brush Coat noted inadequate or discoloration on coating.
area only, with the wrong location. part.
required material,
per drawing notes
#18 and #19.

Material: Corrosion
Preventative film
per Woodward-
Governor SP-949
rev. Y (Sandstrom
9AV-35 or 0 0
alternates).
----------------------
Certs Required

340 RECEIVING Part count is Short parts, or Lost or scrapped Count and inspect
INSPECTION- incorrect. Parts do scrap parts. parts from vendor. parts to traveler.
Inspect incoming not meet
parts to verify the compliances to
part count and the CTM P.O.
vendor compliance
to the requirements
of the previous
operation purchase
order. 0 0
Visually inspect all
parts for handling
damage (nicks and
dings).

350 INSPECTION, Inspector did not Out of tolerance Inspector was Documentation of Implement SPC
FINAL-Final Inspect check dimension part gets to distracted or does all dimensions per monitoring
complete per correctly or did not customer. not comprehend customer throughout the
drawing and the understand the the dimension. requirements and manufacturing
requirements of the requirement. CTM AQL . 0 process. 0
Customer Purchase
Order.

4-06-3451 Rev 1 / 30-Jan-2009

360 PRE-SHIPPING- Incorrect quantity, Rework An operation was Visual. Standart checklist of Page 10 of 20
INSPECTION-Prior dirty or nicked not completed. criteria before
to packing, when all parts, operations Parts were not packing.
parts are complete, are not signed off. cleaned properly.
inspect this traveler
to verify all
operations have
been signed off and
all part counts are
correct.

Visually inspect the

entire lot for foreign
objects (chips/dirt
inside and out), the
correct marking,
handling nicks and
general
appearance.

370 PACKAGE PARTS- Not properly Parts may become Incorrect Traveler sign-off. Improve traveler
Dip in Preserative packaged for nicked or broken packaging. instructions for
Oil and drain. handling. and possible scrap. proper packaging.
Place in **VCI**
plastic bags and
heat seal.

Package in
protective
containers as
required.
Pack containers in
an appropriate box
with all necessary
certifications and
inspection reports.

Label package and

attach shipping 0 0
carrier label.
Place package on
the proper cart to
be picked-up by the
shipping carrier.

4-06-3451 Rev 1 / 30-Jan-2009

 Page 11 of 20

e Mode Effects Analysis

3595-1038

Resulting Action(s)

Status

4-06-3451 Rev 1 / 30-Jan-2009

 Page 12 of 20

4-06-3451 Rev 1 / 30-Jan-2009

 Page 13 of 20

4-06-3451 Rev 1 / 30-Jan-2009

 Page 14 of 20

4-06-3451 Rev 1 / 30-Jan-2009

 Page 15 of 20

4-06-3451 Rev 1 / 30-Jan-2009

 Page 16 of 20

4-06-3451 Rev 1 / 30-Jan-2009

 Page 17 of 20

4-06-3451 Rev 1 / 30-Jan-2009

 Page 18 of 20

4-06-3451 Rev 1 / 30-Jan-2009

 Page 19 of 20

4-06-3451 Rev 1 / 30-Jan-2009

 Page 20 of 20

4-06-3451 Rev 1 / 30-Jan-2009