Version Control

Version Revision notes

0 Rewritten to the standard agreed in November 2017

1
2
3
4
5

Template Instructions
1 For Reference PFMEA press option 1.
For Process / Product application press option 2. to expand the full PFMEA
2 columns.
 Quality
ersion Control
GPO
Date Who GPO Notes Andy Mantle
Theodoros Panagiotidis Andy
12/14/2017 Gregor Kappmeyer Mantle
Andy Mantle
 Quality Check
GPO Head of ME (Central Team)
Andy Mantle Phil Holmshaw
 WARNING STATEMENT AND DESTINATION CONTROL STATEMENT

Export Control
Jurisdiction Classification Date
(Rating)
UK Not Listed 14-Dec-17

© 2017 Rolls-Royce Plc. All Rights Reserved.

This document and the information embodied herein is the property of and proprietary to
Rolls-Royce Corporation, and shall not, without prior written permission of Rolls-Royce
Corporation, be used or disclosed in whole or in part to third parties. This legend shall be
included on any reproduction of this document in whole or in part.

This document contains information which is proprietary and confidential to Rolls-Royce

and may not be used or reproduced, in whole or in part, or communicated to any person
not employed by Rolls-Royce, without the express written consent of Rolls-Royce.
CONTROL STATEMENT

Rated by

Andy Mantle
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Machine geometric/dynamic
Length / Size Too Long / Oversize
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Part distortion from residual

Stress

Part incorrectly loaded in fixture

Datum setting issues

Tool-holder wear/damage

Part temperature not controlled

Incorrect t coolant application

Machine geometric/dynamic
Too short / Undersize
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

 Wrong tool or/and wrong tool
holder or/and tool setting
incorrect.

Part distortion from residual

Stress

Part incorrectly loaded in fixture

Tool-holder wear/damage

Part temperature not controlled

Incorrect coolant application

Datum setting issues

 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring
Tool preset check.
CMM Inspection
Spindle check.
Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Method sealed once approved.
CMM Inspection
Error proof fixture.
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Part setting / checking. CMM Inspection
Tool-holder preset check. CMM Inspection
Coolant check - asset care.
Coolant monitoring.
CMM Inspection
Approved and locked master NC
program.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring
Tool preset check.
CMM Inspection
Spindle check.
 Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Method sealed once approved.
CMM Inspection
Error proof fixture.
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Tool-holder preset check. CMM Inspection
Coolant check - asset care.
Coolant monitoring.
CMM Inspection
Approved and locked master NC
program.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.
Part setting / checking. CMM Inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Machine geometric/dynamic
Thickness Too Thick
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Part distortion from residual

Stress

Part incorrectly loaded in fixture

Datum setting issues

Tool-holder wear/damage

Part temperature not controlled

Incorrect coolant application

Machine geometric/dynamic
Too Thin
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

 Wrong tool or/and wrong tool
holder or/and tool setting
incorrect.

Part distortion from residual

Stress

Part incorrectly loaded in fixture

Datum setting issues

Tool-holder wear/damage

Part temperature not controlled

Incorrect coolant application

 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring
Tool preset check.
CMM Inspection
Spindle check.
Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Method sealed once approved.
CMM Inspection
Error proof fixture.
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Part setting / checking. CMM Inspection
Tool-holder preset check. CMM Inspection
Coolant check - asset care.
Coolant monitoring.
CMM Inspection
Approved and locked master NC
program.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring
Tool preset check.
CMM Inspection
Spindle check.
 Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Method sealed once approved.
CMM Inspection
Error proof fixture.
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Part setting / checking. CMM Inspection
Tool-holder preset check. CMM Inspection
Coolant check - asset care.
Coolant monitoring.
CMM Inspection
Approved and locked master NC
program.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Machine geometric/dynamic
Surface Finish Surface Too Rough
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Part incorrectly loaded in fixture

Incorrect coolant application

Tool-holder wear/damage

Swarf build up/nesting

Wrong tool or/and wrong tool

Too smooth holder or/and tool setting
incorrect.

Incorrect program loaded to

machine and/or incorrect position
in program
 Control (Prevention)
Typical provention controls used
to avoid potential causes occuring
Machine maintenance.
Independent Overcheck of
programs.
Method & parameters sealed
once approved.
Tool preset check.
Power Monitoring
Tool preset check.
Spindle check.
Tool preset check.
Power Monitoring
Manual check of tool grade.
Approved and locked master NC
program.
Error proof fixture.
fixture maintenance.
operator fixture check.
Coolant check - asset care.
Coolant monitoring.
Tool-holder preset check.
Coolant check - asset care
Method sealed once approved
Tool preset check.
Power Monitoring
Manual check of tool grade.
Approved and locked master NC
program.
Independent Overcheck of
programs.
Method & parameters sealed
once approved.
Control (Detection)
How would we detect that the
failure mode has occurred
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
Bino/ Penetrant / Manual
Inspection.
Surface Roughness Inspection.
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Machine geometric/dynamic
Flatness Not Flat (above spec)
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Part distortion from residual

Stress

Part incorrectly loaded in fixture

Datum setting issues

Tool-holder wear/damage

Part temperature not controlled

Incorrect coolant application

 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring
Tool preset check.
CMM Inspection
Spindle check.
Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Method sealed once approved.
CMM Inspection
Error proof fixture.
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Part setting / checking. CMM Inspection
Tool-holder preset check. CMM Inspection
Coolant check - asset care.
Coolant monitoring.
CMM Inspection
Approved and locked master NC
program.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Out of Profile - Insufficient cut - Machine geometric/dynamic

Profile
material on errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

Datum setting issues

Out of Profile - excessive cut - Machine geometric/dynamic

material off errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program
 Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

Datum setting issues

 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

Visual and optical projection of

Machine maintenance. component
CMM Inspection
Independent Overcheck of
Visual and optical projection of
programs.
component
Method & parameters sealed
CMM Inspection
once approved.
Visual and optical projection of
Tool preset check.
component
Power Monitoring
CMM Inspection
Visual and optical projection of
Tool preset check.
component
Spindle check.
CMM Inspection
Tool preset check.
Power Monitoring Visual and optical projection of
Manual check of tool grade. component
Approved and locked master NC CMM Inspection
program.
Visual and optical projection of
Tool-holder preset check. component
CMM Inspection
Error proof fixture. Visual and optical projection of
fixture maintenance. component
operator fixture check. CMM Inspection
Visual and optical projection of
Coolant check - asset care.
component
Coolant monitoring.
CMM Inspection
Visual and optical projection of
Coolant check - asset care
component
Method sealed once approved
CMM Inspection
Visual and optical projection of
Part setting / checking. component
CMM Inspection
Visual and optical projection of
Machine maintenance. component
CMM Inspection
Independent Overcheck of
Visual and optical projection of
programs.
component
Method & parameters sealed
CMM Inspection
once approved.
 Visual and optical projection of
Tool preset check.
component
Spindle check.
CMM Inspection
Tool preset check.
Power Monitoring Visual and optical projection of
Manual check of tool grade. component
Approved and locked master NC CMM Inspection
program.
Visual and optical projection of
Tool-holder preset check. component
CMM Inspection
Error proof fixture. Visual and optical projection of
fixture maintenance. component
operator fixture check. CMM Inspection
Visual and optical projection of
Coolant check - asset care.
component
Coolant monitoring.
CMM Inspection
Visual and optical projection of
Coolant check - asset care
component
Method sealed once approved
CMM Inspection
Visual and optical projection of
Part setting / checking. component
CMM Inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Machine geometric/dynamic
Radius Above spec / Too Big
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

Machine geometric/dynamic
Below spec / Too Small
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring
Tool preset check.
CMM Inspection
Spindle check.
Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Tool-holder preset check. CMM Inspection
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.
Coolant check - asset care
CMM Inspection
Method sealed once approved

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring
Tool preset check.
CMM Inspection
Spindle check.
Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Tool-holder preset check. CMM Inspection
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
 Coolant check - asset care.
CMM Inspection
Coolant monitoring.
Coolant check - asset care
CMM Inspection
Method sealed once approved
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Machine geometric/dynamic
Angle Too big / Excessive angle
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool wear / damaged tool

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

Datum setting issues
Machine geometric/dynamic
Too small / Insufficient angle
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.
 Tool wear / damaged tool

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

Datum setting issues
 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring

Tool preset check.

CMM Inspection
Spindle check.

Tool preset check.

Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Tool-holder preset check. CMM Inspection
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.
Coolant check - asset care
CMM Inspection
Method sealed once approved
Part setting / checking. CMM Inspection
Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring

Tool preset check.

CMM Inspection
Spindle check.
 Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Tool-holder preset check. CMM Inspection
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.
Coolant check - asset care
CMM Inspection
Method sealed once approved
Part setting / checking. CMM Inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Machine geometric/dynamic
Position Out of Position
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

Datum setting issues
 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

Machine maintenance. CMM Inspection

Independent Overcheck of
programs.
CMM Inspection
Method & parameters sealed
once approved.
Tool preset check.
CMM Inspection
Power Monitoring
Tool preset check.
CMM Inspection
Spindle check.
Tool preset check.
Power Monitoring
Manual check of tool grade. CMM Inspection
Approved and locked master NC
program.
Tool-holder preset check. CMM Inspection
Error proof fixture.
fixture maintenance. CMM Inspection
operator fixture check.
Coolant check - asset care.
CMM Inspection
Coolant monitoring.
Coolant check - asset care
CMM Inspection
Method sealed once approved
Part setting / checking. CMM Inspection
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Machine geometric/dynamic
Diameter Too Small
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

Datum setting issues

Machine geometric/dynamic
Too Big
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program
 Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool-holder wear/damage

Part incorrectly loaded in fixture

Incorrect coolant application

Swarf build up/nesting

Datum setting issues

Machine geometric/dynamic
Not Present
errors / Machine wear

Incorrect program loaded to

machine and/or incorrect position
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Tool-holder wear/damage

Part incorrectly loaded in fixture

 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

(Bore) Micrometer manual

Machine maintenance. Inspection.
CMM Inspection.
Independent Overcheck of
(Bore) Micrometer manual
programs.
Inspection.
Method & parameters sealed
CMM Inspection.
once approved.
(Bore) Micrometer manual
Tool preset check.
Inspection.
Power Monitoring
CMM Inspection.
(Bore) Micrometer manual
Tool preset check.
Inspection.
Spindle check.
CMM Inspection.
Tool preset check.
Power Monitoring (Bore) Micrometer manual
Manual check of tool grade. Inspection.
Approved and locked master NC CMM Inspection.
program.
(Bore) Micrometer manual
Tool-holder preset check. Inspection.
CMM Inspection.
Error proof fixture. (Bore) Micrometer manual
fixture maintenance. Inspection.
operator fixture check. CMM Inspection.
(Bore) Micrometer manual
Coolant check - asset care.
Inspection.
Coolant monitoring.
CMM Inspection.
(Bore) Micrometer manual
Coolant check - asset care
Inspection.
Method sealed once approved
CMM Inspection.
(Bore) Micrometer manual
Part setting / checking. Inspection.
CMM Inspection.
(Bore) Micrometer manual
Machine maintenance. Inspection.
CMM Inspection.
Independent Overcheck of
(Bore) Micrometer manual
programs.
Inspection.
Method & parameters sealed
CMM Inspection.
once approved.
 (Bore) Micrometer manual
Tool preset check.
Inspection.
Power Monitoring
CMM Inspection.
(Bore) Micrometer manual
Tool preset check.
Inspection.
Spindle check.
CMM Inspection.
Tool preset check.
Power Monitoring (Bore) Micrometer manual
Manual check of tool grade. Inspection.
Approved and locked master NC CMM Inspection.
program.
(Bore) Micrometer manual
Tool-holder preset check. Inspection.
CMM Inspection.
Error proof fixture. (Bore) Micrometer manual
fixture maintenance. Inspection.
operator fixture check. CMM Inspection.
(Bore) Micrometer manual
Coolant check - asset care.
Inspection.
Coolant monitoring.
CMM Inspection.
(Bore) Micrometer manual
Coolant check - asset care
Inspection.
Method sealed once approved
CMM Inspection.
(Bore) Micrometer manual
Part setting / checking. Inspection.
CMM Inspection.
Visual Inspection.
Machine maintenance.
CMM Inspection.
Independent Overcheck of
programs. Visual Inspection.
Method & parameters sealed CMM Inspection.
once approved.
Tool preset check. Visual Inspection.
Power Monitoring CMM Inspection.
Tool preset check. Visual Inspection.
Spindle check. CMM Inspection.
Tool preset check.
Power Monitoring
Visual Inspection.
Manual check of tool grade.
CMM Inspection.
Approved and locked master NC
program.
Visual Inspection.
Tool-holder preset check.
CMM Inspection.
Error proof fixture.
Visual Inspection.
fixture maintenance.
CMM Inspection.
operator fixture check.
 Requirements (Product
Potential Failure Mode Potential Cause(s) of Failure
Characteristics)

What is the Product Characteristic

1st level why of the 5 whys (the
we need to achieve during the
top things we would look at)…if I
process (diameter, depth, length, What could be wrong with the
get this occuring when I use this
radius, CME, surface finish, Product Characteristic (hole too
FMEA then I need an
metallurgy standard, adhesion, big, hole too small, CME outside
improvement activitiy that would
residual stress, coverage etc - or spec, too rough surface finish)
understand root cause and close
avoid such as damage, weld
out plan.
spatter etc)

Incorrect program loaded to

Conforms to CME 5043 / surface Failure to meet CME 5043 surface
machine and/or incorrect position
integrity requirement integrity requirements
in program

Tool wear / damaged tool

Cutting tool deflection

Wrong tool or/and wrong tool

holder or/and tool setting
incorrect.

Incorrect coolant application

Swarf build up/nesting

 Control (Prevention) Control (Detection)

Typical provention controls used How would we detect that the

to avoid potential causes occuring failure mode has occurred

Independent Overcheck of
programs. NDT Inspections (FPI, MPI, Eddy
Method & parameters sealed Current, Visual/Bino)
once approved.
Tool preset check. NDT Inspections (FPI, MPI, Eddy
Power Monitoring Current, Visual/Bino)
Tool preset check. NDT Inspections (FPI, MPI, Eddy
Spindle check. Current, Visual/Bino)
Tool preset check.
Power Monitoring
NDT Inspections (FPI, MPI, Eddy
Manual check of tool grade.
Current, Visual/Bino)
Approved and locked master NC
program.
Coolant check - asset care. NDT Inspections (FPI, MPI, Eddy
Coolant monitoring. Current, Visual/Bino)
Coolant check - asset care NDT Inspections (FPI, MPI, Eddy
Method sealed once approved Current, Visual/Bino)
 Cause Description
Cutting tool push-off, pull-
out/push-in.
Cutting tool deflection
Tool vibration.
Spindle distortion.

Machine datum incorrectly

manually/automatic set.
Incorrect application of
coordinate systems.
Incorrect verification settings
(probe errors: qualification,
Foreign Object Debris,
Datum setting issues
worn/damaged probe, ruby size,
etc.).
Incorrect incoming Condition of
Supply.
Incorrect dimensional
measurement of part
(inappropriate Gauge R&R).

Reset of program during

processing / power cut / rework,
Incorrect program loaded to wrong speed/feed/depth of
machine and/or incorrect position cut/cutting strategy.
in program Manually altered feed / speed
rate.
Tolerance level used within CAM.

Wrong type, pressure, flow,

concentration, temperature,
Incorrect coolant application
direction, cleanliness.
Swarf obstructing coolant.

Machine axis
misalignement/backlash due to
machine wear/collision.
Insufficient machine warm up.
Kinematic errors.
Thermal induced errors.
Machine geometric/dynamic
Controller positioning errors/
errors / Machine wear
wrong settings.
Spindle vibration / wear.
Axis run out.
Poor Spindle - Tool-holder
interface condition.
Incorrect pull-back forces.

Part distortion from bulk part

Part distortion from residual
Residual Stress, machining
Stress
induced residual stresses
 Fixture condition/wear.
Clamping sequence,
overclamping/underclamping
causes part distortion/movement.
Incorrect fixture.
Foreign Object Debris.
Part incorrectly loaded in fixture Wrong component orientation.
Wrong fixture
orientation/position.
Poor fixture design.
Incorrect documentation /
identification / label / serial
number.

Part temperature not controlled
Swarf build up/nesting
Tool wear / damaged tool
Damaged tool-holder (tool-holder
Tool-holder wear/damage
Expansion/contraction due to
temperature of the part
Swarf build up interfering with
m/c components
Tool wear/damage/breakage.
Built up edge.
- tool interface, Tool-holder -
machine interface).
Clamping mechanism and/or
Taper
damage/wear/deterioration.
Movement of tool in holder.

Insert/tool/tool-holder not
properly located/clamped. Wrong
tool/tool-holder (operator's error /
supplier), Wrong offsets, wrong
length/overhang.
Inappropriate tool/tool-holder
Wrong tool or/and wrong tool
stiffness.
holder or/and tool setting
Tool-holder's pull stud incorrect.
incorrect.
Incorrect tool shape/form/edge
rounding/honing.
Tool runout.
Incorrect documentation /
identification / label / serial
number.