Learning Outcomes

1. Demonstrate the importance of Safety Engineering concepts and their application during manufacturing, the manufacturing processes and during products life cycle.

2. Express the human factors that may adversely impact the effectiveness, efficiency and safety of the operation and maintenance aspects of the engineering activities.

3. Present the activities and tools connected with Project Management for effective and efficient conduction of projects.

Objectives:
- Perform Risk Assessment on metal turning lathe using FMEA (Failure Mode Effects Analysis) methodology.
- Produce a detailed written assignment on the FMEA approach with emphasis on Safety Engineering and applications applied to manufacturing industries.

- Develop critical awareness of hazards and risks associated with industries and apply risk assessment and mitigation techniques.
- Provide industry best practices both to national and international standards related to risk and safety management in engineering with a view towards eliminating/minimizing risks.
- Importantly being the human factors and project management in conducting projects in a military equipment's manufacturing industry are given due emphasis.

For this the students are required to perform two tasks:

Task 1: Risk Assessment on metal turning lathe machines using FMEA table (Workshop 18)

Task 2: Producing a detailed written technical research report of at least 1000 words on the FMEA risk assessment methodology as applied to metal turning lathe operations.

AIM

The main aim of this assignment is to perform risk assessment on a given asset using FMEA (Failure Mode and Effects Analysis) methodology.

TASK 1
Perform a risk assessment on a LATHE used for turning operation using FMEA methodology. Lathe machines are made available in Work Shop 18. A FMEA table is provided to you. The time allocated for this work is 120 minutes

This risk assessment process would involve identifying various parts of a lathe for likelihood of Failure Modes and Failure Effects. A product of all the three i.e., severity, frequency and detection (human or automatic) is calculated to arrive at a RPN (Risk Priority Number).

You need to assign risk rating numbers between 1 and 5 for identified functional parts that are likely to fail, then calculate the Risk Priority Number (RPN). Further, specify effective actions that would mitigate its failure to again re-calculate the new RPN. This RPN will be significantly low.

Follow the instructions as shown below to fill in the FMEA table provided:

1) Identify, fill in the functional or process parts that are likely to fail on your machine.
2) Deduce ‘the cause' and input the failure mode of the functional part.
3) Derive ‘the effect' of the failure mode and input it in the table.
4) Assign the values between 1 to 5 for severity, frequency and detection of failures.
5) Calculate Risk Priority Number (RPN) using the formula:

RPN = Severity x Frequency x Detection

6) Next arrive at corresponding actions necessary to mitigate the stated failures.
7) Again calculate the new RPN and fill in the FMEA table.
8) Check that all the rows and columns are filled.
9) You have completed the Task 1 and is ready for Task 2.

Task 2:

Produce a detailed technical written research report of at least 1000 words on the FMEA risk assessment methodology for a specific application of the activity in Task 1.

The report must emphasize on importance of safety engineering, identifying potential hazards, highlight the risks involved and mitigation measures. Describe in full what the consequences are for the management failing to abide by the legislation and regulation and carrying out their roles and responsibilities. Express also the human factors that may adversely impact the effectiveness, efficiency and safety of the operation and maintenance aspects of the engineering activities. Present the activities and tools connected with project management for effective and efficient conduction of your project. Take into consideration the following key features (Also, please refer to the attached rubric for standard expectation of the report quality):

The report should have a clear structure using right format and paying attention to English grammar and composition and essentially have the following headings:

1. Abstract
2. Introduction
3. Main Body
4. Conclusion
5. References

Abstract: Is an executive summary of your report

Introduction: Briefly describe the purpose of your report

Main body: Please refer to the task section and address all the bullet points listed there. Conclusion: Summarize your work and report the key findings of the assessment. To explain and make the point clear you may include pictures and tables where ever necessary. You should pay special attention to references or bibliography.

Instructions for reporting and conduct in workshop:
- Students are required to work in workshop, classroom and accommodation to complete the given risk assessment tasks.
- Students should work alone to present the results of their efforts and individual reports should be produced and submitted independently.
- Copying other students' work is strictly not allowed and if found shall be reported.
- Attention must be paid to ‘Similarity' on ‘Turnitin' to keep it as low possible as it is linked to plagiarism issues.