FMEA潜在失效模式及分析标准表格模版 (2).xls

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1、潜潜在在的的失失效效模模式式及及效效应应分分析析表表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(Design-FMEA)项目名称 Item:过程责任部门Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类 关键日期Key Date:2009.09.07准备人Prepared By:主要参加人Core Team:QA部QA Dept./模具部Tooling.Dept.;/工程部Eng.Dept.FMEA日期Data(编制(orig):2010.01.25(修订REV)：序号NO.过

2、程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode潜在的失效后果Potential Effect(S)of Failure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)ofFailure频度数Occ现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetection难检度Det风险优先指数R.P.N.建议的措施RecommendedAction(S)责任及目标完成日期

3、Responsibility&TargetCompletionDate措施结果Result严重度Sev频度数Occ难检度Det风险优先指数R.P.N.10原材料进厂In-coming RawMaterial原材料规格错误Material spec iswrong影响零件性能affect partscapability4供应商送原材料的规格有错The supplier send thewrong material1每批送货供应商附上材质证明书The supplier submit thequality certificationevery shipping收料员检查送货单Material rec

4、eiver checkdelivering list936NANA20IQC 检查IQC Inspection尺寸检测有误差measure error影响后续零件生产affect partsproduction nextprocess3供应商送原材料的规格有错The supplier send thewrong material2送货单标明材料尺寸规格define the SPEC.ofraw-material in thedilivery Bills1.IQC按送货单核对原材料规格表IQC confirm the RawMaterial Spec List accordingto the d

5、elivery order.2.IQC按原材料规格表检查原材料尺寸规格,以每批2卷，每卷3个点检查料厚IQC check raw materialspec according to the RawMaterial Spec List,checkmaterials thickness by 3points per coil,2848NANA30移至原材料仓Move Materialto Store材料转移错误mistake therawmaterial影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label2入库前材料上贴来

6、料管理票set the label on theRaw-material beforestore.生产领料时，操作工和QC对材料进行确认Operators and QC verify thematerial in production line.848NANA40存放Storage材料生锈rust of the material影响后续零件生产affect partsproduction nextprocess21.材料入库、出库凌乱。2.放置周期过长。1.Un-sequence in andout store.2.long term store4按照程序要求，材料先进先出。Frist in

7、first outQC复查在库 re-check theparts in period.864NANA50移至生产线Move Materialto ProductionLine材料转移错误mistake therawmaterial影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label2入库前材料上贴来料管理票set the label on theRaw-material beforestore.生产领料时，操作工和QC对材料进行确认Operators and QC verify thematerial in prod

8、uction line.848NANA60P200T 冲压P200TStamping6.250.15尺寸超差is out of tolerance影响客户装配affectcustomer assembly3冲孔冲头磨损The tooling punchwears away2定期维护保养模具maintain the dieperiodicallyPQC用通止规抽检 PQC check with Pin gauge848NANA工1 of 1060P200T 冲压P200TStamping780.25尺寸超差is out of tolerance1.影响客户使用。2.后续磨削无法装夹。1.affe

9、ct customerassembly2.Can not put in thefixture.31.冲孔冲头磨损2.模具调试中，送料步距不对1.The tooling punchwears away2.Non-conformingstamping step in thetooling adjust process.21.定期维护保养模具2.隔离调模品，并要求操作工严格按照操作指导书操作。1.maintain the dieperiodically2.Contain the toolingadjust parts and askoperators follow the WIin the prod

10、uctionprocess.PQC用卡尺抽检 PQC check with VernierCaliper848NANA翻边孔内径过大或者椭圆flanging hole biggeror smaller1.车削后导致32.549尺寸超差。2.内孔车削后无法满足粗糙度要求。1.Cause 32.549 outof diemension.2.Cause theroughness of 32.549hole out ofdimension.31.合模高度不对2.送料步距不对1.Non-conformingshutter height.2.Non-conformingstamping step.21.现

11、场放置操作指导书，并且要求操作工严格按照操作指导书操作。2.Set the WI site andask the operators followit in the productionprocess.增加翻边孔控制尺寸31.8最大并要求操作工按照此尺寸卡尺控制。Add flanging hole diameter31.8Max and PQC check itwith vernier caliper.848NANA翻边高度过低taller or shorter of theblanging height.导致车削和磨削后7尺寸超差。Cause dimension 7out of SPEC.a

12、fterturning and grinding.3合模高度不到位Non-conforming shutterheight.21.现场放置操作指导书，并且要求操作工严格按照操作指导书操作。1.Set the WI site andask the operators followit in the productionprocess.增加翻边孔高度尺寸控制7.5+/-0.3并要求操作工按照此尺寸卡尺控制。Add flanging hole height7.5+/-0.3 and PQC check itwith vernier caliper848NANA60P200T 冲压P200TStamp

13、ing37尺寸超差37 out of dimension影响客户使用affectcustomer using31.合模高度不到位2.来料较薄1.Non-conformingshutter height.2.thinner of thematerial thickness.21.现场放置操作指导书，并且要求操作工严格按照操作指导书操作。1.Set the WI site andask the operators followit in the productionprocess.1.每卷材料上线时，检查材料厚度1.PQC Check the thicknessof material when e

14、very coilused.848NANA偏小偏小偏小偏小偏小偏小偏小偏小偏小偏小偏小偏小偏小偏小潜潜在在的的失失效效模模式式及及效效应应分分析析表表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(Design-FMEA)项目名称 Item:过程责任部门Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类 关键日期Key Date:2009.09.07准备人Prepared By:主要参加人Core Team:QA部QA Dept./模具部Tooling.Dept.;/工程部Eng.

15、Dept.FMEA日期Data(编制(orig):2010.01.25(修订REV)：序号NO.过程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode潜在的失效后果Potential Effect(S)of Failure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)ofFailure频度数Occ现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetection难检度

16、Det风险优先指数R.P.N.建议的措施RecommendedAction(S)责任及目标完成日期Responsibility&TargetCompletionDate措施结果Result严重度Sev频度数Occ难检度Det风险优先指数R.P.N.工2 of 10材料厚度超差 material thicknessout of dimension.导致磨削后3.0+/-0.15尺寸超差。Cause thedimension 3.0+/-0.15 out of SPEC.after grinding.3来料厚度超差the thickness of raw-material out of SPEC.

17、2将来料厚度控制在3.25+/-0.05。Set the thickness of raw-material 3.25+/-0.05。每卷材料上线时，PQC 检查材料厚度PQC Check the thickness ofmaterial when every coilused.848NANA平面度超差flatness out ofdimension1.导致磨削后的平面度超差。2.导致磨削后的材料厚度超差。1.Cause theflatness afergrinding out ofdimension.2.cause thethickness of the partafter grinding

18、 out ofdimension.3合模高度不到位Non-conforming shutterheight.21.现场放置操作指导书，并且要求操作工严格按照操作指导书操作。1.Set the WI site andask the operators followit in the productionprocess.增加冲压过程中的平面度0.15控制并且要求QC抽检。Add flatness control instamping process and PQCcheck it in period.848NANA60P200T 冲压P200TStamping翻边孔与地面拐角过大bigger ra

19、dius of thecrossing between theflanging and theflatness.导致磨削后34.5MAX尺寸超差。Cause 34.5MAXafter grinding out ofdimension.3合模高度不到位Non-conforming shutterheight.21.现场放置操作指导书，并且要求操作工严格按照操作指导书操作。1.Set the WI site andask the operators followit in the productionprocess.增加冲压过程中的尺寸34.5控制并且要求QC抽检。Add 34.5MAX cont

20、rol instamping process and PQCcheck it in period.848NANA毛刺过大 larger burrs影响零件外观及客户使用affect partsappearance andcustomers usage2冲头或凹模镶块磨损punch and die insertwears away4定期维护保养模具maintain the dieperiodically操作工目视检查1pcs/15mins，PQC目视检查4pcs/hOperator check with E,1pcs/15mins,PQC checkwith E,4pcs/h864NANA70半

21、成品包装Package insemi-finishedproduct包装错误Non-conformingpackaging造成零件表面的压伤。Cause the dent inthe surface of thepart.3包装方式不明确Unknown of thepackaging methods.21.现场放置包装指导书，并且要求操作工严格按照包装指导书包装。1.Set the PI site andask the operators followit after stamping.传送前PQC确认包装正确后才可以传送。QC verify the packagingbefore deliv

22、ery848NANA60P200T 冲压P200TStamping潜潜在在的的失失效效模模式式及及效效应应分分析析表表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(Design-FMEA)项目名称 Item:过程责任部门Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类 关键日期Key Date:2009.09.07准备人Prepared By:主要参加人Core Team:QA部QA Dept./模具部Tooling.Dept.;/工程部Eng.Dept.FMEA日期Data(

23、编制(orig):2010.01.25(修订REV)：序号NO.过程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode潜在的失效后果Potential Effect(S)of Failure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)ofFailure频度数Occ现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetection难检度Det风险优先指数R.P.N.建

24、议的措施RecommendedAction(S)责任及目标完成日期Responsibility&TargetCompletionDate措施结果Result严重度Sev频度数Occ难检度Det风险优先指数R.P.N.工3 of 1080移至半成品区Move to semi-finished area零件转移错误mistake the part影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label2入库前每卡板贴上传送单核入库单。set the delivery notesand receipts notes labelo

25、n the Raw-materialbefore store pallet.生产领料时，操作工和QC对材料进行确认Operators and QC verify thematerial in production line.848NANA90存放Storage零件生锈rust of the part.影响后续零件生产affect partsproduction nextprocess31.材料入库、出库凌乱。2.放置周期过长。1.Un-sequence in andout store.2.long term store2按照程序要求，材料先进先出。Frist in first outQC复查在

26、库 re-check theparts in period.848NANA100移至生产线Move Materialto ProductionLine材料转移错误mistake therawmaterial影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label2入库前材料上贴来料管理票set the label on theRaw-material beforestore.生产领料时，操作工和QC对材料进行确认Operators and QC verify thematerial in production line.8

27、48NANA110机加工machining32.5490.012尺寸超差is out oftolerance影响客户装配affectcustomer assembly41.车刀磨损2.零件装夹不到位1.The lathe tool wearsaway2.Non-confromingclamping area21.定期维护保养车床2.现场放置操作指导书，并且要求操作工严格按照操作指导书操作。1.maintain the latheperiodically2.Set the WI site andask the operators followit in the productionprocess

28、.PQC和操作工用气动量仪抽检 PQC and operators checkwith AIR gauge896NANA内孔粗糙度不良Non-conforming ofthe roughness in theinner hole.1.影响客户使用。1.affect customerassembly31.车刀磨损1.The lathe tool wearsaway2定期维护保养车床maintain the latheperiodicallyPQC用粗糙度仪抽检 PQC and operators checkwith roughness machine.848NANA潜潜在在的的失失效效模模式式及

29、及效效应应分分析析表表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(Design-FMEA)项目名称 Item:过程责任部门Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类 关键日期Key Date:2009.09.07准备人Prepared By:主要参加人Core Team:QA部QA Dept./模具部Tooling.Dept.;/工程部Eng.Dept.FMEA日期Data(编制(orig):2010.01.25(修订REV)：序号NO.过程功能要求ProcessFun

30、ctionRequirements潜在的失效模式Potential FailureMode潜在的失效后果Potential Effect(S)of Failure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)ofFailure频度数Occ现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetection难检度Det风险优先指数R.P.N.建议的措施RecommendedAction(S)责任及目标完成日期Responsibility&

31、TargetCompletionDate措施结果Result严重度Sev频度数Occ难检度Det风险优先指数R.P.N.工4 of 10材料厚度超差 material thicknessout of dimension.导致磨削后3.0+/-0.15尺寸超差。Cause thedimension 3.0+/-0.15 out of SPEC.after grinding.5进刀量过大longer of the feeding.1现场放置操作指导书，并且要求操作工严格按照操作指导书操作。Set the WI site and askthe operators follow itin the pr

32、oductionprocess.PQC用千分尺抽检 PQC and operators checkwith micrometer.840NANA110机加工machining尺寸超差is out oftolerance影响客户装配affectcustomer assembly41.车刀磨损2.零件装夹不到位1.The lathe tool wearsaway2.Non-confromingclamping area21.定期维护保养车床2.现场放置操作指导书，并且要求操作工严格按照操作指导书操作。1.Set the WI site andask the operators followit i

33、n the productionprocess.2.maintain the latheperiodicallyPQC和操作工用检具抽检。PQC and operators checkwith gauge864NANA尺寸超差is out oftolerance影响客户装配affectcustomer assembly41.车刀磨损2.零件装夹不到位1.The lathe tool wearsaway2.Non-confromingclamping area21.定期维护保养车床2.现场放置操作指导书，并且要求操作工严格按照操作指导书操作。1.Set the WI site andask th

34、e operators followit in the productionprocess.2.maintain the latheperiodicallyPQC和操作工用检具抽检。PQC and operators checkwith gauge864NANA120半成品包装Package insemi-finishedproduct包装错误Non-conformingpackaging造成零件表面的压伤。Cause the dent inthe surface of thepart.3包装方式不明确Unknown of thepackaging methods.21.现场放置包装指导书，并

35、且要求操作工严格按照包装指导书包装。1.Set the PI site andask the operators followit after stamping.传送前PQC确认包装正确后才可以传送。QC verify the packagingbefore delivery848NANA潜潜在在的的失失效效模模式式及及效效应应分分析析表表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(Design-FMEA)项目名称 Item:过程责任部门Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型

36、年/车辆类 关键日期Key Date:2009.09.07准备人Prepared By:主要参加人Core Team:QA部QA Dept./模具部Tooling.Dept.;/工程部Eng.Dept.FMEA日期Data(编制(orig):2010.01.25(修订REV)：序号NO.过程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode潜在的失效后果Potential Effect(S)of Failure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)ofFai

37、lure频度数Occ现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetection难检度Det风险优先指数R.P.N.建议的措施RecommendedAction(S)责任及目标完成日期Responsibility&TargetCompletionDate措施结果Result严重度Sev频度数Occ难检度Det风险优先指数R.P.N.工5 of 10130移至半成品区Move to semi-finished area零件转移错误mistake the part影响后续零件生产affect

38、partsproduction nextprocess3材料标识不明确Un-clear label2入库前每卡板贴上传送单核入库单。set the delivery notesand receipts notes labelon the pallet beforestore.生产领料时，操作工和QC对材料进行确认Operators and QC verify thematerial in production line.848NANA140存放Storage零件生锈rust of the part.影响后续零件生产affect partsproduction nextprocess31.材料入

39、库、出库凌乱。2.放置周期过长。1.Un-sequence in andout store.2.long term store2按照程序要求，材料先进先出。Frist in first outQC复查在库 re-check theparts in period.848NANA150移至生产线Move Materialto ProductionLine材料转移错误mistake therawmaterial影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label2入库前材料上贴来料管理票set the label on th

40、eRaw-material beforestore.生产领料时，操作工和QC对材料进行确认Operators and QC verify thematerial in production line.424NANA160倒角chamfer倒角大于0.5cthe chamfer morethan 0.5影响零件外观affect partsappearance2倒角限位移动the limit away5定期维护保养机床maintain the machineperiodicallyPQC用投影仪抽检 PQC check with profileprojector.330NANA170半成品包装Pa

41、ckage insemi-finishedproduct包装错误Non-conformingpackaging造成零件表面的压伤。Cause the dent inthe surface of thepart.2包装方式不明确Unknown of thepackaging methods.31.现场放置包装指导书，并且要求操作工严格按照包装指导书包装。1.Set the PI site andask the operators followit after stamping.传送前PQC确认包装正确后才可以传送。QC verify the packagingbefore delivery424

42、NANA180移至半成品区Move to semi-finished area零件转移错误mistake the part影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label2入库前每卡板贴上传送单核入库单。set the delivery notesand receipts notes labelon the pallet beforestore.生产领料时，操作工和QC对材料进行确认Operators and QC verify thematerial in production line.424NANA潜潜在在的

43、的失失效效模模式式及及效效应应分分析析表表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(Design-FMEA)项目名称 Item:过程责任部门Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类 关键日期Key Date:2009.09.07准备人Prepared By:主要参加人Core Team:QA部QA Dept./模具部Tooling.Dept.;/工程部Eng.Dept.FMEA日期Data(编制(orig):2010.01.25(修订REV)：序号NO.过程功能要求

44、ProcessFunctionRequirements潜在的失效模式Potential FailureMode潜在的失效后果Potential Effect(S)of Failure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)ofFailure频度数Occ现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetection难检度Det风险优先指数R.P.N.建议的措施RecommendedAction(S)责任及目标完成日期Respo

45、nsibility&TargetCompletionDate措施结果Result严重度Sev频度数Occ难检度Det风险优先指数R.P.N.工6 of 10190存放Storage零件生锈rust of the part.影响后续零件生产affect partsproduction nextprocess31.材料入库、出库凌乱。2.放置周期过长。1.Un-sequence in andout store.2.long term store4按照程序要求，材料先进先出。Frist in first outQC复查在库 re-check theparts in period.848NANA200

46、移至生产线Move Materialto ProductionLine材料转移错误mistake therawmaterial影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label2入库前材料上贴来料管理票set the label on theRaw-material beforestore.生产领料时，操作工和QC对材料进行确认Operators and QC verify thematerial in production line.848NANA210磨削grinding粗糙度超差roughness of the

47、 flatout of dimension.影响客户使用affectcustomer using3砂轮硬度以及颗粒度不适合。Non-conforming of thehardness and particlegrinding wheel.2选择合适的砂轮并将砂轮规格写入操作指导书Choose conforminggrinding wheel andwrite it into WI生产前，QC和操作工检查砂轮的规格。QC andoperators check the Spec.of the grinding wheel.848NANA210磨削grindingout of dimension.影

48、响客户使用affectcustomer using41.磨床磁力过大2.磨床工作台有异物1.Bigger magneticforce of the grindingmachine2.Un-clearn of theworking flat.21.加工特殊的磨削夹具以减小磁力。2.磨削前用切削液洗刷工作台面。1.Machining specialgrinding gauge toreduce the magneticforce.2.Clearn the workingflat before production.QC对每盘的零件平面度进行抽检PQC check the somesamples o

49、f every plate.896NANA3+/-0.15尺寸超差3+/-0.15 out ofdimension影响客户使用affectcustomer using3车削不到位more or no enoughgrinding21.现场放置包装指导书，并且要求操作工严格按照包装指导书包装。1.Set the PI site andask the operators followit after stamping.QC对每盘的零件进行抽检PQC check the somesamples of every plate.848NANA潜潜在在的的失失效效模模式式及及效效应应分分析析表表POTEN

50、TIAL FAILURE MODE AND EFFECTS ANALYSIS(Design-FMEA)项目名称 Item:过程责任部门Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类 关键日期Key Date:2009.09.07准备人Prepared By:主要参加人Core Team:QA部QA Dept./模具部Tooling.Dept.;/工程部Eng.Dept.FMEA日期Data(编制(orig):2010.01.25(修订REV)：序号NO.过程功能要求ProcessFunctionRequirement