最新的FMEA潜在失效模式及分析标准表格.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POTENTIALPOTENTIAL FAILUREFAILURE MODEMODE ANDAND EFFECTSEFFECTS ANALYSISANALYSIS(过程PROCESS 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.FME

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

3、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.10原材料进厂In-coming RawMaterial原材料规格错误Material spec is wrong影响零件性能affect parts capability4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 ce

4、rtification everyshipping收料员检查送货单Material receiver checkdelivering list936NANA20IQC 检查IQC Inspection尺寸检测有误差measure error影响后续零件生产affect parts productionnext process3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 confi

5、rm the Raw MaterialSpec List according to thedelivery 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 material specaccording to the Raw MaterialSpec List,check materialsthickness by 3 points per coil,2848NANA30移至原材料仓Move Material toStore材料转移错误mistake therawmaterial影响后续零件生产affect partsproduc

6、tion 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 verifythe material inproduction line.848NANA40存放Storage材料生锈rust of thematerial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 inand out st

7、ore.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.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

8、确认Operators and QC verifythe material inproduction line.848NANA60P200T 冲压P200T Stamping6.250.15尺寸超差is out of tolerance影响客户装配affectcustomer assembly3冲孔冲头磨损The tooling punch wearsaway2定期维护保养模具maintain the dieperiodicallyPQC用通止规抽检 PQC check with Pin gauge848NANA60P200T 冲压P200T Stamping780.25尺寸超差is out

9、of tolerance1.影响客户使用。2.后续磨削无法装夹。1.affect customerassembly2.Can not put inthe fixture.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 adjustprocess.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 thetooling adjust partsand a

10、sk operatorsfollow the WI in theproduction process.PQC用卡尺抽检 PQC check with VernierCaliper848NANA工1 of 9翻边孔内径过大或者椭圆flanging holebigger or 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 32.549out of diemension.2.Cause theroughness of32.549 hole out ofdimension.31.合模高度不对2.送料步距不对1.Non-conformingshutt

11、er height.2.Non-conformingstamping step.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。2.Set the WI siteand ask the operatorsfollow it in theproduction process.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 holediameter 31.8Max and PQCcheck it with verniercaliper.848NANA翻边高度过低taller or shorterof the blangingheight.导致

12、车削和磨削后7尺寸超差。Cause dimension 7out of SPEC.afterturning andgrinding.3合模高度不到位Non-conformingshutter height.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 siteand ask the operatorsfollow it in theproduction process.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 checkit with v

13、ernier caliper848NANA60P200T 冲压P200T Stamping37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 siteand ask the operatorsfollow it in theproduction process.1.每卷材料上线时，检查材料厚度1

14、.PQC Check thethickness of materialwhen every coil used.848NANA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 ofSPEC.2将来料厚度控制在3.25+/-0.05。Set the thickness ofraw-material 3.25+/-0.05。每卷材料

15、上线时，PQC 检查材料厚度PQC Check the thicknessof material when everycoil used.848NANA60P200T 冲压P200T Stamping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POTENTIALPOTENTIAL FAILUREFAILURE MODEMODE ANDAND EFFECTSEFFECTS ANALYSISANALYSIS(过程PROCESS 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

16、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Process FunctionRequirements潜在的失效模式Potential Failure Mode潜在的失效后果Potential Effect(S)ofFailure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)of Failu

17、re频度数Occ现行过程预防控制Current Process ControlsPrevention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2 of 9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 theflatne

18、ss afergrinding out ofdimension.2.cause thethickness of thepart aftergrinding out ofdimension.3合模高度不到位Non-conformingshutter height.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 siteand ask the operatorsfollow it in theproduction process.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 proces

19、s and PQCcheck it in period.848NANA60P200T 冲压P200T Stamping翻边孔与地面拐角过大bigger radius ofthe crossingbetween theflanging and theflatness.导致磨削后34.5MAX尺寸超差。Cause 34.5MAXafter grinding outof dimension.3合模高度不到位Non-conformingshutter height.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 siteand ask the operator

20、sfollow it in theproduction process.增加冲压过程中的尺寸34.5控制并且要求QC抽检。Add 34.5MAX control 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，PQ

21、C目视检查4pcs/hOperator check with E,1pcs/15mins,PQC check withE,4pcs/h864NANA70半成品包装Package in semi-finished product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 siteand ask the operators

22、follow it afterstamping.传送前PQC确认包装正确后才可以传送。QC verify the packagingbefore delivery848NANA80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 deliverynotes and receiptsnotes label on theRaw-material beforestor

23、e pallet.生产领料时，操作工和QC对材料进行确认Operators and QC verifythe material inproduction 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 inand out 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.

24、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POTENTIALPOTENTIAL FAILUREFAILURE MODEMODE ANDAND EFFECTSEFFECTS ANALYSISANALYSIS(过程PROCESS 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.D

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

26、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3 of 9100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-m

27、aterial beforestore.生产领料时，操作工和QC对材料进行确认Operators and QC verifythe material inproduction line.848NANA110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 toolwears away2.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

28、 the latheperiodically2.Set the WI siteand ask the operatorsfollow it in theproduction process.PQC和操作工用气动量仪抽检 PQC and operators check withAIR gauge896NANA内孔粗糙度不良Non-conforming ofthe roughness inthe inner hole.1.影响客户使用。1.affect customerassembly31.车刀磨损1.The lathe toolwears away2定期维护保养车床maintain the la

29、theperiodicallyPQC用粗糙度仪抽检 PQC and operators check withroughness machine.848NANA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 thefeeding.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 andask the operatorsfollow it

30、 in theproduction process.PQC用千分尺抽检 PQC and operators check withmicrometer.840NANA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POTENTIALPOTENTIAL FAILUREFAILURE MODEMODE ANDAND EFFECTSEFFECTS ANALYSISANALYSIS(过程PROCESS 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:200

31、9.09.07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Process FunctionRequirements潜在的失效模式Potential Failure Mode潜在的失效后果Potential Effect(S)ofFailure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)of Failure频度数Occ现行过程预防控制Cu

32、rrent Process ControlsPrevention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4 of 9110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

33、 toolwears away2.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 siteand ask the operatorsfollow it in theproduction process.2.maintain the latheperiodicallyPQC和操作工用检具抽检。PQC and operators check withgauge864NANA尺寸超差is out oftolerance影响客户装配affectcustomer assembly41.车刀

34、磨损2.零件装夹不到位1.The lathe toolwears away2.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 siteand ask the operatorsfollow it in theproduction process.2.maintain the latheperiodicallyPQC和操作工用检具抽检。PQC and operators check withgauge864NANA120半成品包装Package insemi-finishedpro

35、duct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 siteand ask the operatorsfollow it afterstamping.传送前PQC确认包装正确后才可以传送。QC verify the packagingbefore delivery848NANA130移至半成品区Move to semi

36、-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 deliverynotes and receiptsnotes label on thepallet before store.生产领料时，操作工和QC对材料进行确认Operators and QC verifythe material inproduction line.848NANA140存放Storage零件生锈rust of the par

37、t.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 inand out 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.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POTENTIALPOTENTIAL FAILUREFAILURE MODEMODE ANDAND EFFECTSEFFECTS ANALYSISANALYSIS(过程PR

38、OCESS 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Process FunctionRequirements潜在的失效模式Potential Failure Mode潜在的失效后果Po

39、tential Effect(S)ofFailure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)of Failure频度数Occ现行过程预防控制Current Process ControlsPrevention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

40、R.P.N.工5 of 9150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 verifythe material inproduction line.424NANA160倒角chamfer倒角大于0.5

41、cthe 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.2包装方式不明确Unknown of th

42、epackaging 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 siteand ask the operatorsfollow it afterstamping.传送前PQC确认包装正确后才可以传送。QC verify the packagingbefore delivery424NANA180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

43、库前每卡板贴上传送单核入库单。set the deliverynotes and receiptsnotes label on thepallet before store.生产领料时，操作工和QC对材料进行确认Operators and QC verifythe material inproduction line.424NANA190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 inand out store.2.long

44、 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Operato

45、rs and QC verifythe material inproduction line.848NANA210磨削grinding粗糙度超差roughness of theflat out ofdimension.影响客户使用affectcustomer using3砂轮硬度以及颗粒度不适合。Non-conforming ofthe hardness andparticle grindingwheel.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 an

46、doperators check the Spec.of the grinding wheel.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POTENTIALPOTENTIAL FAILUREFAILURE MODEMODE ANDAND EFFECTSEFFECTS ANALYSISANALYSIS(过程PROCESS 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

47、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Process FunctionRequirements潜在的失效模式Potential Failure Mode潜在的失效后果Potential Effect(S)ofFailure严重度Sev级别Class潜在的失效原因/机理Potential Cause(s)/Mechanism(s)of Failure频度数Occ现行过程预防控制Current Process ControlsPreve

48、ntion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6 of 9210磨削grindingout of dimension.影响客户使用affectcustomer using41.磨床磁力过大2.磨床工作台有异物1.Bigger magneticforce of thegrinding machine

49、2.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 beforeproduction.QC对每盘的零件平面度进行抽检PQC check the somesamples of 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m

50、ore 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 siteand ask the operatorsfollow it afterstamping.QC对每盘的零件进行抽检PQC check the somesamples of every plate.848NANA7+/-0.3尺寸超差7+/-0.3 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