PFMEA潜在失效模式及后果分析.xls

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1、 Page 1 of 6POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)FMEA Number：潜潜在在失失效效模模式式及及后后果果分分析析（过过程程FMEA）FMEA 编 号：Part name：Process Responsibility：Prepared By:Approval By:零件名称：过程责任部门：编 制:批 准:Part number：Key Date：FMEA Date(Orig):FMEA Date(Rev.):Rev.零件号：关键日期：FMEA 日期(编制):FMEA 日期(修订):版本：Core Tea

2、m:主要参加人:Process Process Potential Cause(s)/Current Process Controls现行工艺控制person in charge负责人Action ResultsstepFunctionPotential FailurePotential Effect(s)SEVspecialMechanism(s)OCCDetec R.P.N.Recommended措施结果工序号 过 程Mode of Failure严重特of FailureUR不易探 风 险Action(s)Action Taken采取的措施SEV OCC DETR.P.N.Require

3、ments潜在失效模式潜在的失效后果度数性潜在的失效起因/机理频度数PreventSurvey测度数 序 数建议的措施严重级不易探 风 险 要 求预防探测度数数测度数 序 数AMaterial incominginspection原材料入库检验ADC12 Chemicalcompositionbeing out of standard.ADC12化学成分不符合标准。Material strength isnot qualified材料强度不合格Product performance,customer complaints产品性能降低，客户抱怨6The supplier didnot test供

4、方未做出厂检验3Supplier quality guarantee andmaterial analysis report供方提供质量保证书和材质分析报告Check each lot with aspectrometer.对每一批抽取1PCS材料做光谱分析236NONEBStorage material材料入库package in damagedcondition包装破损Scattered material,easy mixing材料散落，易混料5Porter did not onthe materialhandlingsafety/protectivenot in place搬运工未对材料

5、搬运安全防护/防护不到位3Material handling using aspecial revolving cars/box/tray材料搬运使用专用周转车/箱/托盘Visual 目视230NONE,material got damp材料受潮Mold material,ledto the decrease ofthe materialperformance材料发霉，导致材料性能下降5Didnt domoistureproofprocessingmaterials piled up材料堆放没有做防潮处理3Material warehouse laying padstorehouse boar

6、d(120 mm)材料仓库铺放垫仓板（高度120mm）Visual 目视230NONEMaterial put wrongidentification材料标识错误shopwork took thewrong materials车间领错材料6Warehouseadministratorwriting labelmistake仓库管理员书写标签错误3Materials piled up housekeepingmanagement.材料堆放施行定置管理。Library records(account/card/)查库记录（帐/卡/物一致）236NONECGet the material领料pack

7、age in damagedcondition包装破损Dirty material offthe ground材料掉地上弄脏4Handling rawmaterials there isnosafety/protectivedoes not reach thedesignated position搬运原材料没有安全防护/防护不到位2Material handling using aspecial revolving cars/box/tray材料搬运使用专用周转车/箱/托盘Visual 目视216NONEDMeltDown,heatpreservation溶解，保温After melting

8、theunqualified material熔炼后的材料成分不合格the part performanceis bad.产品性能不良6Furnace residue ofother materials换料时以前的材料未处理干净3staff training，designatesomeone to do培训并指定专人换料Each furnace by inspector 1PCS material spectralanalysis每炉由检验员抽取1PCS材料做光谱分析236NONETemperature isbeyond thetechnologicalrequirement炉温超出工艺要求c

9、old shut,stickymold产品压铸时出现冷隔，粘模等现象6the material addtoo much熔炉加的料太多3Make the instruction编制作业指导书，Set up automatic alarm设定炉温超差自动报警Visual temperature controlbox随时目视温控箱236NONE表单编号：表单版本：A/0 Page 2 of 6Materials withdirt,Slag,degassingis not clean材料上有污物,杂质，气，未除干净Products areporosity,coldshut,die.产品出现气孔，冷隔，

10、粘模等缺陷，Knifeproducts have hardpoints,resultingin crack产品上有硬点，导致崩刀。6Back to thematerial on thedirt,slag,degassing frequencyis too low回料上有脏污，除渣，除气频率太低，Agent istoo little,back tothe materialproportion is toohigh药剂太少，回料比例太高，3Die casting wi,back to the materialproportion,slag,degassing frequency,reagent r

11、atio,temperature of furnacetemperature setting.Each class everyfurnace sampling analysis of thespectrum,try processing products编制压铸作业指导书，规定回料比例，除渣，除气频率，药剂比例，炉温设置温度。每班每炉都抽样做光谱分析，试加工产品Every time slag,degassingmust be recorded,foreman,according to the process cardcontrol each parameter,eachclass every

12、furnace samplinganalysis of the spectrum,eachtest time,every time twoproducts每次除渣，除气都必须记录，领班按工艺卡对照各个参数，每班每炉都抽样做光谱分析，每班试车一次，每次2个产品472NONEProduct warping产品变形，dehiscence裂开Product deformationcause assemblyperformance isbad,CNC machiningpositioning产品变形导致装配性能不好,影响CNC加工定位Productobsolescence,产品报废6 1.Close m

13、old timeshort,1.合模时间短,2.Moldtemperature is toohigh模温或铝液温度太高3.Thimble,abnormal3.顶针异常4.First hand tappingslag bags andmaterial4.手工敲渣包和料头41.Boot set parameters according tothe process card1.开机按工艺卡设定参数.2.Check the cooling waterpipe connection is correct,leaking正确的连接冷却水管,打开冷却水,检查水管是否有漏水现象,3.To smooth oil

14、thimble and guide pin3.每班定期给顶杆和导柱上嫩滑油。4.Provisionsof slag package and material canonly be removed by trimming4.规定渣包和料头只能靠切边去除Inspectors periodicallychecking productappearance.size检验员定期巡检产品外观。尺寸372NONEProducts in everyskin,flash产品出现隔皮，飞边Products to rework,Get rid of burrs产品要返工，修边5Injection pressureis

15、 too great,theclamping force isnot enough,positioning andwear压射压力太大，锁模力不够，定位机构磨损6Boot according to the processcard set parameters,positioningsurface down开机按工艺卡设定参数，定位机构表面淡化处理Visual 目视390Reduce thepressure ofinjection,moldonce every 50000die casting mouldand replacement减小压射压力，模具每压铸5万模修配一次Die castingd

16、irector压铸主管：su yong.ToolingManager：chenaifu模具部经理：陈爱福Die castingtechnologyparametersmonitored,mouldreplacement压铸工艺参数监控，模具修配54360Gas-hole 气孔coldshut冷隔The part has poorburst strength.产品受力易断，加工面出现气孔导致产品报废61.Processparameters accordingto the process cardset工艺参数未按工艺卡设定2.Mold temperatureis toolow模温太低3.bisc

17、uitis thin.zinc escapes,料柄薄,飞铝,3.Noslag,degassing铝液未按时除渣,除气4.Mould exhaust模具排气不畅31.Process parameters set strictlyaccording to the process card工艺参数严格按照工艺卡设定.2.每次加过料后,都进行一次除渣,除气3.Devicestarts a thermometer is used tomeasure the mold temperature,after passing at the start ofproduction设备启动后使用测温仪测量模具温度,

18、合格后,在开始生产.4.Inopening mould cold-lap exhaust slot模具冷隔处开通排气槽1.Check process parametersconform to the requirements ofthe process card1.检查工艺参数是否符合工艺卡要求2Operator self-inspectionproduct appearance.作业员自检产品外观3Inspectors to tryprocessing check porosity.检验员试加工检查气孔590Improving thestructure of themould改善模具Tool

19、ing Manager：chen aifu模具部经理：陈爱福Increase theporosity and havea cold orincreasing slagpackage,increase exhaustslot有气孔和有冷隔的地方增加或加大渣包，增加排气槽72570DMeltDown,heatpreservation溶解，保温POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)FMEA Number：潜潜在在失失效效模模式式及及后后果果分分析析（过过程程FMEA）FMEA 编 号：Part name：Process Re

20、sponsibility：Prepared By:Approval By:零件名称：过程责任部门：编 制:批 准:Part number：Key Date：FMEA Date(Orig):FMEA Date(Rev.):Rev.零件号：关键日期：FMEA 日期(编制):FMEA 日期(修订):版本：Core Team:主要参加人:Process Process Potential Cause(s)/Current Process Controls现行工艺控制person in charge负责人Action ResultsstepFunctionPotential FailurePotenti

21、al Effect(s)SEVspecialMechanism(s)OCCDetec R.P.N.Recommended措施结果工序号 过 程Mode of Failure严重特of FailureUR不易探 风 险Action(s)Action Taken采取的措施SEV OCC DETR.P.N.Requirements潜在失效模式潜在的失效后果度数性潜在的失效起因/机理频度数PreventSurvey测度数 序 数建议的措施严重级不易探 风 险 要 求预防探测度数数测度数 序 数表单编号：表单版本：A/0 Page 3 of 6corebending型芯弯曲,拉模Product proc

22、essingnot,affect theassembly,leading toproduct scrap产品加工不出，影响装配，导致产品报废。6Core materialhardness is notenough，not usemold release型芯材质不够硬，未喷到脱模剂。6Each product fixed spray head,can automatic sprayingproduction每个产品固定喷雾头，5000 per die casting mold andcore titanium plating生产时只能自动喷涂，每压铸5000模，型芯镀钛一次。the QC ins

23、pector checks thepart appearance according tothe inspection card。检验员应按照产品检验单对产品外观进行检验进行检验3108Fixed spray head,titanium coating onthe surface of thecore固定专用喷雾头，型芯表面镀钛Die castingdirector压铸主管：su yongFixed sprayhead,re，Forevery 5000model core diecasting titaniumcoating again固定专用喷雾头，每压铸5000模型芯重新镀钛73363Pl

24、unger surface istoo high or too low顶杆凹凸Lead to productrework,or evenscrapped导致产品报废，返工5Push rod bent orbroken顶杆弯曲，顶杆断4定期给顶针上嫩滑油On a regularbasis to the thimble oil oftender the QC inspector shouldstrengthen not regularinspection检验员应定期进行巡检240NONETrimming切边Product surfaceblunt injury,bruised产品表面冲伤，压伤Le

25、ad to productrework,or evenscrapped导致产品报废，返工。装配时出现干涉6Aluminum cutting dienot clean切边模上铝屑未吹干净,Blanking die bladewear切边模刀口磨损,Product is not inplace or product notcooling trimming产品未放到位或未冷却就切边6training on the workers for thework instruction 对员工进行培训，指导操作规范.Conveyor beltwith fan cooling time传送带上加装风扇,使产品冷

26、却时间缩短，the QC inspector shouldstrengthen not regularinspection检验员应定期进行巡检3108Staff training,fan has mountedon the conveyorbelt员工培训，传送带加装风扇Die castingdirector压铸主管：su yongStaff training,fan has mountedon the conveyorbelt员工开早会时培训，传送带上风扇已加装63354Burr residualproduct partingline,gate and slagin or protubera

27、nce产品分型线处毛刺残留,浇口和渣包处缺料或凸起Package product burrresidual,slag andgate in excess stockbump lead to reworkproducts,lack ofmaterial to productscrap产品毛刺残留，渣包和浇口处余料凸起导致产品返工，缺料导致产品报废6Blanking die bladewear切边模刀口磨损3Blanking die maintenance on aregular basis切边模定期保养 the QC inspector shouldstrengthen not regulari

28、nspection检验员应定期进行巡检236NONEBlank fullinspection毛坯全检Did not pick out thedefective products有裂开，冷隔等压铸缺陷的产品未挑出Lead to customercomplaints,productselection of reworkagain导致客户投诉，产品重新挑选返工5Operators check isnot careful,therequirement is notclear作业者检查不仔细，对要求不明确3Prepare the cleaning workinstructions,Training Wo

29、rks编制作业指导书,培训员工,工人要求全检Operation theirfull check345NONEPOTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)FMEA Number：潜潜在在失失效效模模式式及及后后果果分分析析（过过程程FMEA）FMEA 编 号：Part name：Process Responsibility：Prepared By:Approval By:零件名称：过程责任部门：编 制:批 准:Part number：Key Date：FMEA Date(Orig):FMEA Date(Rev.):Rev.零件

30、号：关键日期：FMEA 日期(编制):FMEA 日期(修订):版本：Core Team:主要参加人:Process Process Potential Cause(s)/Current Process Controls现行工艺控制person in charge负责人Action ResultsstepFunctionPotential FailurePotential Effect(s)SEVspecialMechanism(s)OCCDetec R.P.N.Recommended措施结果工序号 过 程Mode of Failure严重特of FailureUR不易探 风 险Action(s

31、)Action Taken采取的措施SEV OCC DETR.P.N.Requirements潜在失效模式潜在的失效后果度数性潜在的失效起因/机理频度数PreventSurvey测度数 序 数建议的措施严重级不易探 风 险 要 求预防探测度数数测度数 序 数表单编号：表单版本：A/0 Page 4 of 6FTumblast抛丸Product surfacepeeling,surfaceeffect and samplesare inconsistent,burrs,sharp corners产品表面起皮，有毛刺，有尖角Affect theappearance,leadingto produc

32、t rework,customer complaints.影响其外观,导致产品返工,客户抱怨,5Product surface hasa cold，tumblasttime is toolong,Lead toproductpeeling,tumblastshot time,Lead toproducts have burrsand sharp corners产品表面冷隔，抛丸时间太长导致产品起皮，抛丸时间短导致产品有毛刺和尖角3Prepare the cleaning workinstructions,Training Works编制作业指导书,培训员工,工人要求全检Operation th

33、eirfull check230NONEProducts are oily besoiled,bruise onproducts产品有油渍,产品碰伤，Theblasting effect andthe samples抛丸效果和样品不一致Affect theappearance,leadingto product rework,customer complaints.影响其外观,导致产品返工,客户抱怨,5Workers did not weargloves，Or glovesare too dirty，Thenumber of steel shotwear and tear工人未带手套拿产品 或

34、手套太脏,钢丸磨损 ,钢丸数量偏少2Prepare the cleaning workinstructions,Training Works编制作业指导书,培训员工,工人要求全检Operation theirfull check220NONEGmove to warehouse入库Fallingtransportation,product damage运输跌落，产品受损Product rework产品返工4Crane withoutsafety protectionproducts,handlinghuman error搬运产品没有安全防护，搬运人员失误2Used in the process

35、 of handlingtray,running a forklift forhandling personnel technicaltraining搬运过程中使用托盘，对搬运人员的开叉车技术进行培训Visual 目视324NONEfull inspection全检Did not pick out thedefective products有缺陷的产品未挑出Lead to customercomplaints,productselection of reworkagain导致客户投诉，产品重新挑选返工5Operators check isnot careful,therequirement i

36、s notclear作业者检查不仔细，对要求不明确3Prepare the cleaning workinstructions,Training Works编制作业指导书,培训员工,工人要求全检Operation theirfull check345NONEH车内孔Inner holeof vehicle内孔公差达不到图纸要求Internal holetolerance is not upto drawingrequirements.影响产品装配导致产品报废，流到客户处引起投诉Affect theproduct assemblylead to scrap,flowto the customer

37、complaints8刀具磨损，刀具上粘有铝屑On the toolwear,tool withaluminium crumbs2工人使用塞规自检内孔，检验员按检验卡要求巡检，定期更换刀具Workers use plug hole inspectionaccording to inspection,theinspector card inspection,regular replacement tool更换刀具，使用塞规检查内孔Replace the tool use plugcheck hole348NONEI拉槽trenchexcavated槽宽做不到公差要求Groove width ca

38、n notdo tolerancerequirements影响产品装配导致产品报废，流到客户处引起投诉Affect theproduct assemblylead to scrap,flowto the customercomplaints8刀具磨损，刀具上粘有铝屑On the toolwear,tool withaluminium crumbs2工人使用塞规自检内孔，检验员按检验卡要求巡检，定期更换刀具Workers use plug hole inspectionaccording to inspection,theinspector card inspection,regular rep

39、lacement tool更换刀具，使用塞规检查内孔Replace the tool use plugcheck hole348NONEPOTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)FMEA Number：潜潜在在失失效效模模式式及及后后果果分分析析（过过程程FMEA）FMEA 编 号：Part name：Process Responsibility：Prepared By:Approval By:零件名称：过程责任部门：编 制:批 准:Part number：Key Date：FMEA Date(Orig):FMEA Dat

40、e(Rev.):Rev.零件号：关键日期：FMEA 日期(编制):FMEA 日期(修订):版本：Core Team:主要参加人:Process Process Potential Cause(s)/Current Process Controls现行工艺控制person in charge负责人Action ResultsstepFunctionPotential FailurePotential Effect(s)SEVspecialMechanism(s)OCCDetec R.P.N.Recommended措施结果工序号 过 程Mode of Failure严重特of FailureUR不

41、易探 风 险Action(s)Action Taken采取的措施SEV OCC DETR.P.N.Requirements潜在失效模式潜在的失效后果度数性潜在的失效起因/机理频度数PreventSurvey测度数 序 数建议的措施严重级不易探 风 险 要 求预防探测度数数测度数 序 数表单编号：表单版本：A/0 Page 5 of 6J清洗烘干CleaningdryingProduct surfaceresidual oil导致客户投诉，产品重新挑选返工Lead tocustomer complaints,product selection ofrework again3清洗不够彻底Clean

42、enough to2检查清洗机Check the washingmachine工人要求全检The workersdemands for full inspection530NONEKPacking包装Packing damage,theproduct leakage包装箱破损，产品外漏The product is easyto damage产品易受损5Packing performanceis poor包装箱性能差3Before booking packing proofingconfirmed cases订包装箱之前打样确认包装箱强度MASTER CARTON DROP TEST丢落测试34

43、5NONEPacking quantitydoes not conform tothe requirements包装数量不符合要求Missing parts,customer complain缺件，顾客抱怨41.The packingworker has notfollowed the packingspec.没按包装标准进行包装2.not Check theproduct quantitypackaging包装之前未核对产品数量2Make the packaging instruction编制包装作业指导书，Packing beforeand after the packing must b

44、estatistical quantity,quantity isconsistent包装前和包装完后必须统计数量,前后数量是否一致Operator self-inspection作业员自检324NONELfinal inspection成品检验Nonconformingsentence tononconformingproduct不合格品判为合格品Cause customercomplaints引起客户投诉3Inspection targets,failure检验漏检，检具失效4Prepare the finished goodsinspection,sampling rate,measur

45、ing tool regularmaintenance and calibration编制成品检验卡，规定抽检比例，测量工具定期维护，校正。According to the inspectioncard sampling appearance,size按成品检验卡抽检外观，尺寸336NONEMmove to warehouse入库Fallingtransportation,product damage运输跌落，产品受损Product rework产品返工4Crane withoutsafety protectionproducts,handlinghuman error搬运产品没有安全防护，搬

46、运人员失误2Used in the process of handlingtray,running a forklift forhandling personnel technicaltraining搬运过程中使用托盘，对搬运人员的开叉车技术进行培训the warehouse keeper to re-check the part for correctness.产品运到仓库时有专门的人员进行检查324NONEPOTENTIAL FAILURE MODE AND EFFECTS ANALYSIS(PROCESS FMEA)FMEA Number：潜潜在在失失效效模模式式及及后后果果分分析析（过

47、过程程FMEA）FMEA 编 号：Part name：Process Responsibility：Prepared By:Approval By:零件名称：过程责任部门：编 制:批 准:Part number：Key Date：FMEA Date(Orig):FMEA Date(Rev.):Rev.零件号：关键日期：FMEA 日期(编制):FMEA 日期(修订):版本：Core Team:主要参加人:Process Process Potential Cause(s)/Current Process Controls现行工艺控制person in charge负责人Action Result

48、sstepFunctionPotential FailurePotential Effect(s)SEVspecialMechanism(s)OCCDetec R.P.N.Recommended措施结果工序号 过 程Mode of Failure严重特of FailureUR不易探 风 险Action(s)Action Taken采取的措施SEV OCC DETR.P.N.Requirements潜在失效模式潜在的失效后果度数性潜在的失效起因/机理频度数PreventSurvey测度数 序 数建议的措施严重级不易探 风 险 要 求预防探测度数数测度数 序 数表单编号：表单版本：A/0 Page

49、 6 of 6Nproductverification 产品审核 Dimension are out ofspecification 尺寸超差，The number,thespecification is notcorrect数量，规格不正确customer complaint客户投诉6Didnt do full sizeinspection,salesstaff mistakes没做全尺寸检查，销售人员失误3once per year measure the partfor all dimension 每年以次对产品的全尺寸测量一次，Check thephysical,checklist,d

50、eliveryorders核对实物，出货检查单，订单once per year measure the part forall dimension 每年以次对产品的全尺寸测量一次，Visualphysical,checklist,the order目视实物，检查单，订单354NONEOSend to customer发货发货不及时，包装破损Damaged product，customer complaint产品损坏，客户投诉3Transport vehiclefailure,safetyprotection does notreach thedesignated position运输车辆故障，