工
潜在的失效模式及效应分析表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.车型年/车辆类 关键日期Key Date: 2009.09.07主要参加人Core Team: QA部QA Dept./模具部Tooling. Dept.; /工程部Eng.Dept.过程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode严频潜在的失效后果级潜在的失效原因/机理重度Potential Effect(S) ofPotential Cause(s)/别度数FailureClassMechanism(s) of FailureSevOcc供应商送原材料的规格有错The supplier send thewrong material现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetectionFMEA编号Number:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25页码Page:
(修订REV)：措施结果Result责任及目标完风险难建议的措施成日期严频难优先RecommendeResponsibility检重度检指数d& Target度R.P.度数度Action(S)CompletionDetN.SevOccDetDate序号NO.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4affect parts' capability每批送货供应商附上材质证明书收料员检查送货单1The supplier submit theMaterial receiver checkquality certification everydelivering listshipping1.IQC按送货单核对原材料规格表IQC confirm the RawMaterial Spec List accordingto the delivery 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 RawMaterial Spec List,checkmaterial's thickness by 3points per coil,2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.936NANA20IQC 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 material送货单标明材料尺寸规格2define the SPEC. ofraw-material in thedilivery Bills848NANA30移至原材料仓材料转移错误Move Material tomistake theStorerawmaterial影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label1. 材料入库、出库凌乱。2. 放置周期过长。1. Un-sequence in andout store.2. long term store材料标识不明确Un-clear label入库前材料上贴来料管理票2set the label on theRaw-material beforestore.按照程序要求，材料先进先出。4 Frist in first out848NANA40存放Storage材料生锈rust of the material影响后续零件生产affect partsproduction nextprocess2QC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入库前材料上贴来料管理票2set the label on theRaw-material beforestore.定期维护保养模具2maintain the dieperiodically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.848NANAP200T 冲压60P200TStamping∮6.25±0.15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 awayPQC用通止规抽检 PQC check with Pin gauge848NANA1 of 10
工
潜在的失效模式及效应分析表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.车型年/车辆类 关键日期Key Date: 2009.09.07主要参加人Core Team: QA部QA Dept./模具部Tooling. Dept.; /工程部Eng.Dept.过程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode严频潜在的失效后果级潜在的失效原因/机理重度Potential Effect(S) ofPotential Cause(s)/别度数FailureClassMechanism(s) of FailureSevOcc现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetectionFMEA编号Number:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25页码Page:
(修订REV)：措施结果Result责任及目标完风险难建议的措施成日期严频难优先RecommendeResponsibility检重度检指数d& Target度R.P.度数度Action(S)CompletionDetN.SevOccDetDate序号NO.风险优先指数R.P.N.∮78±0.25尺寸超差is out of tolerance1.影响客户使用。2.后续磨削无法装夹。1. affect 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.1.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 die2periodically2. Contain the toolingadjust parts and askoperators follow the WIin the productionprocess.PQC用卡尺抽检 PQC check with VernierCaliper848NANA60P200T 冲压P200TStamping1. 车削后导致32.549尺寸超差。2. 内孔车削后无法满翻边孔内径过大或者足粗糙度要求。椭圆1. Cause 32.549 outflanging hole bigger orof diemension.smaller2. 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.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。22. 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 导致车削和磨削后7翻边高度过低尺寸超差。taller or shorter of theCause dimension 7blanging height.out of SPEC. afterturning and grinding.3合模高度不到位Non-conforming shutterheight.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。21. 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 caliper848NANA37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.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。21. 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 every coilused.848NANA2 of 10工
潜在的失效模式及效应分析表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.车型年/车辆类 关键日期Key Date: 2009.09.07主要参加人Core Team: QA部QA Dept./模具部Tooling. Dept.; /工程部Eng.Dept.过程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode严频潜在的失效后果级潜在的失效原因/机理重度Potential Effect(S) ofPotential Cause(s)/别度数FailureClassMechanism(s) of FailureSevOcc现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetectionFMEA编号Number:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25页码Page:
(修订REV)：措施结果Result责任及目标完风险难建议的措施成日期严频难优先RecommendeResponsibility检重度检指数d& Target度R.P.度数度Action(S)CompletionDetN.SevOccDetDate序号NO.风险优先指数R.P.N.60P200T 冲压P200TStamping材料厚度超差 material thicknessout of dimension.导致磨削后3.0+/-0.15尺寸超差。Cause the dimension3.0+/-0.15 out ofSPEC. after grinding.3来料厚度超差the thickness of raw-material out of SPEC. 每卷材料上线时，PQC 检查将来料厚度控制在材料厚度3.25+/-0.05。2PQC Check the thickness of8Set the thickness of raw-material when every coilmaterial 3.25+/-0.05。used.48NANA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 the flatnessafer grinding out ofdimension.2.cause thethickness of the partafter grinding out ofdimension.3合模高度不到位Non-conforming shutterheight.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。21. 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.848NANAP200T 冲压60P200TStamping翻边孔与地面拐角过大bigger radius of thecrossing between theflanging and theflatness.导致磨削后34.5MAX尺寸超差。Cause 34.5MAX aftergrinding out ofdimension.3合模高度不到位Non-conforming shutterheight.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。21. 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 control instamping process and PQCcheck it in period.848NANA影响零件外观及客户使用毛刺过大 larger burrsaffect parts'appearance 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/h8Operator check with E,1pcs/15mins,PQC checkwith E,4pcs/h64NANA半成品包装Package in70semi-finishedproduct包装错误Non-conformingpackaging造成零件表面的压伤。Cause the dent in thesurface of the part.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 delivery848NANA3 of 10工
潜在的失效模式及效应分析表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.车型年/车辆类 关键日期Key Date: 2009.09.07主要参加人Core Team: QA部QA Dept./模具部Tooling. Dept.; /工程部Eng.Dept.过程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode严频潜在的失效后果级潜在的失效原因/机理重度Potential Effect(S) ofPotential Cause(s)/别度数FailureClassMechanism(s) of FailureSevOcc现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetectionFMEA编号Number:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25页码Page:
(修订REV)：措施结果Result责任及目标完风险难建议的措施成日期严频难优先RecommendeResponsibility检重度检指数d& Target度R.P.度数度Action(S)CompletionDetN.SevOccDetDate序号NO.风险优先指数R.P.N.移至半成品区80Move 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 label入库前每卡板贴上传送单核入库单。set the delivery notes2and receipts notes labelon the Raw-materialbefore store pallet.按照程序要求，材料先进先出。2 Frist in first out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 store材料标识不明确Un-clear labelQC复查在库 re-check theparts in period.848NANA移至生产线Move Material100to ProductionLine材料转移错误mistake therawmaterial影响后续零件生产affect partsproduction nextprocess3入库前材料上贴来料管理票2set the label on theRaw-material beforestore.1. 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 lathe2periodically2. Set the WI site andask the operators followit in the productionprocess.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.848NANA∮32.549±0.012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 areaPQC和操作工用气动量仪抽检 PQC and operators checkwith AIR gauge896NANA110机加工machining内孔粗糙度不良1.影响客户使用。Non-conforming of the1. affect customerroughness in the innerassemblyhole.31.车刀磨损1.The lathe tool wearsaway定期维护保养车床2maintain the latheperiodicallyPQC用粗糙度仪抽检 PQC and operators checkwith roughness machine.848NANA4 of 10
工
潜在的失效模式及效应分析表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.车型年/车辆类 关键日期Key Date: 2009.09.07
machining主要参加人Core Team: QA部QA Dept./模具部Tooling. Dept.; /工程部Eng.Dept.过程功能要求ProcessFunctionRequirements潜在的失效模式Potential FailureMode严频潜在的失效后果级潜在的失效原因/机理重度Potential Effect(S) ofPotential Cause(s)/别度数FailureClassMechanism(s) of FailureSevOcc现行过程预防控制Current ProcessControls Prevention现行过程检测控制Current Process ControlsDetectionFMEA编号Number:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25页码Page:
(修订REV)：措施结果Result责任及目标完风险难建议的措施成日期严频难优先RecommendeResponsibility检重度检指数d& Target度R.P.度数度Action(S)CompletionDetN.SevOccDetDate序号NO.风险优先指数R.P.N.材料厚度超差 material thicknessout of dimension.导致磨削后3.0+/-0.15尺寸超差。Cause the dimension3.0+/-0.15 out ofSPEC. after grinding.5进刀量过大longer of the feeding.现场放置操作指导书，并且要求操作工严格按PQC用千分尺抽检照操作指导书操作。1 PQC and operators check Set the WI site and askwith micrometer.the operators follow it inthe production process.840NANA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 area1. 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。PQC和操作工用检具抽检。1. Set the WI site and2 PQC and operators checkask the operators followwith gaugeit in the productionprocess.2. maintain the latheperiodically1. 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。PQC和操作工用检具抽检。1. Set the WI site and2 PQC and operators checkask the operators followwith gaugeit in the productionprocess.2. maintain the latheperiodically864NANA110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 area864NANA120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 in thesurface of the part.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 delivery848NANA5 of 10
FMEA潜在失效模式及分析标准表格模版
