潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(过程PROCESS 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.序号NO.过程功能要求潜在的失效后果潜在的失效模式Process FunctionPotential Effect(S) ofPotential Failure ModeRequirementsFailure严级重别度ClassSev潜在的失效原因/机理Potential Cause(s)/Mechanism(s) of Failure供应商送原材料的规格有错The supplier send thewrong material频现行过程预防控制度Current Process Controls数PreventionOcc现行过程检测控制Current Process ControlsDetectionFMEA编号Number:页码Page:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25(修订REV)：责任及目标完措施结果Result难风险建议的措施严频难成日期检优先RecommendedResponsibility重度检度指数Action(S)度数度& TargetDetR.P.NSevOccDet.Completion936NANA工
风险优先指数R.P.N.10原材料进厂In-coming RawMaterial原材料规格错误影响零件性能Material spec is wrongaffect parts' capability41每批送货供应商附上材收料员检查送货单质证明书Material receiver checkThe supplier submit thequality certification everydelivering listshipping20IQC 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 confirm the Raw MaterialSpec List according to thedelivery order.2.IQC按原材料规格表检查原8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 material'sthickness by 3 points per coil,2生产领料时，操作工和QC对材料进行确认Operators and QC verifythe material inproduction line.QC复查在库 re-check theparts in period.48NANA30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 nextprocess影响后续零件生产affect partsproduction nextprocess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 inand out store.2. long term store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.按照程序要求，材料先进先出。 Frist in first out848NANA40存放Storage材料生锈rust of thematerial24864NANA50移至生产线Move Materialto ProductionLine材料转移错误mistake therawmaterial32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.PQC用通止规抽检 PQC check with Pin gauge848NANA∮6.25±0.15P200T 冲压60尺寸超差P200T Stampingis out of tolerance影响客户装配affectcustomer assembly3冲孔冲头磨损The tooling punch wearsaway定期维护保养模具2maintain the dieperiodically848NANA1 of 10
潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(过程PROCESS 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.序号NO.过程功能要求潜在的失效后果潜在的失效模式Process FunctionPotential Effect(S) ofPotential Failure ModeRequirementsFailure严级重别度ClassSev潜在的失效原因/机理Potential Cause(s)/Mechanism(s) of Failure频现行过程预防控制度Current Process Controls数PreventionOcc现行过程检测控制Current Process ControlsDetectionFMEA编号Number:页码Page:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25(修订REV)：责任及目标完措施结果Result难风险建议的措施严频难成日期检优先RecommendedResponsibility重度检度指数Action(S)度数度& TargetDetR.P.NSevOccDet.Completion工
风险优先指数R.P.N.∮78±0.25尺寸超差is out oftolerance1.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.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。PQC用卡尺抽检1.maintain the die2periodically PQC check with Vernier2. Contain theCalipertooling adjust partsand ask operatorsfollow the WI in theproduction process.848NANA60P200T 冲压P200T Stamping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-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 siteand ask theoperators follow itin 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 holediameter 31.8Max and PQCcheck it with verniercaliper.848NANA翻边高度过低taller or shorterof the blangingheight. 导致车削和磨削后7尺寸超差。Cause dimension 7out of SPEC. afterturning andgrinding.3合模高度不到位Non-conformingshutter height.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 siteand ask theoperators follow itin 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 checkit with vernier caliper848NANA37尺寸超差37 out ofdimension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。1. Set the WI site2and ask theoperators follow itin the productionprocess.1. 每卷材料上线时，检查材料厚度1. PQC Check thethickness of materialwhen every coil used.848NANA2 of 10潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(过程PROCESS 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.序号NO.过程功能要求潜在的失效后果潜在的失效模式Process FunctionPotential Effect(S) ofPotential Failure ModeRequirementsFailure严级重别度ClassSev潜在的失效原因/机理Potential Cause(s)/Mechanism(s) of Failure频现行过程预防控制度Current Process Controls数PreventionOcc现行过程检测控制Current Process ControlsDetectionFMEA编号Number:页码Page:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25(修订REV)：责任及目标完措施结果Result难风险建议的措施严频难成日期检优先RecommendedResponsibility重度检度指数Action(S)度数度& TargetDetR.P.NSevOccDet.Completion工
风险优先指数R.P.N.60P200T 冲压材料厚度超差P200T Stamping materialthickness out ofdimension.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 ofraw-material out ofSPEC.将来料厚度控制在3.25+/-0.05。2Set the thickness ofraw-material 3.25+/-0.05。 每卷材料上线时，PQC 检查材料厚度PQC Check the thicknessof material when everycoil used.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 thepart aftergrinding out of3合模高度不到位Non-conformingshutter height.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 siteand ask theoperators follow itin 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.848NANA翻边孔与地面拐角过大bigger radius ofP200T 冲压60the crossingP200T Stampingbetween 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.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 siteand ask theoperators follow itin 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毛刺过大 larger burrs影响零件外观及客户使用affect parts' appearanceand customers' usage2冲头或凹模镶块磨损punch and die insert wearsaway4定期维护保养模具maintain the dieperiodically1. 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 theoperators follow itafter stamping.操作工目视检查1pcs/15mins，PQC目视检查4pcs/hOperator check with E,1pcs/15mins,PQC check withE,4pcs/h传送前PQC确认包装正确后才可以传送。QC verify the packagingbefore delivery864NANA半成品包装包装错误70Package in semi-Non-conformingfinished productpackaging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.2848NANA3 of 10潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(过程PROCESS 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.序号NO.过程功能要求潜在的失效后果潜在的失效模式Process FunctionPotential Effect(S) ofPotential Failure ModeRequirementsFailure严级重别度ClassSev潜在的失效原因/机理Potential Cause(s)/Mechanism(s) of Failure频现行过程预防控制度Current Process Controls数PreventionOcc入库前每卡板贴上传送单核入库单。set the deliverynotes and receiptsnotes label on theRaw-material beforestore pallet.按照程序要求，材料先进先出。 Frist in first out现行过程检测控制Current Process ControlsDetection生产领料时，操作工和QC对材料进行确认Operators and QC verifythe material inproduction line.FMEA编号Number:页码Page:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25(修订REV)：责任及目标完措施结果Result难风险建议的措施严频难成日期检优先RecommendedResponsibility重度检度指数Action(S)度数度& TargetDetR.P.NSevOccDet.Completion工
风险优先指数R.P.N.移至半成品区零件转移错误80Move to semi-mistake the partfinished area影响后续零件生产affect partsproduction nextprocess3材料标识不明确Un-clear label2848NANA90存放Storage零件生锈rust of the part.影响后续零件生产affect partsproduction nextprocess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 store材料标识不明确Un-clear label2QC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 therawmaterial32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.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 toolwears away2.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。1. maintain thelathe periodically22. Set the WI siteand ask theoperators follow itin the productionprocess.PQC和操作工用气动量仪抽检 PQC and operators check withAIR gauge896NANA110机加工machining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 away定期维护保养车床2maintain the latheperiodicallyPQC用粗糙度仪抽检 PQC and operators check withroughness machine.848NANA4 of 10
潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(过程PROCESS FMEA)
项目名称 Item: 过程责任部门Process Responsibility: 质量部 QA Dept.machining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.序号NO.过程功能要求潜在的失效后果潜在的失效模式Process FunctionPotential Effect(S) ofPotential Failure ModeRequirementsFailure严级重别度ClassSev潜在的失效原因/机理Potential Cause(s)/Mechanism(s) of Failure频现行过程预防控制度Current Process Controls数PreventionOcc现行过程检测控制Current Process ControlsDetectionFMEA编号Number:页码Page:准备人Prepared By:
FMEA日期Data(编制(orig):2010.01.25(修订REV)：责任及目标完措施结果Result难风险建议的措施严频难成日期检优先RecommendedResponsibility重度检度指数Action(S)度数度& TargetDetR.P.NSevOccDet.Completion工
风险优先指数R.P.N.材料厚度超差 materialthickness out ofdimension.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.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 Set the WI site and PQC and operators check withask the operatorsmicrometer.follow it in theproduction 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 toolwears away2.Non-confromingclamping area110机加工machining1. 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 site2and ask theoperators follow itin the productionprocess.2. maintain thelathe periodically1. 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 site2and ask theoperators follow itin the productionprocess.2. maintain thelathe periodically1. 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 theoperators follow itafter stamping.PQC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.车刀磨损2.零件装夹不到位1.The lathe toolwears away2.Non-confromingclamping areaPQC和操作工用检具抽检。 PQC and operators check withgauge864NANA120半成品包装包装错误Package inNon-conformingsemi-finishedpackagingproduct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.2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 - 图文
