机械加工pfmea案例GOOD

罗信精密零件（上海）有限公司 LX Precision (Shanghai) Co., Ltd. Thomas Magnete GMBH 448817 / 02 A01-002 Cone ng 2009/11/16 Rev.DateRevised by B10/Dec Lu Xianming 潜在的失效模式及后果分析潜在的失效模式及后果分析 Potential Failure Mode and Effects Analysis (Process) FMEA Revised Minutes Revised Item The document format has been changed 初始制定日期 Original Maked Date ： 客户名称 Customer Name： 客户零件图号/版本 Customer Part No./Rev. 罗信零件图号 LX Part No 零件名称 Part Name/Description ： 日期(修订) Revised date 采取的措施及生 效日期 Action Taken & Effective Date 严重 度 Seve ruty 频度 Occ yran ce 探测 度 Dete ction RPN 10.Raw material in coming来料 4 transit method was unreasonable 搬运方法不合理 2648NANANANANANANA 28 -0.03 6 Suppliers dimension out of spec 供应商生产尺寸超差 3354NANANANANANANA American code:AISI 1215 8 Supplier delivery wrong material 供应商送错材料 2696 Check certificate of raw materials in line with the label of raw materials 检查材质证明与原材料 标识一致 Warehouse keeper 仓库管理员 11-15 Warehouse keeper confirm delivery list and the raw material certification 库管员确认送货 单和材质证明 81648 8 Supplier production control out of spec. 供应商材质成份控制超 差 2696 Send the material to the third party to conduct an overall checking once a year 每年一次第三方原材料 检测 Quality department 质量保证部 11-19 The materials chemical composition are all according with Spec. 确定化学成份符 合规定 81648 Issue Material 发料 6 Warehouse keeper issue wrong material 仓库发料错误 1318NANANANANANANA 201. Turning Facing 光平面3 Tools wear 刀具磨损 2318NANANANANANANA 202. Drilling hole 钻孔 5.46 Tools wear 刀具磨损 2336NANANANANANANA 203. Brilling Hole 镗孔 （20）5.6 +0.26 Tools wear 刀具磨损 3354NANANANANANANA Cant be machined 无法加工 Impact the functionality of parts 影响零件使用性能 Impact the functionality of parts 影响零件使用性能 1.Impact machining 2.Impact function of parts 1.影响后续加工 2.影响产品使用功能 Impact machining 影响后续加工 Impact machining 影响后续加工 Customer dissatisfaction 客户不满意 Supplier provide material certification 供应商提供材质证书 1.Check purchasing order of raw material 2.Supplier should inform us before delivery 1.材料订购进行审核 2.供应商送货之前提前通知 Supplier provide material certification 供应商提供材质证书 Paint the different color at the bar end to manage different raw material 材料进行颜色管理 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Incoming inspection engineer check with material certification 2.Send the material to the third party to conduct an overall checking once three years 1.来料检验核对材料证书 2.每3年一次第三方原材料检测 Operator and warehouse keeper check each other 操作员人员和仓库管理员互相检验 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 RPN 建议措施 Recommended Action 责任和目标完成日期 Responsibility & Target Completion Date 措施执行结果 Action Results Incoming Inspection 来 料检验 Warehouse keeper checks the raw material according with delivery list 仓库人员按送货单检查原材料 潜在失效起因 Potential Cause of Failure 频度 （O)O ccurre nce 产品 分类 Produ ct Classi ficatio n 现行过程控制预防 Current Process Controls Prevention 现行过程控制探测 Current Process Controls delection 探测 度 （D ） Dete ction 初始生产日期 Orignal Production Date 编制者 Prepared By 过程责任 Process Responsibility 零件程序编号 /版本号 Part Program No./Rev. 核心小组 Core Team 零件名称 /客户图号 /版本： Part Name /Drawing No. / Rev. incoming inspection 来料检验 Material type wrong 材料牌号不对 Impact machining 影响后续加工 过程步骤/功 能 Process Step / Function 要求 Requirements 潜在失效模式 Potential Failure Mode 潜在失效后果 Potential Effect of Failure The materials chemical composition are out of spec. 材料成份超差 Issue wrong material 发错材料 Face is not flat 端面不平整 严重 度 （S) Seve rity 过程 分类 Proce ss Classi ficatio n Dimension out of tolerance 尺寸超差 Dimension out of spec 尺寸超差 Dimension out of tolerance 尺寸超差 *-FMEA-* Potential Failure Mode and Effects Analysis (Process FMEA) 潜在的失效模式及后果分析潜在的失效模式及后果分析 FMEA日期（原始） Date (Orig.) Transit way was regulated 规定搬运方法 Incoming Inspection 来料检验 Surface crash 表面碰伤 采取的措施及生 效日期 Action Taken & Effective Date 严重 度 Seve ruty 频度 Occ yran ce 探测 度 Dete ction RPN RPN 建议措施 Recommended Action 责任和目标完成日期 Responsibility & Target Completion Date 措施执行结果 Action Results 潜在失效起因 Potential Cause of Failure 频度 （O)O ccurre nce 产品 分类 Produ ct Classi ficatio n 现行过程控制预防 Current Process Controls Prevention 现行过程控制探测 Current Process Controls delection 探测 度 （D ） Dete ction 过程步骤/功 能 Process Step / Function 要求 Requirements 潜在失效模式 Potential Failure Mode 潜在失效后果 Potential Effect of Failure 严重 度 （S) Seve rity 过程 分类 Proce ss Classi ficatio n 203. Brilling Hole 镗孔 （32,42）205 Tools wear 刀具磨损 3345NANANANANANANA （19）5.90.1 5 Tools wear 刀具磨损 3345NANANANANANANA （15）14.5+0.26 Tools wear 刀具磨损 3354NANANANANANANA 204 Reamering hole 铰孔 （21）5.5 +0.02/-0.005 8 Tools wear 刀具磨损 44128 1.Determine the tool material and enactment tool life 2.Determine the process parameters on the machine 3.SPC control 1.确定刀具材质和设定 刀具使用寿命 2.确定过程参数 3.SPC控制 Technology Department 技术部 Production Department 生产部 11-17 1.Tool material and tool life were determined. 2.PPK1.67. 1.刀具材质和刀 具寿命已经确定 2.PPK1.67 82464 205. Dilling hole 钻孔 104 Tools wear 刀具磨损 2324NANANANANANANA 206. Boring hole 镗孔 （18） 12.2+0.04/0 8 Tools wear 刀具磨损 44128 1.Determine the tool material and enactment tool life 2.Determine the process parameters on the machine 3.SPC control 1.确定刀具材质和设定 刀具使用寿命 2.确定过程参数 3.SPC控制 Technology Department 技术部 Production Department 生产部 11-17 1.Tool material and tool life were determined. 2.PPK1.67. 1.刀具材质和刀 具寿命已经确定 2.PPK1.67 82464 （16）17.5 +0.02/- 0.03 6 Tools wear 刀具磨损 3354NANANANANANANA Impact assembly 影响客户装配 Customer dissatisfaction 客户不满意 Impact assembly 影响客户装配 Impact machining 影响后续加工 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 Checking dimensions on line 在线检查尺寸 采取的措施及生 效日期 Action Taken & Effective Date 严重 度 Seve ruty 频度 Occ yran ce 探测 度 Dete ction RPN RPN 建议措施 Recommended Action 责任和目标完成日期 Responsibility & Target Completion Date 措施执行结果 Action Results 潜在失效起因 Potential Cause of Failure 频度 （O)O ccurre nce 产品 分类 Produ ct Classi ficatio n 现行过程控制预防 Current Process Controls Prevention 现行过程控制探测 Current Process Controls delection 探测 度 （D ） Dete ction 过程步骤/功 能 Process Step / Function 要求 Requirements 潜在失效模式 Potential Failure Mode 潜在失效后果 Potential Effect of Failure 严重 度 （S) Seve rity 过程 分类 Proce ss Classi ficatio n 206. Boring hole 镗孔 （37）6 1,Tools wear 刀具磨损 2,The machine center line offset 机床中心线偏移 3354NANANANANANANA 207. Turning Outside Diameter车 外圆 （4）14.035 Tools wear 刀具磨损 3345NANANANANANANA （5） 12.6 0.03 5 Tools wear 刀具磨损 3345NANANANANANANA （1）16.18 0/- 0.04 6 Tools wear 刀具磨损3354NANANANANANANA （25）45.65 4 Tools wear 刀具磨损3336NANANANANANANA 208.Groovin g 割槽 （2） 14+0.05 7 Tools wear 刀具磨损44112 1.Determine the tool material and enactment tool life 2.Determine the process parameters on the machine 3.SPC control 1.确定刀具材质和设定 刀具使用寿命 2.确定过程参数 3.SPC控制 Technology Department 技术部 Production Department 生产部 11-17 1.Tool material and tool life were determined. 2.PPK1.67. 1.刀具材质和刀 具寿命已经确定 2.PPK1.67 72456 （11）2.2 +0.2/06 Tools wear 刀具磨损3354NANANANANANANA （26）R0.1 +0.1(2X) 5 Tools wear 刀具磨损3345NANANANANANANA Impact assembly 影响客户装配 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Impact functionality 影响使用性能 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 3,Setup the machine center line periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 3.定期调整机床中心 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Dimension out of tolerance 尺寸超差 1.Dimension out of tolerance 2.Surface is rough 1.尺寸超差 2.表面粗糙 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 1.Dimension out of tolerance 2.Surface is rough 1.尺寸超差 2.表面粗糙 Dimension out of tolerance 尺寸超差 采取的措施及生 效日期 Action Taken & Effective Date 严重 度 Seve ruty 频度 Occ yran ce 探测 度 Dete ction RPN RPN 建议措施 Recommended Action 责任和目标完成日期 Responsibility & Target Completion Date 措施执行结果 Action Results 潜在失效起因 Potential Cause of Failure 频度 （O)O ccurre nce 产品 分类 Produ ct Classi ficatio n 现行过程控制预防 Current Process Controls Prevention 现行过程控制探测 Current Process Controls delection 探测 度 （D ） Dete ction 过程步骤/功 能 Process Step / Function 要求 Requirements 潜在失效模式 Potential Failure Mode 潜在失效后果 Potential Effect of Failure 严重 度 （S) Seve rity 过程 分类 Proce ss Classi ficatio n 208.Groovin g 割槽 （3）11.80.2 6 Tools wear 刀具磨损3354NANANANANANANA 209 Cutting off 切断 （17）23.45 1, The part length is not stable 2. The machine main spindle loosing 1.原材料外径尺寸不均匀 2.机床主轴夹头松动 3345NANANANANANANA 210 Drilling hole 钻孔 （22）6+0.16 Tools wear 刀具磨损3354NANANANANANANA (36)6 1,Tools wear 刀具磨损 2,The machine center line offset 机床中心线偏移 3354NANANANANANANA (14)90.25 6 Tools wear 刀具磨损 3354NANANANANANANA (33)11835 Tools wear 刀具磨损 3345NANANANANANANA (37)0.2 +0.2/0.1*45 5 Tools wear 刀具磨损3345NANANANANANANA 211. Drilling hole 钻孔 104 Tools wear 刀具磨损 2324NANANANANANANA 212 Boring Hole 镗孔 (22)8.80.1 6 Tools wear 刀具磨损3354NANANANANANANA Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 1.Customer dissatisfaction 2.Impact machining 1.客户不满意 2.影响后续加工 Customer dissatisfaction 客户不满意 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Check the raw material when changing material and make sure the outer diameter within 0.03mm on each point 2.Check the collect loose or not periodically 1.每次换料时，测量材料外径, 要 求变化在0.03 mm 以内 2.定期进行检查工装松紧程度 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 Checking dimensions on line 在线检查尺寸 1.Inspecting on line 2.Use the cutting off detection fixture 1.在线检查尺寸 2.使用切断检测功能 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 1.Dimension out of tolerance 2.Surface is rough 1.尺寸超差 2.表面粗糙 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Impact machining 影响后续加工 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 Checking dimensions on line 在线检查尺寸 Dimension out of tolerance 尺寸超差 Impact functionality 影响使用性能 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 3,Setup the machine center line periodically 1.估算刀具寿命,定时换刀 Checking dimensions on line 在线检查尺寸 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 采取的措施及生 效日期 Action Taken & Effective Date 严重 度 Seve ruty 频度 Occ yran ce 探测 度 Dete ction RPN RPN 建议措施 Recommended Action 责任和目标完成日期 Responsibility & Target Completion Date 措施执行结果 Action Results 潜在失效起因 Potential Cause of Failure 频度 （O)O ccurre nce 产品 分类 Produ ct Classi ficatio n 现行过程控制预防 Current Process Controls Prevention 现行过程控制探测 Current Process Controls delection 探测 度 （D ） Dete ction 过程步骤/功 能 Process Step / Function 要求 Requirements 潜在失效模式 Potential Failure Mode 潜在失效后果 Potential Effect of Failure 严重 度 （S) Seve rity 过程 分类 Proce ss Classi ficatio n 212 Boring Hole 镗孔 (30)0.1*455 Tools wear 刀具磨损3345NANANANANANANA (13)2.5+0.26 Tools wear 刀具磨损3354NANANANANANANA (12)1.20.025 6 Tools wear 刀具磨损3354NANANANANANANA (35)6 The machine center offset 机床中心线偏移 3354NANANANANANANA (24) 13 +0.048 Tools wear 刀具磨损 3496 1.Determine the tool material and enactment tool life 2.Determine the process parameters on the machine 3.SPC control 1.确定刀具材质和设定 刀具使用寿命 2.确定过程参数 3.SPC控制 Technology Department 技术部 Production Department 生产部 11-17 1.Tool material and tool life were determined. 2.PPK1.67. 1.刀具材质和刀 具寿命已经确定 2.PPK1.67 82464 213.Turning Outside Diameter车 外圆 (6) 14.6+0.1 6 Tools wear 刀具磨损 3354NANANANANANANA (29)0.20.1*45 4 Tools wear 刀具磨损 2324NANANANANANANA (9)3.8+0.1 6 Tools wear 刀具磨损 3354NANANANANANANA 0.20.01*45 5 Tools wear 刀具磨损 3345NANANANANANANA Impact functionality 影响使用性能 Impact assembly 影响客户装配 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Customer dissatisfaction 客户不满意 Setup the machine center periodically 定期调整机床中心 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 2.Correct the tooling parameters periodically 1.估算刀具寿命,定时换刀 2.定期对刀具参数进行补正 1.Estimate the tool life, change tools periodically 1.估算刀具寿命,定时换刀 2.Correct the tooling parameters periodically 2.定期对刀具参数进行补正 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 1.Dimension out of tolerance 2.Surface is rough 1.尺寸超差 2.表面粗糙 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Dimension out of tolerance 尺寸超差 Checking dimensions on line 在线检查尺寸 Checking dimensions on line 在线检查尺寸 采取的措施及生 效日期 Action Taken & Effective Date 严重 度 Seve ruty 频度 Occ yran ce 探测 度 Dete ction RPN RPN 建议措施 Recommended Action 责任和目标完成日期 Responsibility & Target Completion Date 措施执行结果 Action Results 潜在失效起因 Potential Cause of Failure 频度 （O)O ccurre nce 产品 分类 Produ ct Classi ficatio n 现行过程控制预防 Current Process Controls Prevention 现行过程控制探测 Current Process Controls delection 探测 度 （D ） Dete ction 过程步骤/功 能 Process Step / Function 要求 Requirements 潜在失效模式 Potential Failure Mode 潜在失效后果 Potential Effect of Failure 严重 度 （S) Seve rity 过程 分类 Proce ss Classi ficatio n 213.Turning Outside Diameter车 外圆 (27)0.30.05*20 5 Tools wear 刀具磨损 3345NANANANANANANA (7)19.6+0.05/06 Tools wear 刀具磨损 3354NANANANANANANA (28)0.2 0.05*45 5 Tools wear 刀具磨损 3345NANANANANANANA (3) 27.3 +0.06/+0.02 7 Tools wear 刀具磨损 44112 1.Determine the tool material and enactment tool life 2.Determine the pro