机械加工pfmea案例.xls

罗信精密零件 上海 有限公司 LX Precision Shanghai Co Ltd 潜潜在在的的失失效效模模式式及及后后果果分分析析 Potential Failure Mode and Effects Analysis Process 客户名称 Customer Name Thomas Magnete GMBH 客户零件图号 版本 Customer Part No Rev 448817 02 罗信零件图号 LX Part No A01 002 零件名称 Part Name Description Cone ng 初始制定日期 Original Maked Date 2009 11 16 FMEA Revised Minutes Rev DateRevised ItemRevised by B10 DecThe document format has been changed Lu Xianming PotentialPotential FailureFailure ModeMode andand EffectsEffects AnalysisAnalysis Process Process FMEA FMEA 潜潜在在的的失失效效模模式式及及后后果果分分析析 FMEA 零件名称 客户图号 版本 Part Name Drawing No Rev 过程责任 Process Responsibility FMEA日期 原始 Date Orig 日期 修订 Revised date 零件程序编号 版本号 Part Program No Rev 初始生产日期 Orignal Production Date 编制者 Prepared By 核心小组 Core Team 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 Sever ity 过程 分类 Proce ss Class ificati on 产品 分类 Produ ct Class ificati on 潜在失效起因 Potential Cause of Failure 频度 O Occurr ence 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 Det ecti on 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 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 Surface crash 表面碰伤 Impact machining 影响后续加工 4 transit method was unreasonable 搬运方法不合理 2 Transit way was regulated 规定搬运方法 Incoming Inspection 来料检验 648NANANANANANANA incoming inspection 来料检验 28 0 03 Dimension out of spec 尺寸超差 Can t be machined 无法加工 6 Supplier s dimension out of spec 供应商生产尺寸超差 3 Supplier provide material certification 供应商提供材质证书 Incoming Inspection 来料检验 354NANANANANANANA American code AISI 1215 Material type wrong 材料牌号不对 Impact the functionality of parts 影响零件使用性能 8 Supplier delivery wrong material 供应商送错材料 2 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 Warehouse keeper checks the raw material according with delivery list 仓库人员按送货单检查原材料 696 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 The material s chemical composition are out of spec 材料成份超差 Impact the functionality of parts 影响零件使用性能 8 Supplier production control out of spec 供应商材质成份控制超差 2 Supplier provide material certification 供应商提供材质证书 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 696 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 material s chemical composition are all according with Spec 确定化学成份符 合规定 81648 Issue Material 发料 Issue wrong material 发错材料 1 Impact machining 2 Impact function of parts 1 影响后续加工 2 影响产品使用功能 6 Warehouse keeper issue wrong material 仓库发料错误 1 Paint the different color at the bar end to manage different raw material 材料进行颜色管理 Operator and warehouse keeper check each other 操作员人员和仓库管理员互相检验 318NANANANANANANA 201 Turning Facing 光平面 Face is not flat 端面不平整 Impact machining 影响后续加工 3 Tools wear 刀具磨损 2 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 318NANANANANANANA 202 Drilling hole 钻孔 5 4 Dimension out of tolerance 尺寸超差 Impact machining 影响后续加工 6 Tools wear 刀具磨损 2 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 336NANANANANANANA 203 Brilling Hole 镗孔 20 5 6 0 2 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 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 Sever ity 过程 分类 Proce ss Class ificati on 产品 分类 Produ ct Class ificati on 潜在失效起因 Potential Cause of Failure 频度 O Occurr ence 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 Det ecti on 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 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 203 Brilling Hole 镗孔 32 42 20 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 19 5 9 0 1 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 15 14 5 0 2 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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354 NANANANANANANA 204 Reamering hole 铰孔 21 5 5 0 02 0 005 Dimension out of tolerance 尺寸超差 Impact assembly 影响客户装配 8 Tools wear 刀具磨损 4 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 4128 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 PPK 1 67 1 刀具材质和刀 具寿命已经确定 2 PPK 1 67 82464 205 Dilling hole 钻孔 10 Dimension out of tolerance 尺寸超差 Impact machining 影响后续加工 4 Tools wear 刀具磨损 2 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 324NANANANANANANA 206 Boring hole 镗孔 18 12 2 0 04 0 Dimension out of tolerance 尺寸超差 Impact assembly 影响客户装配 8 Tools wear 刀具磨损 4 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 4128 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 PPK 1 67 1 刀具材质和刀 具寿命已经确定 2 PPK 1 67 82464 16 17 5 0 02 0 03 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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354 NANANANANANANA 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 Sever ity 过程 分类 Proce ss Class ificati on 产品 分类 Produ ct Class ificati on 潜在失效起因 Potential Cause of Failure 频度 O Occurr ence 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 Det ecti on 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 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 206 Boring hole 镗孔 37 Dimension out of tolerance 尺寸超差 Impact functionality 影响使用性能 6 1 Tools wear 刀具磨损 2 The machine center line offset 机床中心线偏移 3 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 Checking dimensions on line 在线检查尺寸 354NANANANANANANA 207 Turning Outside Diameter车 外圆 4 14 03 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 5 12 6 0 03 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 1 16 18 0 0 04 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 25 45 6 5 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 4 Tools wear 刀具磨损 3 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 336NANANANANANANA 208 Groovin g 割槽 2 14 0 05 1 Dimension out of tolerance 2 Surface is rough 1 尺寸超差 2 表面粗糙 Impact assembly 影响客户装配 7 Tools wear 刀具磨损 4 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 4112 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 PPK 1 67 1 刀具材质和刀 具寿命已经确定 2 PPK 1 67 72456 11 2 2 0 2 0 1 Dimension out of tolerance 2 Surface is rough 1 尺寸超差 2 表面粗糙 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 26 R0 1 0 1 2X Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 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 Sever ity 过程 分类 Proce ss Class ificati on 产品 分类 Produ ct Class ificati on 潜在失效起因 Potential Cause of Failure 频度 O Occurr ence 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 Det ecti on 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 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 208 Groovin g 割槽 3 11 8 0 2 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 209 Cutting off 切断 17 23 4 Dimension out of tolerance 尺寸超差 1 Customer dissatisfaction 2 Impact machining 1 客户不满意 2 影响后续加工 5 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 3 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 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 345NANANANANANANA 210 Drilling hole 钻孔 22 6 0 1 1 Dimension out of tolerance 2 Surface is rough 1 尺寸超差 2 表面粗糙 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 36 Dimension out of tolerance 尺寸超差 Impact functionality 影响使用性能 6 1 Tools wear 刀具磨损 2 The machine center line offset 机床中心线偏移 3 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 Checking dimensions on line 在线检查尺寸 354NANANANANANANA 14 9 0 25 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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354 NANANANANANANA 33 118 3 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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345 NANANANANANANA 37 0 2 0 2 0 1 45 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 211 Drilling hole 钻孔 10 Dimension out of tolerance 尺寸超差 Impact machining 影响后续加工 4 Tools wear 刀具磨损 2 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 324NANANANANANANA 212 Boring Hole 镗孔 22 8 8 0 1 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 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 Sever ity 过程 分类 Proce ss Class ificati on 产品 分类 Produ ct Class ificati on 潜在失效起因 Potential Cause of Failure 频度 O Occurr ence 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 Det ecti on 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 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 212 Boring Hole 镗孔 30 0 1 45 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 13 2 5 0 2 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 12 1 2 0 025 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 35 Dimension out of tolerance 尺寸超差 Impact functionality 影响使用性能 6 The machine center offset 机床中心线偏移 3 Setup the machine center periodically 定期调整机床中心 Checking dimensions on line 在线检查尺寸 354NANANANANANANA 24 13 0 04 Dimension out of tolerance 尺寸超差 Impact assembly 影响客户装配 8 Tools wear 刀具磨损 3 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 496 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 PPK 1 67 1 刀具材质和刀 具寿命已经确定 2 PPK 1 67 82464 213 Turning Outside Diameter车 外圆 6 14 6 0 1 1 Dimension out of tolerance 2 Surface is rough 1 尺寸超差 2 表面粗糙 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 29 0 2 0 1 45 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 4 Tools wear 刀具磨损 2 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 324NANANANANANANA 9 3 8 0 1 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 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 354NANANANANANANA 0 2 0 01 45 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 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 Sever ity 过程 分类 Proce ss Class ificati on 产品 分类 Produ ct Class ificati on 潜在失效起因 Potential Cause of Failure 频度 O Occurr ence 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 Det ecti on 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 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 213 Turning Outside Diameter车 外圆 27 0 3 0 05 20 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 5 Tools wear 刀具磨损 3 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 345NANANANANANANA 7 19 6 0 05 0 Dimension out of tolerance 尺寸超差 Customer dissatisfaction 客户不满意 6 Tools wear 刀具磨损 3 1 Estimate the tool life ch