PFEMA-中文格式

1、 东风汽车公司商用车铸造一厂DFM foundry #1. 潜在失效模式及影响分析（PFMEA） PPAP-3Page 10 of 10Supplier Part No.供应商零件号：3970955-00Part Name零件名称：CAP, MAIN BEARINGFMEA & Rev FMEA编号及版本：S8Z0622-2005 00Part No. & Rev.零件号和级别：3970955-00Key Date 关键日期：2005/6/22Prepared By 编制人：杨士周 Yang shi zhouCore Team 核心小组： Product Development

2、 team for CAP,MAIN BEARINGProcess Responsibility 过程责任部门： Technique departmentDate(Orig.) 编制日期：2005/6/22Date(Rev) 修改日期：Part/Process Function产品/过程功能PCID/描述Potential FailureMode潜在失效模式Potential Effects Of Failure潜在失效影响Sev严重度Class级别Potential Causes Of Failure潜在的失效原因Occu频度数CurrentProcessControls现行控制方法Dete

3、c不可探测数RPN风险序数Recommend-Ed Corrective Actions建议采取措施responsibility & Target Completion Date责任和目标完成日期Actions Taken采取的措施Occu频度数Sev.严重度Detec不可探测数RPN风险序数10A金属材料进厂验收Acceptance Inspection Of Metal MaterialG1:分供方质保书Quality Guarantee From Sub-Supplier无质保书No Quality warrant拒收Rejection6分供方质量体系不完善Imperfect S

4、ub-Suppliers Quality System1检查Inspection16G2:进厂检验合格单Qualification Sheet Of Acceptance Inspection无检验单No Check Sheet混料Materials mixed6检验滞后Inspection Delay2检验报告Inspection report11210B非金属材料进厂验收Acceptance Inspection Of Nonmetal MaterialG1: 分供方质保书Sub-Suppliers Quality Guarantee无质保书No Quality Warrant拒收Reje

5、ction6分供方质量体系不完善imperfect Sub-suppliersquality system1检查Inspection16G2:进厂检验合格单Qualification Sheet Of Acceptance Inspection无检验单No Check Sheet混料Materials mixed6检验滞后Inspection Delay2检验报告Inspection report11220A室内存放Ware-House StoringG3:存放时间Storing Time过长Too Long品质变差Quality Variation6库存周期长Too LongStock Cy

6、cle1先进先出First in , first out21220A室内存放Ware-House StoringG4:存放标识Storing Identification错误标识Wrong identification无标识No identification用错料Material Used Wrongly6失误miscarriage1定期检查check termly21220B室外存放Outdoor StoringG3:存放时间Storing Time过长Too Long品质变差Quality Variation6库存周期长Too Long Stock Cycle2先进先出First in ,

7、 first out224G4:存放标识Storing Identification错误标识Wrong identification无标识No identification用错料Material Wrongly Used6失误miscarriage1定期检查check termly21230A配型砂prepara-tion Of Molding SandP1:湿压强度Green Compressive Strength过低Too Low型废多Too Many Scrap Moulds5粘土量低Low Clay Content21次/小时测定Determining Once/h SPC110P2

8、:紧实率Compactability过高Too High铸件气孔Casting Blow-Hole4*水份含量低Low Moisture Content21次/小时测定Determining Once/h SPC18过低Too Low铸件砂眼Casting Sand Hole5*水份含量高High Moisture Content21次/小时测定Determining Once/h SPC110P3:透气性Permeability过低Too Low铸件气孔Casting Blow-Hole5有效煤粉含量高High Effective Coal Dust Content21次/班测定Determ

9、ining Once/shift330粘土量过高TooHigh Clay Content21次/班测定Determining Once /shift33030B配芯砂Preparation of Core SandP6:常温抗拉强度Normal Temperature Tensile Strength过低Too Low断芯裂纹Core Rupture or Crack4*过烧Over Burnt21次/2小时检测Inspection Once/2h324覆膜不均匀Resin-Coated Inhomogenously21次/2小时检测Inspection Once/2h324P7:熔点Fusi

10、on Point过高Too High结壳过薄Too Thin Shell7乌洛托品超量Too Much Urotropine11次/2小时检测Inspection Once/2h321过低Too Low脱壳Shell Peeling Off6乌洛托品不足Shortage of Urotropine11次/2小时检测Inspection Once/2h31830C化料MeltingR1:含碳量C%过低Too low缩松porosity8*炉料定量不准Inexact Furnace Charges Ration1炉前成分分析Pretreatment Chemical Composition Ana

11、lysis21630C化料MeltingR1:含碳量C%过高Too high强度偏低8*炉料定量不准Inexact Furnace Charges Ration1炉前成分分析Pretreatment Chemical Composition Analysis216R2:含硅量Si%过低Too low铸件白口8*炉料定量不准Inexact Furnace Charges Ration1炉前成分分析Pretreatment Chemical Composition Analysis216过高Too High铁素体量高too much Ferrite8*炉料定量不准Inexact Furnace C

12、harges Ration1炉前成分分析Pretreatment Chemical Composition Analysis216R3:含锰量Mn%过低Too Low珠光体量低too much pearlite8*炉料定量不准Inexact Furnace Charges Ration1炉前成分分析Pretreatment Chemical Composition Analysis216R6:含铬量Cr%过低Too Low珠光体量低too much pearlite8*炉料定量不准Inexact Furnace Charges Ration1炉前成分分析Pretreatment Chemica

13、l Composition Analysis216R8:取样品质Quality Of Samples白口化不足Insufficient White Fracture成分测量不准Inaccurate Chemical CompositionAnalysis7光谱样激冷不足Insufficient Chilling Of Spectographic Specimen3水冷Water Cooling1217碳片质量差 Poor Quality Of Carbon Flake3清洁激冷铁板Cleaning Refrigeration Iron Board12135C炉前处理pre-treatmentC

14、1:出炉温度Tapping Temperature过高Too High孕育不良Poor Inoculation6未按时测温temperature measurement not on schedule2每半小时测 温Once / 30 Minutes224过低Too Low铸件冷隔或浇不足Coldshut or Misrun7未按时测温temperature measurement not on schedule2每半小时测 温Once / 30 Minutes228C2:孕育剂量Inoculant Quantity过多Too High终硅超量Last Silicon Content Too

15、Much4台秤失准Inaccurate Bench Scales2称量weigh216过少Too Low白口组织White fracture4台秤失准Inaccurate Bench Scales2称量weigh21640A造型MoldingZ1:铸造日期标识Casting Identification标识错误indistinct or wrong identification铸件报废casting be scrapped8操作失误miscarriage operation2首检Initial Inspection116Z2:模板加热温度Heating Of Pattern Plate过低To

16、o Low起型不良Withdrawing The Pattern Difficulty3断电Power Supply Failure3加热Heating118Z3:砂型硬度Sand Mold Hardness过低Too Low胀箱Swell4压实压力不足Insufficient Squeezing Force2调整Adjusting21640A造型MoldingZ5:模板销子销套Status Of Pin And pin bush of Pattern Plate错型Shift尺寸错误dimensional errors不能加工will not machine6磨损过量wear damage2

17、定检Regular Inspection224量规special gage下不到位Incorrectly偏芯Core Shift5操作不熟练Poor Skill1目视检查VisualInspection21050浇注PouringJ1:浇注温度Pouring Temperature过低Too Low冷隔浇不足Cold Shut or Misrun7等待时间过长Waiting Time Too Long2每包测温Determining Temperatureevery ladle228J2:孕育Inoculation衰退Fading出现碳化物Carbide Appears8*有效时间短Short

18、 Effective Time2三次孕育Three Batches Of Inoculation being Used232J3:可浇注时间Pourable Time过长Too Long孕育衰退Inoculation Fading6型废多Too Many Scrap Molds3报警装置Alarm device118设备故障Equipment Breakdown2报警装置Alarm device112J4:浇试块Pouring Test Specimen品质不良Poor Quality材质判断不准Material Deciding Inexactly7取样时间不正确Improper Time

19、For Making Sample2结合破坏性检查判定Judgement By Destroying inspection11460落砂ShakeoutL1:堆积Heaping过多Too Many压坏铸件Product Damage7铸件卡住Castings Jammed2随时钩出被卡住的铸件Taking Out Jammed Castings Timely22870清理CleaningL2:去浇口Remov-ing Gates残余过长Remains Too Much余量过大 too much stock4失误miscarriage2100% visual inspection目测216缺肉I

20、usuffici-ent Metal不被加工will not machine4失误miscarriage2100% visual inspection目测216S:表面粗糙度Surface Finish太粗糙Too rough加工问题machine problems6钢丸不足lack of Steel Grit2首检Initial Inspection112Q5:毛坯清整Casting Finishing缺肉Iusufficient Metal铸件报废casting be scrapped6失误miscarriage2100% visual inspection目测112不足Insuffici

21、ency多肉Surplus Metal4失误miscarriage2100% visual inspection目测216Q6: 飞边残余joint flash remains过长too long铸件不合格Unqualified Products未磨到位grinding not to position100% visual inspection目测Q7: 定位点pick up point不平整accident-ed影响加工affect machining缺陷或清理损伤defect or cleaning damage100% visual inspection目测80铸件检查Inspectio

22、nH1:力学性能Mechanics performance错判Wrong Decision不合格品出厂Unqualified Products8*操作技能差Poor Skill Of Operator2试验报告experiment report232H7:金相Microstructure错判Wrong Decision不合格品出厂Unqualified Products8*技能差Poor Skill Of Operator2检验报告Inspection report232H2:外观判定Surface Check漏检Failing To Inspection不合格品出厂Unqualified P

23、roducts8*技能差Poor Skill Of Operator2目视全检Full Visual Inspection232错判Wrong Decision内废率高High Internal Scrap Rate6技能差Poor Skill Of Operator1目视全检Full Visual Inspection212H3:标识状态Status of Identification标识不清indistinct identification铸件报废casting be scrapped8*起模不良 withdrawing difficult2目视全检Full Visual Inspection116H6:全尺寸检查Full dimension inspection超出铸件尺寸公差overtop castings tolerances铸件报废casting be scrapped8*模具磨损mould abrasion2定检模具Regular Inspection mould116H8：关键尺寸key dimension超出铸件尺寸公差overtop castings tolerances铸件报废casting be scrapped8*模具磨损mouldabrasion2定检模具Regular Inspection mould116H9:壁厚Wall thi