PFMEA潜在失效模式及后果分析

,,,,POTENTIALFAILUREMODEANDEFFECTSANALYSIS,,,,,,,,,,,,,,

,,,,(PROCESSFMEA),,,,,,,,,FMEANumber：,,,,,

,,,,潜在失效模式及后果分析,,,,,,,,,,,,,,

,,,,（过程FMEA）,,,,,,,,,FMEA编号：,,,,,

,,,,,,,,,,,,,,,,,,,

,Partname：,,,,ProcessResponsibility：,,,,,,,PreparedBy:,,ApprovalBy:,,,,

,零件名称：,,,,过程责任部门：,,,,,,,编制:,,批准:,,,,

,,,,,,,,,,,,,,,,,,,

,Partnumber：,,,KeyDate：,,,,,FMEADate(Orig):,,,,FMEADate(Rev.):,,,Rev.,,

,零件号：,,,关键日期：,,,,,FMEA日期(编制):,,,,FMEA日期(修订):,,,版本：,,

,CoreTeam:,,,,,,,,,,,,,,,,,

,主要参加人:,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

Process,Process,,,,,PotentialCause(s)/,,"CurrentProcessControls

现行工艺控制",,,,,personincharge负责人,ActionResults,,,,

step,Function,PotentialFailure,PotentialEffect(s),SEV,special,Mechanism(s),OCC,,,Detec,R.P.N.,Recommended,,措施结果,,,,

工序号,过程,Mode,ofFailure,严重,特,ofFailure,UR,,,不易探,风险,Action(s),,"ActionTaken

采取的措施",SEV,OCC,DET,R.P.N.

,Requirements,潜在失效模式,潜在的失效后果,度数,性,潜在的失效起因/机理,频度数,Prevent,Survey,测度数,序数,建议的措施,,,严重,级,不易探,风险

,要求,,,,,,,预防,探测,,,,,,度数,数,测度数,序数

A,Materialincominginspection原材料入库检验,"ADC12Chemicalcomposition

beingoutofstandard.ADC12化学成分不符合标准。Materialstrengthisnotqualified材料强度不合格","Productperformance,customercomplaints产品性能降低，客户抱怨",6,,Thesupplierdidnottest供方未做出厂检验,3,"

Supplierqualityguaranteeandmaterialanalysisreport供方提供质量保证书和材质分析报告","Checkeachlotwithaspectrometer.

对每一批抽取1PCS

材料做光谱分析",2,36,NONE,,,,,,

B,Storagematerial材料入库,packageindamagedcondition包装破损,"Scatteredmaterial,easymixing材料散落，易混料",5,,Porterdidnotonthematerialhandlingsafety/protectivenotinplace搬运工未对材料搬运安全防护/防护不到位,3,Materialhandlingusingaspecialrevolvingcars/box/tray材料搬运使用专用周转车/箱/托盘,Visual目视,2,30,NONE,,,,,,

,,",materialgotdamp材料受潮","Moldmaterial,ledtothedecreaseofthematerialperformance材料发霉，导致材料性能下降",5,,Didn'tdomoistureproofprocessingmaterialspiledup材料堆放没有做防潮处理,3,Materialwarehouselayingpadstorehouseboard(120mm)材料仓库铺放垫仓板（高度120mm）,Visual目视,2,30,NONE,,,,,,

,,Materialputwrongidentification材料标识错误,shopworktookthewrongmaterials车间领错材料,6,,"Warehouseadministratorwritinglabelmistake仓库管理员书写标签错误

",3,Materialspileduphousekeepingmanagement.材料堆放施行定置管理。,Libraryrecords(account/card/)查库记录（帐/卡/物一致）,2,36,NONE,,,,,,

C,Getthematerial领料,packageindamagedcondition包装破损,Dirtymaterialofftheground材料掉地上弄脏,4,,Handlingrawmaterialsthereisnosafety/protectivedoesnotreachthedesignatedposition搬运原材料没有安全防护/防护不到位,2,Materialhandlingusingaspecialrevolvingcars/box/tray材料搬运使用专用周转车/箱/托盘,Visual目视,2,16,NONE,,,,,,

D,"MeltDown,heatpreservation溶解，保温",Aftermeltingtheunqualifiedmaterial熔炼后的材料成分不合格,"thepartperformanceisbad.

产品性能不良",6,,Furnaceresidueofothermaterials换料时以前的材料未处理干净,3,stafftraining，designatesomeonetodo培训并指定专人换料,Eachfurnacebyinspector1PCSmaterialspectralanalysis每炉由检验员抽取1PCS材料做光谱分析,2,36,NONE,,,,,,

,,Temperatureisbeyondthetechnologicalrequirement炉温超出工艺要求,"coldshut,stickymold产品压铸时出现冷隔，粘模等现象",6,,thematerialaddtoomuch熔炉加的料太多,3,Maketheinstruction编制作业指导书，Setupautomaticalarm设定炉温超差自动报警,Visualtemperaturecontrolbox随时目视温控箱,2,36,NONE,,,,,,

,,"

Materialswithdirt,,Slag,degassingisnotclean材料上有污物,杂质，气，未除干净","

Productsareporosity,coldshut,die.产品出现气孔，冷隔，粘模等缺陷，Knifeproductshavehardpoints,resultingincrack产品上有硬点，导致崩刀。",6,,"

Backtothematerialonthedirt,slag,degassingfrequencyistoolow回料上有脏污，除渣，除气频率太低，Agentistoolittle,backtothematerialproportionistoohigh药剂太少，回料比例太高，",3,"

Diecastingwi,backtothematerialproportion,slag,degassingfrequency,reagentratio,temperatureoffurnacetemperaturesetting.Eachclasseveryfurnacesamplinganalysisofthespectrum,tryprocessingproducts编制压铸作业指导书，规定回料比例，除渣，除气频率，药剂比例，炉温设置温度。每班每炉都抽样做光谱分析，试加工产品","

Everytimeslag,degassingmustberecorded,foreman,accordingtotheprocesscardcontroleachparameter,eachclasseveryfurnacesamplinganalysisofthespectrum,eachtesttime,everytimetwoproducts每次除渣，除气都必须记录，领班按工艺卡对照各个参数，每班每炉都抽样做光谱分析，每班试车一次，每次2个产品",4,72,NONE,,,,,,

,,Productwarping产品变形，dehiscence裂开,"Productdeformationcauseassemblyperformanceisbad,CNCmachiningpositioning产品变形导致装配性能不好,影响CNC加工定位Productobsolescence,产品报废",6,,"1.Closemoldtimeshort,1.合模时间短,2.Moldtemperatureistoohigh模温或铝液温度太高3.Thimble,abnormal3.顶针异常4.Firsthandtappingslagbagsandmaterial4.手工敲渣包和料头",4,"

1.Bootsetparametersaccordingtotheprocesscard1.开机按工艺卡设定参数.2.Checkthecoolingwaterpipeconnectioniscorrect,leaking正确的连接冷却水管,打开冷却水,检查水管是否有漏水现象,3.Tosmoothoilthimbleandguidepin3.每班定期给顶杆和导柱上嫩滑油。4.Provisionsofslagpackageandmaterialcanonlyberemovedbytrimming4.规定渣包和料头只能靠切边去除",Inspectorsperiodicallycheckingproductappearance.size检验员定期巡检产品外观。尺寸,3,72,NONE,,,,,,

,,"Productsineveryskin,flash产品出现隔皮，飞边","Productstorework,Getridofburrs产品要返工，修边",5,,"Injectionpressureistoogreat,theclampingforceisnotenough,positioningandwear压射压力太大，锁模力不够，定位机构磨损",6,"Bootaccordingtotheprocesscardsetparameters,positioningsurfacedown开机按工艺卡设定参数，定位机构表面淡化处理",Visual目视,3,90,"Reducethepressureofinjection,moldonceevery50000diecastingmouldandreplacement减小压射压力，模具每压铸5万模修配一次",Diecastingdirector压铸主管：suyong.ToolingManager：chenaifu模具部经理：陈爱福,"Diecastingtechnologyparametersmonitored,mouldreplacement压铸工艺参数监控，模具修配",5,4,3,60

,,Gas-hole气孔coldshut冷隔,"Theparthaspoorburststrength.

产品受力易断，加工面出现气孔导致产品报废",6,,"1.Processparametersaccordingtotheprocesscardset工艺参数未按工艺卡设定

2.Moldtemperatureistoolow模温太低3.biscuitisthin.zincescapes,料柄薄,飞铝,3.Noslag,degassing铝液未按时除渣,除气4.Mouldexhaust模具排气不畅",3,"1.Processparameterssetstrictlyaccordingtotheprocesscard工艺参数严格按照工艺卡设定.2.每次加过料后,都进行一次除渣,除气3.Devicestartsathermometerisusedtomeasurethemoldtemperature,afterpassingatthestartofproduction设备启动后使用测温仪测量模具温度,合格后,在开始生产.4.Inopeningmouldcold-lapexhaustslot模具冷隔处开通排气槽",1.Checkprocessparametersconformtotherequirementsoftheprocesscard1.检查工艺参数是否符合工艺卡要求2Operatorself-inspectionproductappearance.作业员自检产品外观3Inspectorstotryprocessingcheckporosity.检验员试加工检查气孔,5,90,Improvingthestructureofthemould改善模具,ToolingManager：chenaifu模具部经理：陈爱福,"Increasetheporosityandhaveacoldorincreasingslagpackage,increaseexhaustslot有气孔和有冷隔的地方增加或加大渣包，增加排气槽",7,2,5,70

,,"corebending型芯弯曲,拉模","Productprocessingnot,affecttheassembly,leadingtoproductscrap产品加工不出，影响装配，导致产品报废。",6,,Corematerialhardnessisnotenough，notusemoldrelease型芯材质不够硬，未喷到脱模剂。,6,"Eachproductfixedsprayhead,canautomaticsprayingproduction每个产品固定喷雾头，5000perdiecastingmoldandcoretitaniumplating生产时只能自动喷涂，每压铸5000模，型芯镀钛一次。",theQCinspectorchecksthepartappearanceaccordingtotheinspectioncard。检验员应按照产品检验单对产品外观进行检验进行检验,3,108,"Fixedsprayhead,titaniumcoatingonthesurfaceofthecore固定专用喷雾头，型芯表面镀钛",Diecastingdirector压铸主管：suyong,"Fixedsprayhead,re，Forevery5000modelcorediecastingtitaniumcoatingagain固定专用喷雾头，每压铸5000模型芯重新镀钛",7,3,3,63

,,Plungersurfaceistoohighortoolow顶杆凹凸,"Leadtoproductrework,orevenscrapped导致产品报废，返工",5,,Pushrodbentorbroken顶杆弯曲，顶杆断,4,定期给顶针上嫩滑油Onaregularbasistothethimbleoiloftender,theQCinspectorshouldstrengthennotregularinspection检验员应定期进行巡检,2,40,NONE,,,,,,

,Trimming切边,"Productsurfacebluntinjury,bruised产品表面冲伤，压伤","Leadtoproductrework,orevenscrapped导致产品报废，返工。装配时出现干涉",6,,"Aluminumcuttingdienotclean切边模上铝屑未吹干净,

,Blankingdiebladewear切边模刀口磨损,Productisnotinplaceorproductnotcoolingtrimming产品未放到位或未冷却就切边",6,"trainingontheworkersfortheworkinstruction对员工进行培训，指导操作规范.Conveyorbeltwithfancoolingtime传送带上加装风扇,使产品冷却时间缩短，",theQCinspectorshouldstrengthennotregularinspection检验员应定期进行巡检,3,108,"Stafftraining,fanhasmountedontheconveyorbelt员工培训，传送带加装风扇",Diecastingdirector压铸主管：suyong,"Stafftraining,fanhasmountedontheconveyorbelt员工开早会时培训，传送带上风扇已加装",6,3,3,54

,,"Burrresidualproductpartingline,gateandslaginorprotuberance产品分型线处毛刺残留,浇口和渣包处缺料或凸起","Packageproductburrresidual,slagandgateinexcessstockbumpleadtoreworkproducts,lackofmaterialtoproductscrap产品毛刺残留，渣包和浇口处余料凸起导致产品返工，缺料导致产品报废",6,,Blankingdiebladewear切边模刀口磨损,3,Blankingdiemaintenanceonaregularbasis切边模定期保养,theQCinspectorshouldstrengthennotregularinspection检验员应定期进行巡检,2,36,NONE,,,,,,

,Blankfullinspection毛坯全检,Didnotpickoutthedefectiveproducts有裂开，冷隔等压铸缺陷的产品未挑出,"Leadtocustomercomplaints,productselectionofreworkagain导致客户投诉，产品重新挑选返工",5,,"Operatorscheckisnotcareful,therequirementisnotclear作业者检查不仔细，对要求不明确",3,"Preparethecleaningworkinstructions,TrainingWorks

编制作业指导书,培训员工,",工人要求全检Operationtheirfullcheck,3,45,NONE,,,,,,

F,Tumblast抛丸,"Productsurfacepeeling,surfaceeffectandsamplesareinconsistent,burrs,sharpcorners产品表面起皮，有毛刺，有尖角","Affecttheappearance,leadingtoproductrework,customercomplaints.影响其外观,导致产品返工,客户抱怨,",5,,"Productsurfacehasacold，tumblasttimeistoolong,Leadtoproductpeeling,tumblastshottime,Leadtoproductshaveburrsandsharpcorners产品表面冷隔，抛丸时间太长导致产品起皮，抛丸时间短导致产品有毛刺和尖角",3,"Preparethecleaningworkinstructions,TrainingWorks

编制作业指导书,培训员工,",工人要求全检Operationtheirfullcheck,2,30,NONE,,,,,,

,,"Productsareoilybesoiled,bruiseonproducts产品有油渍,产品碰伤，Theblastingeffectandthesamples抛丸效果和样品不一致","Affecttheappearance,leadingtoproductrework,customercomplaints.影响其外观,导致产品返工,客户抱怨,",5,,"Workersdidnotweargloves，Orglovesaretoodirty，Thenumberofsteelshotwearandtear工人未带手套拿产品或手套太脏,钢丸磨损,钢丸数量偏少",2,"Preparethecleaningworkinstructions,TrainingWorks

编制作业指导书,培训员工,",工人要求全检Operationtheirfullcheck,2,20,NONE,,,,,,

G,movetowarehouse入库,"Fallingtransportation,productdamage运输跌落，产品受损",Productrework产品返工,4,,"Cranewithoutsafetyprotectionproducts,handlinghumanerror搬运产品没有安全防护，搬运人员失误",2,"Usedintheprocessofhandlingtray,runningaforkliftforhandlingpersonneltechnicaltraining搬运过程中使用托盘，对搬运人员的开叉车技术进行培训",Visual目视,3,24,NONE,,,,,,

,fullinspection全检,Didnotpickoutthedefectiveproducts有缺陷的产品未挑出,"Leadtocustomercomplaints,productselectionofreworkagain导致客户投诉，产品重新挑选返工",5,,"Operatorscheckisnotcareful,therequirementisnotclear作业者检查不仔细，对要求不明确",3,"Preparethecleaningworkinstructions,TrainingWorks

编制作业指导书,培训员工,",工人要求全检Operationtheirfullcheck,3,45,NONE,,,,,,

H,车内孔Innerholeofvehicle,内孔公差达不到图纸要求Internalholetoleranceisnotuptodrawingrequirements.,"影响产品装配导致产品报废，流到客户处引起投诉Affecttheproductassemblyleadtoscrap,flowtothecustomercomplaints",8,,"刀具磨损，刀具上粘有铝屑Onthetoolwear,toolwithaluminiumcrumbs",2,"工人使用塞规自检内孔，检验员按检验卡要求巡检，定期更换刀具Workersuseplugholeinspectionaccordingtoinspection,theinspectorcardinspection,regularreplacementtool",更换刀具，使用塞规检查内孔Replacethetooluseplugcheckhole,3,48,NONE,,,,,,

I,拉槽trenchexcavated,槽宽做不到公差要求Groovewidthcannotdotolerancerequirements,"影响产品装配导致产品报废，流到客户处引起投诉Affecttheproductassemblyleadtoscrap,flowtothecustomercomplaints",8,,"刀具磨损，刀具上粘有铝屑Onthetoolwear,toolwithaluminiumcrumbs",2,"工人使用塞规自检内孔，检验员按检验卡要求巡检，定期更换刀具Workersuseplugholeinspectionaccordingtoinspection,theinspectorcardinspection,regularreplacementtool",更换刀具，使用塞规检查内孔Replacethetooluseplugcheckhole,3,48,NONE,,,,,,

J,清洗烘干Cleaningdrying,Productsurfaceresidualoil,"导致客户投诉，产品重新挑选返工Leadtocustomercomplaints,productselectionofreworkagain",3,,清洗不够彻底Cleanenoughto,2,检查清洗机Checkthewashingmachine,工人要求全检Theworkers'demandsforfullinspection,5,30,NONE,,,,,,

K,Packing包装,"Packingdamage,theproductleakage包装箱破损，产品外漏",Theproductiseasytodamage产品易受损,5,,Packingperformanceispoor包装箱性能差,3,Beforebookingpackingproofingconfirmedcases订包装箱之前打样确认包装箱强度,MASTERCARTONDROPTEST丢落测试,3,45,NONE,,,,,,

,,Packingquantitydoesnotconformtotherequirements包装数量不符合要求,"Missingparts,customercomplain缺件，顾客抱怨",4,,"1.Thepackingworkerhasnotfollowedthepackingspec.没按包装标准进行包装

2.notChecktheproductquantitypackaging包装之前未核对产品数量",2,"Makethepackaginginstruction编制包装作业指导书，Packingbeforeandafterthepackingmustbestatisticalquantity,quantityisconsistent包装前和包装完后必须统计数量,前后数量是否一致",Operatorself-inspection作业员自检,3,24,NONE,,,,,,

L,finalinspection成品检验,Nonconformingsentencetononconformingproduct不合格品判为合格品,Causecustomercomplaints引起客户投诉,3,,"Inspectiontargets,failure检验漏检，检具失效",4,"Preparethefinishedgoodsinspection,samplingrate,measuringtoolregularmaintenanceandcalibration编制成品检验卡，规定抽检比例，测量工具定期维护，校正。","Accordingtotheinspectioncardsamplingappearance,size按成品检验卡抽检外观，尺寸",3,36,NONE,,,,,,

M,movetowarehouse入库,"Fallingtransportation,productdamage运输跌落，产品受损",Productrework产品返工,4,,"Cranewithoutsafetyprotectionproducts,handlinghumanerror搬运产品没有安全防护，搬运人员失误",2,"Usedintheprocessofhandlingtray,runningaforkliftforhandlingpersonneltechnicaltraining搬运过程中使用托盘，对搬运人员的开叉车技术进行培训",thewarehousekeepertore-checkthepartforcorrectness.产品运到仓库时有专门的人员进行检查,3,24,NONE,,,,,,

N,productverification产品审核,"Dimensionareoutofspecification尺寸超差，Thenumber,thespecificationisnotcorrect数量，规格不正确",customercomplaint客户投诉,6,,"Didn'tdofullsizeinspection,salesstaffmistakes没做全尺寸检查，销售人员失误",3,"onceperyearmeasurethepartforalldimension每年以次对产品的全尺寸测量一次，Checkthephysical,checklist,deliveryorders核对实物，出货检查单，订单","onceperyearmeasurethepartforalldimension每年以次对产品的全尺寸测量一次，Visualphysical,checklist,theorder目视实物，检查单，订单",3,54,NONE,,,,,,

O,"Sendtocustomer

发货",发货不及时，包装破损,Damagedproduct，customercomplaint产品损坏，客户投诉,3,,"Transportvehiclefailure,safetyprotectiondoesnotreachthedesignatedposition运输车辆故障，安全防护不到位",2,Signacontractwiththemodeoftransportation与运输方式签订合同,Phonefollow-up电话追踪,3,18,NONE,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,