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1、FMEA 编号N 准备人Prep 10 原材料进厂 In-coming Raw Material 原材料规格错误 Material spec is wrong 影响零件性能 affect parts capability 4 供应商送原材料的规格 有错 The supplier send the wrong material 1 每批送货供应商附上材质证 明书 The supplier submit the quality certification every shipping 收料员检查送货单 Material receiver check delivering list 9 20 IQC
2、 检查 IQC Inspection 尺寸检测有误差 measure error 影响后续零件生产 affect parts production next process 3 供应商送原材料的规格 有错 The supplier send the wrong material 2 送货单标明材料尺寸规格 define the SPEC. of raw- material in the dilivery Bills 1.IQC按送货单核对原材料规 格表 IQC confirm the Raw Material Spec List according to the delivery order.
3、 2.IQC按原材料规格表检查原 材料尺寸规格 ,以每批2卷,每 卷3个点检查料厚 IQC check raw material spec according to the Raw Material Spec List,check materials thickness by 3 points per coil,2 8 30 移至原材料仓 Move Material to Store 材料转移错误 mistake the rawmaterial 影响后续零件生产 affect parts production next process 3 材料标识不明确 Un-clear label 2 入库
4、前材料上贴来料管理票 set the label on the Raw- material before store. 生产领料时,操作工和 QC 对材 料进行确认 Operators and QC verify the material in production line. 8 40 存放 Storage 材料生锈 rust of the material 影响后续零件生产 affect parts production next process 2 1. 材料入库、出库凌乱 。 2. 放置周期过长。 1. Un-sequence in and out store. 2. long ter
5、m store 4 按照程序要求,材料先进先 出。 Frist in first out QC 复查在库 re-check the parts in period. 8 50 移至生产线 Move Material to Production Line 材料转移错误 mistake the rawmaterial 影响后续零件生产 affect parts production next process 3 材料标识不明确 Un-clear label 2 入库前材料上贴来料管理票 set the label on the Raw- material before store. 生产领料时,操
6、作工和 QC 对材 料进行确认 Operators and QC verify the material in production line. 8 60 P200T 冲压 P200T Stamping 6.250.15 尺寸超差 is out of tolerance 影响客户装配 affect customer assembly 3 冲孔冲头磨损 The tooling punch wears away 2 定期维护保养模具 maintain the die periodically PQC 用通止规抽检 PQC check with Pin gauge 8 现行过程预防控制 Curren
7、t Process Controls Prevention 现行过程检测控制 Current Process Controls Detection 难检 度Det 潜在的失效模式 Potential Failure Mode 潜在的失效后果 Potential Effect(S) of Failure 严 重 度Sev 级 别Class 潜在的失效原因 /机理 Potential Cause(s)/ Mechanism(s) of Failure 频度 数Occ 过程功能要求 Process Function Requirements 序号 NO. 主要参加人 Core Team: QA部QA
8、 Dept./ 模具部Tooling. Dept.; /工程部Eng.Dept.FMEA 日期D 潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSI (PFMEA) 项目名称 Item: 过程责任部门 Process Responsibility: 车型年/车辆类 关键日期 Key Date: 工 1 of 22 FMEA 编号N 准备人Prep 现行过程预防控制 Current Process Controls Prevention 现行过程检测控制 Current Process Controls Detection 难检 度De
9、t 潜在的失效模式 Potential Failure Mode 潜在的失效后果 Potential Effect(S) of Failure 严 重 度Sev 级 别Class 潜在的失效原因 /机理 Potential Cause(s)/ Mechanism(s) of Failure 频度 数Occ 过程功能要求 Process Function Requirements 序号 NO. 主要参加人 Core Team: QA部QA Dept./ 模具部Tooling. Dept.; /工程部Eng.Dept.FMEA 日期D 潜在的失效模式及效应分析表POTENTIAL FAILURE
10、MODE AND EFFECTS ANALYSI (PFMEA) 项目名称 Item: 过程责任部门 Process Responsibility: 车型年/车辆类 关键日期 Key Date: 工 780.25 尺寸超差 is out of tolerance 1.影响客户使用。 2.后续磨削无法装夹。 1. affect customer assembly 2. Can not put in the fixture. 3 1.冲孔冲头磨损 2.模具调试中,送料步 距不对 1.The tooling punch wears away 2.Non-conforming stamping ste
11、p in the tooling adjust process. 2 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 。 1.maintain the die periodically 2. Contain the tooling adjust parts and ask operators follow the WI in the production process. PQC 用卡尺抽检 PQC check with Vernier Caliper 8 翻边孔内径过大或者椭 圆 flanging hole bigger or smaller 1. 车削后导致 3
12、2.549 尺寸超差。 2. 内孔车削后无法满 足粗糙度要求。 1. Cause 32.549 out of diemension. 2. Cause the roughness of 32.549 hole out of dimension. 3 1. 合模高度不对 2. 送料步距不对 1. Non-conforming shutter height. 2. Non-conforming stamping step. 2 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。 2. Set the WI site and ask the operators follow it
13、in the production process. 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 hole diameter 31.8Max and PQC check it with vernier caliper. 8 翻边高度过低 taller or shorter of the blanging height. 导致车削和磨削后 7尺 寸超差。 Cause dimension 7 out of SPEC. after turning and grinding. 3 合模高度不到位 Non-conforming shutter heig
14、ht. 2 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 site and ask the operators follow it in the production process. 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 height 7.5+/-0.3 and PQC check it with vernier caliper 8 P200T 冲压 P200T Stamping 60 2 of 22 FMEA 编号N 准备人Prep 现行过程预防控制 Curre
15、nt Process Controls Prevention 现行过程检测控制 Current Process Controls Detection 难检 度Det 潜在的失效模式 Potential Failure Mode 潜在的失效后果 Potential Effect(S) of Failure 严 重 度Sev 级 别Class 潜在的失效原因 /机理 Potential Cause(s)/ Mechanism(s) of Failure 频度 数Occ 过程功能要求 Process Function Requirements 序号 NO. 主要参加人 Core Team: QA部Q
16、A Dept./ 模具部Tooling. Dept.; /工程部Eng.Dept.FMEA 日期D 潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSI (PFMEA) 项目名称 Item: 过程责任部门 Process Responsibility: 车型年/车辆类 关键日期 Key Date: 工 37尺寸超差 37 out of dimension 影响客户使用 affect customer using 3 1. 合模高度不到位 2. 来料较薄 1. Non-conforming shutter height. 2. thinn
17、er of the material thickness. 2 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 site and ask the operators follow it in the production process. 1. 每卷材料上线时,检查材 料厚度 1. PQC Check the thickness of material when every coil used. 8 材料厚度超差 material thickness out of dimension. 导致磨削后 3.0+/-0.15 尺寸超差。 Cause
18、the dimension 3.0+/-0.15 out of SPEC. after grinding. 3 来料厚度超差 the thickness of raw- material out of SPEC. 2 将来料厚度控制在 3.25+/- 0.05。 Set the thickness of raw- material 3.25+/-0.05。 每卷材料上线时, PQC 检查 材料厚度 PQC Check the thickness of material when every coil used. 8 平面度超差 flatness out of dimension 1.导致磨削后
19、的平面度 超差。 2.导致磨削后的材料厚 度超差。 1. Cause the flatness afer grinding out of dimension. 2.cause the thickness of the 3 合模高度不到位 Non-conforming shutter height. 2 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 site and ask the operators follow it in the production process. 增加冲压过程中的平面度 0.15 控制并且要求 QC 抽检。 Add
20、flatness control in stamping process and PQC check it in period. 8 P200T 冲压 P200T Stamping 60 3 of 22 FMEA 编号N 准备人Prep 现行过程预防控制 Current Process Controls Prevention 现行过程检测控制 Current Process Controls Detection 难检 度Det 潜在的失效模式 Potential Failure Mode 潜在的失效后果 Potential Effect(S) of Failure 严 重 度Sev 级 别Cl
21、ass 潜在的失效原因 /机理 Potential Cause(s)/ Mechanism(s) of Failure 频度 数Occ 过程功能要求 Process Function Requirements 序号 NO. 主要参加人 Core Team: QA部QA Dept./ 模具部Tooling. Dept.; /工程部Eng.Dept.FMEA 日期D 潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSI (PFMEA) 项目名称 Item: 过程责任部门 Process Responsibility: 车型年/车辆类 关键日
22、期 Key Date: 工 60 P200T 冲压 P200T Stamping 翻边孔与地面拐角过大 bigger radius of the crossing between the flanging and the flatness. 导致磨削后 34.5MAX 尺 寸超差。 Cause 34.5MAX after grinding out of dimension. 3 合模高度不到位 Non-conforming shutter height. 2 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 site and ask the op
23、erators follow it in the production process. 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 in stamping process and PQC check it in period. 8 毛刺过大 larger burrs 影响零件外观及客户使 用 affect parts appearance and customers usage 2 冲头或凹模镶块磨损 punch and die insert wears away 4 定期维护保养模具 maintain the die periodic
24、ally 操作工目视检查 1pcs/15mins ,PQC 目视检查 4pcs/h Operator check with E, 1pcs/15mins,PQC check with E,4pcs/h 8 70 半成品包装 Package in semi- finished product 包装错误 Non-conforming packaging 造成零件表面的压伤。 Cause the dent in the surface of the part. 3 包装方式不明确 Unknown of the packaging methods. 2 1. 现场放置包装指导书,并 且要求操作工严格按
25、照包装 指导书包装。 1. Set the PI site and ask the operators follow it after stamping. 传送前PQC 确认包装正确后才 可以传送。 QC verify the packaging before delivery 8 80 移至半成品区 Move to semi- finished area 零件转移错误 mistake the part 影响后续零件生产 affect parts production next process 3 材料标识不明确 Un-clear label 2 入库前每卡板贴上传送单核 入库单。 set t
26、he delivery notes and receipts notes label on the Raw-material before store pallet. 生产领料时,操作工和 QC 对材 料进行确认 Operators and QC verify the material in production line. 8 90 存放 Storage 零件生锈 rust of the part. 影响后续零件生产 affect parts production next process 3 1. 材料入库、出库凌乱 。 2. 放置周期过长。 1. Un-sequence in and o
27、ut store. 2. long term store 2 按照程序要求,材料先进先 出。 Frist in first out QC 复查在库 re-check the parts in period. 8 100 移至生产线 Move Material to Production Line 材料转移错误 mistake the rawmaterial 影响后续零件生产 affect parts production next process 3 材料标识不明确 Un-clear label 2 入库前材料上贴来料管理票 set the label on the Raw- material
28、 before store. 生产领料时,操作工和 QC 对材 料进行确认 Operators and QC verify the material in production line. 8 4 of 22 FMEA 编号N 准备人Prep 现行过程预防控制 Current Process Controls Prevention 现行过程检测控制 Current Process Controls Detection 难检 度Det 潜在的失效模式 Potential Failure Mode 潜在的失效后果 Potential Effect(S) of Failure 严 重 度Sev 级
29、别Class 潜在的失效原因 /机理 Potential Cause(s)/ Mechanism(s) of Failure 频度 数Occ 过程功能要求 Process Function Requirements 序号 NO. 主要参加人 Core Team: QA部QA Dept./ 模具部Tooling. Dept.; /工程部Eng.Dept.FMEA 日期D 潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSI (PFMEA) 项目名称 Item: 过程责任部门 Process Responsibility: 车型年/车辆类
30、关键日期 Key Date: 工 32.5490.012 尺寸超差 is out of tolerance 影响客户装配 affect customer assembly 4 1.车刀磨损 2.零件装夹不到位 1.The lathe tool wears away 2.Non-confroming clamping area 2 1. 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 the lathe periodically 2. Set the WI site and ask the operators follow it i
31、n the production process. PQC 和操作工用气动量仪抽检 PQC and operators check with AIR gauge 8 内孔粗糙度不良 Non-conforming of the roughness in the inner hole. 1.影响客户使用。 1. affect customer assembly 3 1.车刀磨损 1.The lathe tool wears away 2 定期维护保养车床 maintain the lathe periodically PQC 用粗糙度仪抽检 PQC and operators check with
32、 roughness machine. 8 材料厚度超差 material thickness out of dimension. 导致磨削后 3.0+/-0.15 尺寸超差。 Cause the dimension 3.0+/-0.15 out of SPEC. after grinding. 5 进刀量过大 longer of the feeding. 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。 Set the WI site and ask the operators follow it in the production process. PQC 用千分尺抽检
33、PQC and operators check with micrometer. 8 机加工 machining 110 5 of 22 FMEA 编号N 准备人Prep 现行过程预防控制 Current Process Controls Prevention 现行过程检测控制 Current Process Controls Detection 难检 度Det 潜在的失效模式 Potential Failure Mode 潜在的失效后果 Potential Effect(S) of Failure 严 重 度Sev 级 别Class 潜在的失效原因 /机理 Potential Cause(s
34、)/ Mechanism(s) of Failure 频度 数Occ 过程功能要求 Process Function Requirements 序号 NO. 主要参加人 Core Team: QA部QA Dept./ 模具部Tooling. Dept.; /工程部Eng.Dept.FMEA 日期D 潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSI (PFMEA) 项目名称 Item: 过程责任部门 Process Responsibility: 车型年/车辆类 关键日期 Key Date: 工 尺寸超差 is out of tole
35、rance 影响客户装配 affect customer assembly 4 1.车刀磨损 2.零件装夹不到位 1.The lathe tool wears away 2.Non-confroming clamping area 2 1. 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 site and ask the operators follow it in the production process. 2. maintain the lathe periodically PQC 和操作工用检具抽检。 PQC and
36、 operators check with gauge 8 尺寸超差 is out of tolerance 影响客户装配 affect customer assembly 4 1.车刀磨损 2.零件装夹不到位 1.The lathe tool wears away 2.Non-confroming clamping area 2 1. 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 site and ask the operators follow it in the production process. 2. maint
37、ain the lathe periodically PQC 和操作工用检具抽检。 PQC and operators check with gauge 8 120 半成品包装 Package in semi- finished product 包装错误 Non-conforming packaging 造成零件表面的压伤。 Cause the dent in the surface of the part. 3 包装方式不明确 Unknown of the packaging methods. 2 1. 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 P
38、I site and ask the operators follow it after stamping. 传送前PQC 确认包装正确后才 可以传送。 QC verify the packaging before delivery 8 130 移至半成品区 Move to semi- finished area 零件转移错误 mistake the part 影响后续零件生产 affect parts production next process 3 材料标识不明确 Un-clear label 2 入库前每卡板贴上传送单核 入库单。 set the delivery notes and
39、receipts notes label on the pallet before store . 生产领料时,操作工和 QC 对材 料进行确认 Operators and QC verify the material in production line. 8 机加工 machining 110 6 of 22 FMEA 编号N 准备人Prep 现行过程预防控制 Current Process Controls Prevention 现行过程检测控制 Current Process Controls Detection 难检 度Det 潜在的失效模式 Potential Failure Mo
40、de 潜在的失效后果 Potential Effect(S) of Failure 严 重 度Sev 级 别Class 潜在的失效原因 /机理 Potential Cause(s)/ Mechanism(s) of Failure 频度 数Occ 过程功能要求 Process Function Requirements 序号 NO. 主要参加人 Core Team: QA部QA Dept./ 模具部Tooling. Dept.; /工程部Eng.Dept.FMEA 日期D 潜在的失效模式及效应分析表POTENTIAL FAILURE MODE AND EFFECTS ANALYSI (PFME
41、A) 项目名称 Item: 过程责任部门 Process Responsibility: 车型年/车辆类 关键日期 Key Date: 工 140 存放 Storage 零件生锈 rust of the part. 影响后续零件生产 affect parts production next process 3 1. 材料入库、出库凌乱 。 2. 放置周期过长。 1. Un-sequence in and out store. 2. long term store 2 按照程序要求,材料先进先 出。 Frist in first out QC 复查在库 re-check the parts in
42、 period. 8 150 移至生产线 Move Material to Production Line 材料转移错误 mistake the rawmaterial 影响后续零件生产 affect parts production next process 3 材料标识不明确 Un-clear label 2 入库前材料上贴来料管理票 set the label on the Raw- material before store. 生产领料时,操作工和 QC 对材 料进行确认 Operators and QC verify the material in production line.
43、4 160 倒角 chamfer 倒角大于 0.5c the chamfer more than 0.5 影响零件外观 affect parts appearance 2 倒角限位移动 the limit away 5 定期维护保养机床 maintain the machine periodically PQC 用投影仪抽检 PQC check with profile projector. 3 170 半成品包装 Package in semi- finished product 包装错误 Non-conforming packaging 造成零件表面的压伤。 Cause the dent
44、in the surface of the part. 2 包装方式不明确 Unknown of the packaging methods. 3 1. 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 site and ask the operators follow it after stamping. 传送前PQC 确认包装正确后才 可以传送。 QC verify the packaging before delivery 4 180 移至半成品区 Move to semi- finished area 零件转移错误 mistake the pa
45、rt 影响后续零件生产 affect parts production next process 3 材料标识不明确 Un-clear label 2 入库前每卡板贴上传送单核 入库单。 set the delivery notes and receipts notes label on the pallet before store . 生产领料时,操作工和 QC 对材 料进行确认 Operators and QC verify the material in production line. 4 190 存放 Storage 零件生锈 rust of the part. 影响后续零件生产
46、affect parts production next process 3 1. 材料入库、出库凌乱 。 2. 放置周期过长。 1. Un-sequence in and out store. 2. long term store 4 按照程序要求,材料先进先 出。 Frist in first out QC 复查在库 re-check the parts in period. 8 7 of 22 FMEA 编号N 准备人Prep 现行过程预防控制 Current Process Controls Prevention 现行过程检测控制 Current Process Controls De
47、tection 难检 度Det 潜在的失效模式 Potential Failure Mode 潜在的失效后果 Potential Effect(S) of Failure 严 重 度Sev 级 别Class 潜在的失效原因 /机理 Potential Cause(s)/ Mechanism(s) of Failure 频度 数Occ 过程功能要求 Process Function Requirements 序号 NO. 主要参加人 Core Team: QA部QA Dept./ 模具部Tooling. Dept.; /工程部Eng.Dept.FMEA 日期D 潜在的失效模式及效应分析表POTE
48、NTIAL FAILURE MODE AND EFFECTS ANALYSI (PFMEA) 项目名称 Item: 过程责任部门 Process Responsibility: 车型年/车辆类 关键日期 Key Date: 工 200 移至生产线 Move Material to Production Line 材料转移错误 mistake the rawmaterial 影响后续零件生产 affect parts production next process 3 材料标识不明确 Un-clear label 2 入库前材料上贴来料管理票 set the label on the Raw-
49、material before store. 生产领料时,操作工和 QC 对材 料进行确认 Operators and QC verify the material in production line. 8 210 磨削 grinding 粗糙度超差 roughness of the flat out of dimension. 影响客户使用 affect customer using 3 砂轮硬度以及颗粒度不 适合。 Non-conforming of the hardness and particle grinding wheel. 2 选择合适的砂轮并将砂轮规 格写入操作指导书 Choose conforming grinding wheel and write it into WI 生产前, QC 和操作工检查砂轮 的规格。 QC and operators check the Spec. of the grinding wheel. 8 out of dimension. 影响客户使用 affect customer using 4 1. 磨床
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