FMEA表格

PotentialFailureModeAndEffectsAnalysis-----Process潜在的失效模式及后果分析-----过程FMEA（PFMEA）FMEANo./FMEA编号：XX/XX.JS.SE15.04Project项目名称:ProcessResponsibilityDep.过程责任部门:Tech.Dept.ManufactureDept.LogisticsDept.QualityDeptModelYear/Vehicle车型年/车辆类型：KeyDate/关键日期:ReviseDate/修改日期：CoreTeam核心小组：过程步骤/功能ProcessSteps/Function要求Requirement潜在失效模式PotentialFailureModes失效模式的潜在后果PotentialEffect(s)ofFailure严重度SEV分类等级class失效的潜在要因PotentialCauseofFailure发生率OCC现有过程控制预防CurrentProcessControlsPrevent现有过程控制探测CurrentProcessControlsDetect探测率DETRPN建议措施RecommendedAction(s)职责&目标完成时间Responsibility&TargetCompletionDate措施结果ActionResults采取措施和生效日期Action(s)andValidateDate严重度SEV发生率OCC探测度DETRPN00rawmaterialinspection原检验rawmaterialcouldnotcomplywiththespecifiedstandard不符合入厂验收partsscrap产品报废8contractorwithweakqualityassurancecapability供方质量保证能力差4toauditandevaluatetheperformanceofcontractortermly,selectmorethen2contractors定期对供方进行审核、业绩评价；至少择优选择2个供方aluminumalloyreceivinginspectionspecification铝合金入厂检验细则）供方资质调查及评定表5160Nothing无rawmaterialsupplybreaksoff原材料供应中断influencesafestock影响安全库存8contractorstopsproduction供方停产4requirecontractortosetupsafetyinventory要求供方建立安全库存Supplierperformanceevaluation(includessupplierstimelydeliveryrate)供应商业绩评价表（里面包含供应商交付及时率）5160Nothing无8contractordeliverynotintime供方供货不及时4selectmorethen2contractors选择至少2家供方5160Nothing无8notreleasetheordertocontractorintime原材料订货不及时3setupsafetyinventory建立安全库存Regularlymonitorrawmaterialinventory定时监控原材料库存量5120Nothing无05Concentratesmeltingrawmaterials原材料集中熔炼Productswithimpurities产品有杂质influencetheproductcapacity影响产品性能7△熔炼时未除渣或除渣不彻底withoutdeslaggingordeslaggingincompletelyinsmelting3slagremovingspecificationinthedie-castingworkshop压铸车间清渣inspectwitheye-view目测8168Nothing无materialcouldnotcomplywiththespecifiedstandard材料成分不合格partsscrap产品报废8材料混料materialmix3光谱分析Spectrumanalyzer（原材料油漆标识规范）列入检验指导书inspectionWI（光谱分析）5120Nothing无8proportionoffeedbackdoesn'tmeetthespecification回料比例不符合规定3theworkinginstructionofdumpingfurnace(stipulatetheproportionoffeedbackandaddingmethods)压铸车间倾倒炉使用/作业指导书（规定了回料比例和添加方法）theratiotableofaddingmaterialforconcentratemeltingfurnaceindie-castingworkshop压铸车间集中熔化炉材料添加比例表5120Nothing无10diecCast压铸materialcouldnotcomplywiththespecifiedstandard材料成分不合格partsscrap产品报废8材料混料materialmix3光谱分析Spectrumanalyzer列入检验指导书inspectionWI5120Nothing无porosity气孔influencefunction影响功能8improperdesignoffillingsystem浇注系统不合理4simulation模流分析checkedbyX-raytermly定期探伤5160Nothing无8toohightemperatureofrawmaterial料温太高4setpropertemperatureofalloyfluid设置适当的铝液温度temperaturecontrollingequipmentmonitorautomatically温控仪自动监控5160Nothing无8releaseagentissprayedtoomuch脱模剂喷涂过多4setproperspraytime设置适当的喷涂时间visualinspectscreen目测显示屏5160Nothing无10diecast压铸drawplate拉模influenceassemblageorfunction影响装配或功能7△draftangleofthetoolingistoosmall出模斜度太小4selectpropertoolingdraftangle设计合理的出模斜度validatedbytoolingtrialrun试模验证5140Nothing无7highAlfluidtemperature铝液温度高4setpropertemperatureofalloyfluid设置适当的铝液温度autocontrol自动控制5140Nothing无7releaseagentisnotsprayedenough脱模剂喷涂不够4autosprayandsetpropersprayamount自动喷涂、设定合理的喷涂量100%appearanceinspection外观全检7196Nothing无7toolingtemperatureoverhigh模具温度高4simulation模流分析infraredthermometer红外线温度计5140Nothing无pinholedrawplate,dimensiondeviated拉模influenceassemblageandfunction影响装配或功能8pinsarebended销子弯曲3purchasepinwithhighquality外购优质销子receivinginspect进货检验6144Nothing无8toolingpinabrasion模具销子磨损5changethepinperiodically定期更换销子firstpartinspect首件检查5200Nothing无845160Nothing无8Badroughness销子粗糙度不良3Criterionreasonablecoarseness规定合理的粗糙度Stockinspect进货检验5120Nothing无10diecast压铸oilspot油斑influenceappearance影响外观7△toomuchlubeonthepunch冲头油太多4settheputtingtimeofthelube设定冲头油投放时间firstpartinspect首件检查5140Nothing无7spraytoomuchreleaseagent脱模剂喷涂太多4autosprayandsetpropersprayamount自动喷涂、设定合理的喷涂量visualinspectscreen目测显示屏5140Nothing无7concentrationoftoolingreleaseagenttoohigh脱模剂浓度太高4confirmtheconcentrationbytoolingtrial,useautoassignmachine通过试模确定配比浓度，采用自动配比机checkassignrecord检查配比5140Nothing无coldflowsonthesurface表面冷隔influenceappearance影响外观7lowAlliquidtemperature铝液温度太低3specifypropertemperatureofAlliquid规定合理的铝液温度automonitor自动监控363Nothing无7improperfillingandexhaustsystem模具浇注、排气系统不合理3simulation模流分析checkthetoolingtrial试模检查5105Nothing无7improperdiecastingparameters压铸工艺参数不合理3specifypropertechnicparameter规定合理的工艺参数checkthetoolingtrial试模检查5105Nothing无龟裂heatcrackinfluenceassemblage影响装配7增压压力大strongpressure4规定增压压力范围，控制最大增压压力ordertherangeofpressure,andcontrolthebiggestpressure试模验证trailtoolingvalidate5140Nothing无7模具老化toolingaging4模具定期保养toolingmaintainperiod保养记录maintainrecord5140Nothing无incorrectlettering刻字标识错误difficulttotraceparts产品追溯困难7didn'tupdatetoolingletteringintime未及时更新模具刻字3firstpartcheck首件检查firstpartcheck首件检查5105Nothing无10diecast压铸withthickflashing披锋厚,12.7±0.2influenceassemblageandfunction影响装配或功能8toolinglockforcenotenough锁模力不足3selectproperdiecastingmachine选用合适的压铸机simulation模流分析7168Nothing无8didn'tclearupthetoolingfin模具披锋未清干净4clearuptoolingperiodically定期清理试模验证trailtoolingvalidate5160专用检具控制Controlbyspecialcheckingtool尺寸不良8toohighejectingpressure压力太大4confirmthepressurebytoolingtrial试模确定压力validatebytoolingtrial试模验证5160Nothing无deforminganddimensiondeviation变形，尺寸不良influenceassembly影响装配8releaseagentissprayedtooless喷涂太少4setproperspraytime设置适当的喷涂时间visualinspectscreen目测显示屏5160Nothing无8concentrationoftoolingreleaseagenttoolow脱模剂浓度太低4confirmtheconcentrationbytoolingtrial,useautoassignmachine通过试模确定配比浓度，采用自动配比机checkassignrecord检查配比记录5160Nothing无8shortcoolingtime冷却时间短4setpropercoolingtime设置适当的冷却时间diecastingdailyreport压铸日报5160Nothing无deforminganddimensiondeviation变形，尺寸不良influenceassembly影响装配8improperdirectiontoremovegateandoverflow去浇口渣包方向不当3specifytheoperationdirection规定操作方向visualinspection目测7168Nothing无8ejectnotflat顶出不平4checktoolingejectorpinandejectplatewhenassemblethetooling装模具时检查模具顶杆和顶板validatebytoolingtrialrun试模验证5160Nothing无10diecast压铸materialmissing缺料influenceappearance影响外观7lowshotpressurerate压射比压低4selectpropershotpressurerate选用适当的压射比压validatebytoolingtrialrun试模验证5140Nothing无7materialshortage料少3maintaincethescoopperiodically定期保养汤勺checkthethicknessoffillinghandle检查料柄厚度6126Nothing无punchingfilling冲浇influenceappearance影响外观7highshotpressurerate压射比压太高4selectpropershotpressurerate选用适当的压射比压validatebytoolingtrialrun试模验证5140Nothing无7highspeeddistancetooshort高速距离太短4selectproperhighspeeddistance选用适当的高速距离validatebytoolingtrialrun试模验证5140Nothing无7hightoolingtemperature模具温度高4increasecoolingwater增开冷却水infraredthermometer红外线温度计5140Nothing无20Trimmingscrap去料柄缺料materialscarcity影响外观Effectingappearance7Jockeyhandleunsuitable操作工操作不当4设置作业指导书setupworkinginstruction目测visualinspection7196Nothing无30冲孔Bluntborelackofmaterial,bumps,distorted多肉,碰伤,少肉,变形，漏序Visualfailure,outoftolerance外观不良,7Usemethodimproper使用方法不当，漏序4Instructionforremovethegate规定去料柄作业指导文件目测visualinspection7196NothingImpactmachiningfixtures影响加工装夹7Toolingdefects模具不良4Periodicmaintaintooling定期维护模具Checkthefirstpart,visual首件确认，目测5140Nothing开裂craze产品报废partscrap8切边模刃口钝theedgeoftrimmingdieisdull3切边模定期保养maintainthetrimmingdietermly外观检查checktheappearance5120Nothing8切边模上下错模dismatchofthetrimmingdie3每批生产前合模检查checkthetrimmingdiebeforeproductioneverybatch首件检查checkthefirstofftoolpart496Nothing40Removingburrs修毛刺burrdidn'tremovecompletely毛刺未清干净influenceassemblageandfunction影响装配或功能8processmissing漏序3specifyremvoemethodandsteps规定去除方法和步骤checkappearance外观检查7168Nothing无Removeburrsovermuch毛刺修挫过度、锉刀痕influenceassemblageandfunction影响装配或功能7operatorsdonotusespecifiedtool未使用规定工具4validateworkingpreparation作业准备验证workingpreparationvalidationrecord作业准备验证记录5140Nothing无7operatoroperatesimproperly操作工操作手法不当4trainoperator,specifythemethodandstepstoremovetheburrs培训操作工，规定去除方法和步骤checkappearance外观检查7196Nothing无40Removingburrs修毛刺Theremainderburrs有残余毛刺influenceassemblage影响装配7processmissing漏序3specifyremvoemethodandsteps规定去除方法和步骤checkappearance外观检查7147Nothing无50振动研磨vibrationtumbling卡磨料stoneinproduct影响装配或功能Impactassemblageorfuncation8磨料规格不合适Thestandardofgrindingmaierialisnotsuitable4选用合适的磨料Choosetheappropriategrindingmaterial研磨验证grindingvalidate4128Nothing无变形碰伤metamorphose8振动频率太高Libratefrequencyistoohigh3设置适当的频率Setsuitablefrequency研磨验证grindingvalidate496Nothing无8一次研磨产品太多Toomuchpartsforoncegrinding4规定适当的数量Regulatethesuitablequantity研磨验证grindingvalidate4128Nothing无发黑Nigrescence影响外观Effectingappearanc7研磨后未及时烘干Dryingnotintimeaftergrinding4规定产品的流转时间Regulatetheflowthmefortheparts研磨验证grindingvalidate4112Nothing无60Cleaninganddryingone清洗、烘干一序uncleanpartsurface,theremoldy,ect.产品表面不清洁，有霉斑等不良现象customerisnotfulfilled顾客不满意6dryingtimenotenough烘烤时间不足3specifyproperdryingtime规定合理的烘烤时间autocontrol自动控制590Nothing无6drygingtemperaturetoolow烘烤温度太低3specifyproperdryingtemperature设置合理的烘烤温度visualinspectscreen目测显示屏7126Nothing无6waterintheholedidn'tdrycompletely孔内积水未吹干3drythewaterinthehole吹干孔内水分appearancecheck外观检查7126Nothing无scratch碰伤,划伤influenceappearance影响外观influencefunction影响功能6partsputimproperly产品摆放不当4specifyproperputmethod规定合适的摆放方式cleaningvalidation清洗验证5120Nothing无6scratchedbygasgun气枪划伤3covergasgunendbyplasticcover气枪头使用塑料套appearancecheck外观检查7126Nothing无70全检100%checkinspectleak漏检out-flowofNGparts不合格品流出8confusionofparts'flow产品流转混乱4statemark状态标识processflowcard工序流转卡5160Nothing无卡磨料stoneinproduct影响装配和性能affecttheassemblyandfunction8检具失效gaugeabate3checkthegaugeperiodic定期检查检具spotcheckbyCMM三坐标抽检5120Nothing无80CNCmachining加序影响装配或功能Impactassemblageorfuncation8uttingtoolweaandtear，locationofclamphavesubstance(aluminiumscrapsetc.);theprecisionofmachinetoolfalling刀具磨损，装夹定位面有杂物(铝屑等，夹具定位销磨损，程序编制不合理,processmissing漏序41，装夹前用气枪吹清产品和夹具上的铝屑blowawaythechipsbeforefixing2，毛坯定位尺寸与夹具修配repairthelocationdimensionandjigverifythefirstpartsinspectatsiteinspectionrecordlist首件验证现场检验检验记录单5160Nothing无11-84516023.4+0.2/084516043.2+0.2/084516030-Φ3.65+0.075/0影响装配或功能Impactassemblageorfuncation845160Φ6.4±0.18451608451608451604.3±0.28451604-Φ4±0.284516010-Φ4.6+0.075/0845160Φ3.4+0.1/084516019-8451602-Φ2.5+0.2/-0.184516019-Φ4.5±0.188451605-Φ21±0.184516090Removingburrs去毛刺Theremainderburrs有残余毛刺influenceassemblage影响装配7processmissing漏序3specifyremvoemethodandsteps规定去除方法和步骤checkappearance外观检查7147Nothing无100Cleaninganddryingtwo清洗、烘干二序uncleanpartsurface,theremoldy,ect.产品表面不清洁，有霉斑等不良现象customerisnotfulfilled顾客不满意6dryingtimenotenough烘烤时间不足3specifyproperdryingtime规定合理的烘烤时间autocontrol自动控制590Nothing无6drygingtemperaturetoolow烘烤温度太低3specifyproperdryingtemperature设置合理的烘烤温度visualinspectscreen目测显示屏7126Nothing无6waterintheholedidn'tdrycompletely孔内积水未吹干3drythewaterinthehole吹干孔内水分appearancecheck外观检查7126Nothing无scratch碰伤,划伤influenceappearance影响外观influencefunction影响功能6partsputimproperly产品摆放不当4specifyproperputmethod规定合适的摆放方式cleaningvalidation清洗验证5120Nothing无6scratchedbygasgun气枪划伤3covergasgunendbyplasticcover气枪头使用塑料套appearancecheck外观检查7126Nothing无110密封性测试leakagetest产品碰伤scratch影响外观influenceapperance7装夹时碰伤scratchduringfixing5要求操作工轻拿轻放，目测全检carefulhandling,100%visualinspection目测Visual7245Nothing测试压力0.2bar,泄露量为＜6ml/min影响性能influenceperformance8产品质密度不好lowdensity4压铸时X光探伤Xraytestduringcasting气密性测试仪器全检leakagetest100%inspection5160Nothing120Cleaninganddryingtwo清洗、烘干三序uncleanpartsurface,theremoldy,ect.产品表面不清洁，有霉斑等不良现象customerisnotfulfilled顾客不满意6dryingtimenotenough烘烤时间不足3specifyproperdryingtime规定合理的烘烤时间autocontrol自动控制590Nothing无6△drygingtemperaturetoolow烘烤温度太低3specifyproperdryingtemperature设置合理的烘烤温度visualinspectscreen目测显示屏7126Nothing无6△waterintheholedidn'tdrycompletely孔内积水未吹干3drythewaterinthehole吹干孔内水分appearancecheck外观检查7126Nothing无scratch碰伤,划伤influenceappearance影响外观influencefunction影响功能6△partsputimproperly产品摆放不当4specifyproperputmethod规定合适的摆放方式cleaningvalidation清洗验证5120Nothing无6△scratchedbygasgun气枪划伤3covergasgunendbyplasticcover气枪头使用塑料套appearancecheck外观检查7126Nothing无130finalinspection终检defectappearance外观不良influenceappearance影响外观6taketheproductwiththehanddirectly用手直接拿产品3usingspeicalgloveandtrainingtheoperator使用专用手套并培训操作工checkonsite现场检查7126Nothing无140packing包装wrongquantitywrongandunclearoutpackinglabel数量不符,外包装标识错误和不清Tradedissatisfaction顾客不满意6restpartswhichnotfitoneboxwillbeputtogetherintoonebox零头并箱3markontheoutterbox外箱做并字标记packingrecord包装记录单590Nothing无6nospecialclapboard没有专用隔档3chooseproperclapboard选用适当隔档checkonsite现场检查7126Nothing无140packing包装scratch,deform碰伤,划伤,变形poorapperance外观不良6takemorethanoneparttopackageboxeachtime包装时多件取放3handlespecifiedamountpartsandcarefulhandling按规定数量取放,轻拿轻放checkonsite现场检查7126Nothing无6clapboardandscaleboardnotsuitable隔档隔板不合适3specifytheproperclapboards规定合适的隔档隔板checkonsite现场检查7126Nothing无Thewrongindefinite错误标识Tradedissatisfaction顾客不满意6操作现场合格证摆放混乱3合格证定置管理qualitychecking品质检验7126Nothing无150store入库productdeformation产品变形influenceassembly影响装配8fileuptoohigh堆放高度太高3pileupasperlayersofbox按纸箱规定层数内堆放checkonsite现场检查7168Nothing无partsbump产品碰伤influenceappearance影响外观6transitmethodunproperly搬运方式不当3transitbyhydraulicpressurevehicleandwoodpalletpileuplightly使用液压车和木托进行搬运堆放时轻拿轻放checkonsite现场检查7126Nothing无160dispatchinspection出货检dispatchreportdoesnotconformtotherequirementofcustomer出货报告不符合顾客要求customercomplaint顾客抱怨6QCdidn'trealizetherequirementofcustomer品质人员不了解顾客要求4perfecttheinspectioninstruction完善检验指导书dispatchreport出货报告5120Nothing无170delivery交付deliverydoesnotcomplywithFIFO未按先进先出批次顺序发货difficulttotrace追溯困难6pileupdidn'taccordingtoFIFO未按先进先出次序堆放货物deliverystaffdidn'trealizetherequirementofFIFO发货员不了解先进先出发货要求4applyEPRsystem采用ERP系统deliveryrecord发货记录单5120Nothing无EDIT编制：<**编制签字**><**编制签字日期**>CHECK审核：<**审核签字**><**审核签字日期**>APPROVAL批准：<**批准签字**><**批准签字日期**>QF/71.JS.01.10BPage页码:&Pof&N第&P页共&N页修改:B01