FMEA潜在失效模式及分析标准表格模版

1、潜在的失效模式及效应分析表 POTENTIAL FAILURE MODE AND EFFECTS ANAL YSIS(过程 PROCESS FMEA)项目名称Item:过程责任部门 Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类关键日期Key Date:2009.09.07准备人Prepared By:主要参加人 Core Team: QA 部 QA Dept./ 模具部 Tooling. Dept.; /工程部 Eng.Dept.FMEA 日期 Data(编制(orig):2010.01.25(修订 REV):序号

2、NO.过程功能要求Process Fun cti onRequireme nts潜在的失效模式Potential Failure Mode潜在的失效后果Potential Effect(S) ofFailure严 重 度Sev级 别Class潜在的失效原因/机理Pote ntial Cause(s)/ Mecha ni sm(s) of Failure频 度 数Occ现行过程预防控制Curre nt Process Con trolsPreve nti on现行过程检测控制Curre nt Process Con trolsDetectio n难 检 度Det风险 优先 指数R.P.N建议的措

3、施Recomme ndedActio n(S)责任及目标兀 成日期Resp on sibility & Target Completion措施结果Result严 重 度Sev频 度 数Occ难 检 度Det风险 优先 指数R.P.N.10原材料进厂 n-coming RawMaterial原材料规格错误Material spec is wrong影响零件性能affect parts' capability4供应商送原材料的规格 有错The supplier send the wrong material1每批送货供应商附上材 质证明书The supplier submit th

4、e quality certification every shipp ing收料员检查送货单Material receiver check deliveri ng list936NANA20QC检查 QC In specti on尺寸检测有误差measure error影响后续零件生产 affect parts producti on n ext process3供应商送原材料的规格 有错The supplier send the wrong material2送货单标明材料尺寸规 格define the SPEC. of raw-material in the dilivery Bills

5、1.IQC按送货单核对原材料规 格表IQC confirm the Raw Material Spec List accord ing to the delivery order.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 accord ing to the Raw Material Spec List,check materia l's thick ness by 3 points per coil,2848NANA30移至原材料仓Move Material toStore材料转移错误 mist

6、ake the rawmaterial影响后续零件生产 affect parts producti on n ext process3材料标识不明确Un-clear label2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寸 材料进行确认Operators and QC verify the material in producti on line848NANA40存放Storage材料生锈 rust of the material影响后续零件生产 affect parts producti on

7、 n ext process21. 材料入库、出库凌乱。2. 放置周期过长。1. Un-seque nee in and out store.2 long term store4按照程序要求，材料先 进先岀。Frist in first outQCt查在库 re-check the parts in period.864NANA50移至生产线Move Material to Producti on _ine材料转移错误 mistake the rawmaterial影响后续零件生产 affect parts producti on n ext process3材料标识不明确Un-clear l

8、abel2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寸 材料进行确认Operators and QC verify the material in production line848NANA60P200T冲压 °200T Stampi ng为 6.25 ±).15尺寸超差is out of tolera nee影响客户装配affect customer assembly3冲孔冲头磨损The tooli ng punch wears away2定期维护保养模具 maintai

9、n the die periodicallyPQC用通止规抽检PQC check with Pin gauge848NANA1 of 10潜在的失效模式及效应分析表 POTENTIAL FAILURE MODE AND EFFECTS ANAL YSIS项目名称Item:过程责任部门 Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类关键日期Key Date:2009.09.07准备人Prepared By:主要参加人 Core Team: QA 部 QA Dept./ 模具部 Tooling. Dept.; /工程部

10、Eng.Dept.FMEA 日期 Data(编制(orig):2010.01.25(修订 REV):序号NO.过程功能要求Process Fun cti onRequireme nts潜在的失效模式Potential Failure Mode潜在的失效后果Potential Effeet(S) ofFailure严 重 度Sev级 别Class潜在的失效原因/机理Pote ntial Cause(s)/ Mecha ni sm(s) of Failure频 度 数Occ现行过程预防控制Curre nt Process Con trolsPreve nti on现行过程检测控制Curre nt

11、Process Con trolsDetectio n难 检 度Det风险 优先 指数R.P.N建议的措施Recomme ndedActio n(S)责任及目标兀 成日期Resp on sibility & Target Completion措施结果Result严 重 度Sev频 度 数Occ难 检 度Det风险 优先 指数R.P.N.60P200T冲压P200T Stampi ng为 78 ± 0.25 尺寸超差 is out of tolera nee1. 影响客户使用。2. 后续磨削无法装夹 。1. affect customer assembly2. Can not

12、put in the fixture.31. 冲孔冲头磨损2. 模具调试中，送料步 距不对1. The tooli ng punch wears away2. N on-conforming stamping step in the tooli ng adjust process.21. 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 periodically2. Con tain the tooli ng adjust parts and ask operators follow the WI in the producti

13、on process.PQC用卡尺抽检PQC check with Ver nierCaliper848NANA翻边孔内径过大或者 椭圆flanging holebigger or smaller1. 车削后导致 32.549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 dieme nsion.2. Cause the rough ness of 32.549 hole out of dime nsion.31. 合模高度不对2. 送料步距不对1. Non-conforming shutter height.2. Non-c on formi n

14、g stamping step.21. 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 siteand ask the operators follow it in the producti on 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.848NANA翻边高度过低 taller or shorter of the bla nging height.导致车削和磨削后7

15、尺寸超差。Cause dime nsion 7 out of SPEC. after turning and gri nding.3合模高度不到位 Non-con formi ng shutter height.21.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 siteand ask the operators follow it in the producti on 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 ch

16、eck it with ver nier caliper848NANA37尺寸超差37 out of dime nsion影响客户使用affect customer using31. 合模高度不到位2. 来料较薄1. Non-conforming shutter height.2. thinner of the material thick ness.21.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 siteand ask the operators follow it in the producti on process.1.每卷材料上线时，检查

17、材 料厚度1. PQC Check the thick ness of material when every coil used.848NANA703 of 10潜在的失效模式及效应分析表 POTENTIAL FAILURE MODE AND EFFECTS ANAL YSIS(过程 PROCESS FMEA)项目名称Item:过程责任部门 Process Responsibility: 质量部 QA Dept.车型年/车辆类关键日期Key Date: 2009.09.07主要参加人 Core Team: QA 部 QA Dept./ 模具部 Tooling. Dept.; /工程部 Eng

18、.Dept.FMEA 编号 Number: 准备人 Prepared By:FMEA 日期 Data(编制(orig):2010.01.25(修订 REV):页码Page:序号NO.6060过程功能要求Process Fun cti onRequireme ntsP200T冲压P200T Stamp ingP200T冲压P200T Stamp ing潜在的失效模式Potential Failure Mode材料厚度超差materialthick ness out of dime nsion.平面度超差flat ness out of dime nsion翻边孔与地面拐角过 大bigger ra

19、dius of the cross ing betwee n the flanging and the flat ness.毛刺过大 larger burrs半成品包装Package in semi- ：ini shed product包装错误Non-con formi ng packag ing潜在的失效后果Potential Effect(S)Failure导致磨削后3.0+/-0.15尺寸超差。Cause the dime nsion 3.0+/0.15 out of SPEC. after gri nding.of重度Sev级别Class潜在的失效原因/机理Pote ntial Cau

20、se(s)/ Mecha ni sm(s) of Failure来料厚度超差the thick ness of raw-material out of SPEC.频度数Occ现行过程预防控制Curre nt Process Con trolsPreve nti on现行过程检测控制Curre nt Process Con trolsDetectio n难检度DetM险 优先 指数R.P.N建议的措施Recomme ndedActio n(S)责任及目标完成日期Resp on sibility& TargetCompleti on措施结果Result将来料厚度控制在3.25+/-0.05

21、。Set the thick ness of raw-material 3.25+/- 0.05。每卷材料上线时，PQC检查 材料厚度PQC Check the thick ness of material whe n every coil used.48NANA重度Sev频度数Occ难检度Det风险优先指数R.P.N.1. 导致磨削后的平面 度超差。2. 导致磨削后的材料 厚度超差。1. Cause the flat ness afer gr inding out of dime nsion.2. cause the thick ness of the part aftergr indina

22、 out of造成零件表面的压伤oCause the dent in the surface of the part.合模高度不到位 Non-con formi ng shutter height.合模高度不到位 Non-con formi ng shutter height.导致磨削后34.5MAX 尺寸超差。Cause 34.5MAX after gri nding out of dime nsion.影响零件外观及客户 使用affect parts' appeara nee and customers' usage冲头或凹模镶块磨损punch and die in ser

23、t wears away包装方式不明确Unknown of the packagi ng methods.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o1. Set the WI site and ask the operators follow it in the producti on process.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o1. Set the WI site and ask the operators follow it in the producti on process.定期维护保养模具 maintain the die

24、 periodically1.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o1. Set the PI site and ask the operators follow it after stamping.增加冲压过程中的平面度 0.15控制并且要求QC由检。Add flat ness con trol in stamp ing process and PQC check it in period.增加冲压过程中的尺寸34.5 控制并且要求QC由检。Add 34.5MAX control in stamp ing process and PQC check it in per

25、iod.操作工目视检查1pcs/15mins，PQC目视检查 4pcs/hOperator check with E, 1pcs/15mins,PQC check with E,4pcs/h传送前PQ确认包装正确后才 可以传送。QC verify the packag ing before delivery48486448NANANANANANANANA705 of 10潜在的失效模式及效应分析表 POTENTIAL FAILURE MODE AND EFFECTS ANAL YSIS项目名称Item:过程责任部门 Process Responsibility:质量部 QA Dept.FMEA

26、编号Number:页码Page:车型年/车辆类关键日期Key Date:2009.09.07准备人Prepared By:主要参加人 Core Team: QA 部 QA Dept./ 模具部 Tooling. Dept.; /工程部 Eng.Dept.FMEA 日期 Data(编制(orig):2010.01.25(修订 REV):序号NO.过程功能要求Process Fun cti onRequireme nts移至半成品区Move to semi-fini shed area潜在的失效模式Potential Failure Mode零件转移错误mistake the part潜在的失效后

27、果Potential Effect(S) of Failure影响后续零件生产affect partsproducti on n ext process严 重 度Sev3级 别Class潜在的失效原因/机理Pote ntial Cause(s)/Mecha ni sm(s) of Failure材料标识不明确Un-clear label频 度 数Occ2现行过程预防控制Curre nt Process Con trols Preve nti on入库前每卡板贴上传送 单核入库单。set the delivery no tes and receipts no tes label on the R

28、aw-material before store pallet.现行过程检测控制Curre nt Process Con trols Detectio n生产领料时，操作工和QC寸 材料进行确认Operators and QC verify the material in producti on line.难 检 度Det8风险优先 指数R.P.N48建议的措施Recomme ndedActio n(S)NA责任及目标完 成日期Resp on sibility & Target Completi on措施结果Result严 重 度Sev频 度 数Occ难 检 度Det风险 优先 指数R

29、.P.N.80NA90存放Storage零件生锈rust of the part.影响后续零件生产 affect parts producti on n ext process31. 材料入库、出库凌乱。2. 放置周期过长。1. Un-seque nee in and out store.2 long term store2按照程序要求，材料先 进先岀。Frist in first outQCt查在库 re-check the parts in period.848NANA100移至生产线Move Material to Producti on _ine材料转移错误 mistake the r

30、awmaterial影响后续零件生产 affect parts producti on n ext process3材料标识不明确Un-clear label2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寸 材料进行确认Operators and QC verify the material in production line.848NANA110机加工machi ning为 32.549 士 0.012 尺寸超差is out of tolera nee影响客户装配affect custome

31、r assembly41. 车刀磨损2. 零件装夹不到位1. The lathe tool wears away2. N on-confroming clamp ing area21. 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 periodically2. Set the WI site and ask the operators follow it in the producti on process.PQC和操作工用气动量仪抽 检PQC and operators check with AIR gauge

32、896NANA内孔粗糙度不良Non-c on formi ng of the rough ness in the inner hole.1.影响客户使用。1. affect customer assembly31.车刀磨损1.The lathe toolwears away2定期维护保养车床 maintain the lathe periodicallyPQC用粗糙度仪抽检PQC and operators check with rough ness machi ne.848NANA70# of 10潜在的失效模式及效应分析表 POTENTIAL FAILURE MODE AND EFFECT

33、S ANAL YSIS序号NO.过程功能要求Process Fun cti onRequireme nts潜在的失效模式Potential Failure Mode潜在的失效后果Potential Effect(S) ofFailure严 重 度Sev级 别Class潜在的失效原因/机理Pote ntial Cause(s)/ Mecha ni sm(s) of Failure频 度 数Occ现行过程预防控制Curre nt Process Con trolsPreve nti on现行过程检测控制Curre nt Process Con trolsDetectio n难 检 度Det风险 优

34、先 指数R.P.N建议的措施Recomme ndedActio n(S)责任及目标完 成日期Resp on sibility & Target Completi on措施结果Result严 重 度Sev频 度 数Occ难 检 度Det风险 优先 指数R.P.N.材料厚度超差materialthick ness out of dime nsion.导致磨削后3.0+/-0.15尺寸超差。Cause the dime nsion 3.0+/0.15 out of SPEC. after gri nding.5进刀量过大 lon ger of the feed ing.1现场放置操作指导书，

35、 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 producti on process.PQC用千分尺抽检PQC and operators check with micrometer.840NANA110机加工 machi ning影响客户装配affect customer assembly41. 车刀磨损2. 零件装夹不到位1. The lathe tool wears away2. N on-confroming clamp ing area21. 定期维护保养车床2. 现场放置操作指

36、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 producti on process.2. maintain the lathe periodicallyPQC和操作工用检具抽检。PQC and operators check with gauge864NANAL1-1 11 j i尺寸超差is out of tolera nee41. 车刀磨损2. 零件装夹不到位1. The lathe tool wears away2. N on-confroming clamp ing

37、area21. 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 producti on process.2. maintain the lathe periodicallyPQC和操作工用检具抽检。PQC and operators check with gauge864NANA一F尺寸超差is out of tolera nee影响客户装配affect customer assembly120半成品包装Package in semi-fi n

38、i shed product包装错误Non-con formi ng packag ing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 packagi ng methods.21.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 stamp ing.传送前PQd认包装正确后才 可以传送。QC verify the packag ing before delivery8

39、48NANA(过程 PROCESS FMEA)项目名称 ItmmChining过程责任部门 Process Responsibility: 质量部 QA Dept.FMEA 编号 Number:页码 Page:车型年/车辆类关键日期Key Date: 2009.09.07准备人Prepared By:主要参加人 Core Team: QA 部 QA Dept./ 模具部 Tooling. Dept.; /工程部 Eng.Dept.FMEA 日期 Data(编制(orig):2010.01.25(修订 REV):7 of 10潜在的失效模式及效应分析表 POTENTIAL FAILURE MOD

40、E AND EFFECTS ANAL YSIS严潜在的失效原因/机理Pote ntial Cause(s)/ Mecha ni sm(s) of Failure频 度 数Occ难 检 度Det风险责任及目标完措施结果Result序号NO.过程功能要求Process Fun cti onRequireme nts潜在的失效模式Potential Failure Mode潜在的失效后果Potential Effect(S) ofFailure重 度Sev级 别Class现行过程预防控制Curre nt Process Con trolsPreve nti on现行过程检测控制Curre nt Pr

41、ocess Con trolsDetectio n优先 指数R.P.N建议的措施Recomme ndedActio n(S)成日期Resp on sibility& TargetCompleti on严 重 度Sev频 度 数Occ难 检 度Det风险 优先 指数R.P.N.130移至半成品区Move to semi- fini shed area零件转移错误 mistake the part影响后续零件生产 affect parts producti on n ext process3材料标识不明确Un-clear label2入库前每卡板贴上传送 单核入库单。set the del

42、ivery no tes and receipts no tes label on the pallet before store生产领料时，操作工和QC寸 材料进行确认Operators and QC verify the material in producti on line.848NANA140存放Storage零件生锈rust of the part.影响后续零件生产 affect parts producti on n ext process31. 材料入库、出库凌乱。2. 放置周期过长。1. Un-seque nee in and out store.2. lo ng term

43、store2按照程序要求，材料先 进先岀。Frist in first outQCt查在库 re-check the parts in period.848NANA150移至生产线Move Material to Producti on _ine材料转移错误 mistake the rawmaterial影响后续零件生产 affect parts producti on n ext process3材料标识不明确Un-clear label2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寸 材料进

44、行确认Operators and QC verify the material in producti on line.424NANA160倒角chamfer倒角大于0.5cthe chamfer moretha n 0.5影响零件外观affect parts' appeara nee2倒角限位移动the limit away5定期维护保养机床 maintain the machine periodicallyPQC用投影仪抽检PQC check with profile projector.330NANA170半成品包装Package in semi-fi ni shed produ

45、ct包装错误Non-con formi ng packag ing造成零件表面的压伤。Cause the dent in the surface of the part.2包装方式不明确Unknown of the packagi ng methods.31.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 stamp ing.传送前PQd认包装正确后才 可以传送。QC verify the packag ing before delivery424NANA180移至半

46、成品区Move to semi- fini shed area零件转移错误 mistake the part影响后续零件生产 affect parts producti on n ext process3材料标识不明确Un-clear label2入库前每卡板贴上传送 单核入库单。set the delivery no tes and receipts no tes label on the pallet before store生产领料时，操作工和QC寸 材料进行确认Operators and QC verify the material in producti on line.424NAN

47、A项目名称Item:车型年/车辆类主要参加人 Core Team: QA 部 QA Dept./ 模具部 Tooling. Dept.; /工程部 Eng.Dept.FMEA 编号 Number:页码 Page:准备人 Prepared By:FMEA 日期 Data(编制(orig):2010.01.25(修订 REV):(过程 PROCESS FMEA)过程责任部门 Process Responsibility: 质量部 QA Dept.关键日期 Key Date:2009.09.079 of 10潜在的失效模式及效应分析表 POTENTIAL FAILURE MODE AND EFFEC

48、TS ANAL YSIS(过程 PROCESS FMEA)项目名称Item:过程责任部门 Process Responsibility:质量部 QA Dept.FMEA编号Number:页码Page:车型年/车辆类关键日期Key Date:2009.09.07准备人Prepared By:主要参加人 Core Team: QA 部 QA Dept./ 模具部 Tooling. Dept.; /工程部 Eng.Dept.FMEA 日期 Data(编制(orig):2010.01.25(修订 REV):序号NO.过程功能要求Process Fun cti onRequireme nts潜在的失效模

49、式Potential Failure Mode潜在的失效后果Potential Effect(S) ofFailure严 重 度Sev级 别Class潜在的失效原因/机理Pote ntial Cause(s)/ Mecha ni sm(s) of Failure频 度 数Occ现行过程预防控制Curre nt Process Con trolsPreve nti on现行过程检测控制Curre nt Process Con trolsDetectio n难 检 度Det风险 优先 指数R.P.N建议的措施Recomme ndedActio n(S)责任及目标兀 成日期Resp on sibil

50、ity & Target Completi on措施结果Result严 重 度Sev频 度 数Occ难 检 度Det风险 优先 指数R.P.N.190存放Storage零件生锈 rust of the part.影响后续零件生产 affect parts producti on n ext process31. 材料入库、出库凌乱。2. 放置周期过长。1. Un-seque nee in and out store.2. lo ng term store4按照程序要求，材料先 进先岀。Frist in first outQCt查在库 re-check the parts in peri

51、od.848NANA200移至生产线Move Material to Producti on _ine材料转移错误 mistake the rawmaterial影响后续零件生产 affect parts producti on n ext process3材料标识不明确Un-clear label2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寸 材料进行确认Operators and QC verify the material in producti on line.848NANA210磨削grin di ng粗糙度超差rough ness of the flat out ofdime nsion.影响客户使用affect customer using3砂轮硬度以及颗粒度不 适合。Non-c on formi