机械加工PFMEA

1、罗信精密零件（上海）有限公司 LX Precision (Shanghai) Co., Ltd.潜潜在在的的失失效效模模式式及及后后果果分分析析Potential Failure Mode and Effects Analysis (Process) 客户名称 Customer Name：Thomas Magnete GMBH 客户零件图号/版本 Customer Part No./Rev.448817 / 02 罗信零件图号 LX Part No.A01-002 零件名称 Part Name/Description ：Cone ng 初始制定日期 Original Maked Date ：2

2、009/11/16FMEA Revised Minutes Rev.DateRevised ItemRevised byB10/DecThe document format has been changed LuXianming PotentialPotential FailureFailure ModeMode andand EffectsEffects AnalysisAnalysis (Process(Process FMEA)FMEA)潜潜在在的的失失效效模模式式及及后后果果分分析析*-FMEA-*零件名称 /客户图号 /版本：Part Name /Drawing No. / Rev.

3、过程责任Process ResponsibilityFMEA日期（原始）Date (Orig.)日期(修订)Revised date零件程序编号 /版本号Part Program No./Rev.初始生产日期Orignal Production Date编制者 Prepared By核心小组Core Team过程步骤/功能 ProcessStep /Function要求 Requirements潜在失效模式Potential Failure Mode潜在失效后果Potential Effect of Failure严重度（S)Severity过程分类ProcessClassification产

4、品分类ProductClassification潜在失效起因Potential Cause of Failure频度（O)Occurrence现行过程控制预防Current Process ControlsPrevention现行过程控制探测Current Process Controls delection探测度（D）DetectionRPN建议措施Recommended Action责任和目标完成日期Responsibility &Target CompletionDate措施执行结果Action Results采取的措施及生效日期 Action Taken &Effect

5、ive Date严重度Severuty频度Occyrance探测度DetectionRPN10.Rawmaterial incoming来料Surface crash表面碰伤Impact machining 影响后续加工4transit method wasunreasonable搬运方法不合理2Transit way was regulated 规定搬运方法 Incoming Inspection来料检验648NANANANANANANA incominginspection来料检验28 -0.03Dimension out ofspec尺寸超差Cant be machined无法加工6Su

6、ppliers dimension outof spec供应商生产尺寸超差3Supplier provide materialcertification供应商提供材质证书Incoming Inspection来料检验354NANANANANANANAAmericancode:AISI 1215Material type wrong材料牌号不对Impact the functionalityof parts影响零件使用性能8Supplier delivery wrongmaterial供应商送错材料21.Check purchasing order of rawmaterial2.Supplie

7、r should inform us beforedelivery1.材料订购进行审核2.供应商送货之前提前通知Warehouse keeper checks the rawmaterial according with delivery list仓库人员按送货单检查原材料696Check certificate of rawmaterials in line withthe label of rawmaterials检查材质证明与原材料标识一致Warehouse keeper仓库管理员11-15Warehousekeeper confirmdelivery list andthe raw m

8、aterialcertification库管员确认送货单和材质证明81648The materialschemicalcomposition are outof spec.材料成份超差Impact the functionalityof parts影响零件使用性能8Supplier productioncontrol out of spec.供应商材质成份控制超差2Supplier provide materialcertification供应商提供材质证书1.Incoming inspection engineercheck with material certification2.Send

9、 the material to the thirdparty to conduct an overallchecking once three years1.来料检验核对材料证书2.每3年一次第三方原材料检测696Send the material to thethird party to conduct anoverall checking once ayear每年一次第三方原材料检测Quality department质量保证部11-19The materialschemicalcompositionare allaccording withSpec.确定化学成份符合规定81648Iss

10、ue Material发料Issue wrong material发错材料1.Impact machining2.Impact function of parts1.影响后续加工2.影响产品使用功能6Warehouse keeper issuewrong material仓库发料错误1Paint the different color at the barend to manage different rawmaterial材料进行颜色管理Operator and warehouse keepercheck each other操作员人员和仓库管理员互相检验318NANANANANANANA2

11、01.TurningFacing光平面Face is not flat端面不平整Impact machining影响后续加工3Tools wear刀具磨损21.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸318NANANANANANANA202.Drilling hole 钻孔5.4Dimension out oftolerance尺寸超差

12、Impact machining影响后续加工6Tools wear刀具磨损21.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸336NANANANANANANA203.Brilling Hole 镗孔（20）5.6 +0.2Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6T

13、ools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA过程步骤/功能 ProcessStep /Function要求 Requirements潜在失效模式Potential Failure Mode潜在失效后果Potential Effect of Failure严重度（S)Sever

14、ity过程分类ProcessClassification产品分类ProductClassification潜在失效起因Potential Cause of Failure频度（O)Occurrence现行过程控制预防Current Process ControlsPrevention现行过程控制探测Current Process Controls delection探测度（D）DetectionRPN建议措施Recommended Action责任和目标完成日期Responsibility &Target CompletionDate措施执行结果Action Results采取的措施及

15、生效日期 Action Taken &Effective Date严重度Severuty频度Occyrance探测度DetectionRPN203.Brilling Hole 镗孔（32,42）20Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Che

16、cking dimensions on line在线检查尺寸345NANANANANANANA（19）5.90.1 Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸345NANANANANANA

17、NA（15）14.5+0.2Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA204Reameringhole铰孔（21）5.5 +0.02/-0.005 Dim

18、ension out oftolerance尺寸超差Impact assembly影响客户装配8Tools wear刀具磨损41.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸41281.Determine the toolmaterial and enactmenttool life2.Determine theprocess parame

19、ters onthe machine3.SPC control1.确定刀具材质和设定刀具使用寿命2.确定过程参数3.SPC控制TechnologyDepartment技术部ProductionDepartment 生产部11-171.Tool materialand tool lifeweredetermined.2.PPK1.67.1.刀具材质和刀具寿命已经确定2.PPK1.6782464205.Dilling hole钻孔10Dimension out oftolerance尺寸超差Impact machining影响后续加工4Tools wear刀具磨损21.Estimate the t

20、ool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸324NANANANANANANA206.Boring hole镗孔（18）12.2+0.04/0Dimension out oftolerance尺寸超差Impact assembly影响客户装配8Tools wear刀具磨损41.Estimate the tool life, changetools periodical

21、ly2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸41281.Determine the toolmaterial and enactmenttool life2.Determine theprocess parameters onthe machine3.SPC control1.确定刀具材质和设定刀具使用寿命2.确定过程参数3.SPC控制TechnologyDepartment技术部ProductionDepartment 生产部1

22、1-171.Tool materialand tool lifeweredetermined.2.PPK1.67.1.刀具材质和刀具寿命已经确定2.PPK1.6782464（16）17.5 +0.02/-0.03Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正

23、Checking dimensions on line在线检查尺寸354NANANANANANANA过程步骤/功能 ProcessStep /Function要求 Requirements潜在失效模式Potential Failure Mode潜在失效后果Potential Effect of Failure严重度（S)Severity过程分类ProcessClassification产品分类ProductClassification潜在失效起因Potential Cause of Failure频度（O)Occurrence现行过程控制预防Current Process ControlsPr

24、evention现行过程控制探测Current Process Controls delection探测度（D）DetectionRPN建议措施Recommended Action责任和目标完成日期Responsibility &Target CompletionDate措施执行结果Action Results采取的措施及生效日期 Action Taken &Effective Date严重度Severuty频度Occyrance探测度DetectionRPN206.Boring hole镗孔（37）Dimension out oftolerance尺寸超差Impact fun

25、ctionality影响使用性能61,Tools wear刀具磨损2,The machine centerline offset机床中心线偏移31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically3,Setup the machine center lineperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正3.定期调整机床中心Checking dimensions on line在线检查尺寸354NANANANANANANA207.T

26、urningOutsideDiameter车外圆（4）14.03Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸345NANANANANANANA（5）12.60.03Dimension out

27、 oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸345NANANANANANANA（1）16.18 0/-0.04Dimension out oftolerance尺寸超差Customer dissatisfaction

28、客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA（25）45.65Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意4Tools wear刀具磨损31.Estimate the tool life,

29、changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸336NANANANANANANA208.Grooving 割槽（2） 14+0.051.Dimension out oftolerance2.Surface is rough1.尺寸超差2.表面粗糙Impact assembly影响客户装配7Tools wear刀具磨损41.Estimate the tool life, changetool

30、s periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸41121.Determine the toolmaterial and enactmenttool life2.Determine theprocess parameters onthe machine3.SPC control1.确定刀具材质和设定刀具使用寿命2.确定过程参数3.SPC控制TechnologyDepartment技术部ProductionDep

31、artment 生产部11-171.Tool materialand tool lifeweredetermined.2.PPK1.67.1.刀具材质和刀具寿命已经确定2.PPK1.6772456（11）2.2 +0.2/01.Dimension out oftolerance2.Surface is rough1.尺寸超差2.表面粗糙Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperi

32、odically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA（26）R0.1+0.1(2X)Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checki

33、ng dimensions on line在线检查尺寸345NANANANANANANA过程步骤/功能 ProcessStep /Function要求 Requirements潜在失效模式Potential Failure Mode潜在失效后果Potential Effect of Failure严重度（S)Severity过程分类ProcessClassification产品分类ProductClassification潜在失效起因Potential Cause of Failure频度（O)Occurrence现行过程控制预防Current Process ControlsPreventi

34、on现行过程控制探测Current Process Controls delection探测度（D）DetectionRPN建议措施Recommended Action责任和目标完成日期Responsibility &Target CompletionDate措施执行结果Action Results采取的措施及生效日期 Action Taken &Effective Date严重度Severuty频度Occyrance探测度DetectionRPN208.Grooving 割槽（3）11.80.2Dimension out oftolerance尺寸超差Customer dis

35、satisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA209Cutting off切断（17）23.4Dimension out oftolerance尺寸超差1.Customerdissatisfaction2.Impact machining1

36、.客户不满意2.影响后续加工51, The part length is notstable2. The machine mainspindle loosing1.原材料外径尺寸不均匀2.机床主轴夹头松动31.Check the raw material whenchanging material and make surethe outer diameter within 0.03mmon each point2.Check the collect loose or notperiodically1.每次换料时，测量材料外径, 要求变化在0.03 mm 以内2.定期进行检查工装松紧程度1.I

37、nspecting on line2.Use the cutting off detectionfixture1.在线检查尺寸2.使用切断检测功能345NANANANANANANA210Drilling hole钻孔（22）6+0.11.Dimension out oftolerance2.Surface is rough1.尺寸超差2.表面粗糙Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parameter

38、speriodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA(36)Dimension out oftolerance尺寸超差Impact functionality影响使用性能61,Tools wear刀具磨损2,The machine centerline offset机床中心线偏移31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically3,

39、Setup the machine center lineperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正3.定期调整机床中心Checking dimensions on line在线检查尺寸354NANANANANANANA(14)90.25Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodic

40、ally1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA(33)1183Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimension

41、s on line在线检查尺寸345NANANANANANANA(37)0.2 +0.2/0.1*45Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸345NANANANANANANA211.D

42、rilling hole钻孔10Dimension out oftolerance尺寸超差Impact machining影响后续加工4Tools wear刀具磨损21.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸324NANANANANANANA212Boring Hole 镗孔(22)8.80.1Dimension out oftole

43、rance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA过程步骤/功能 ProcessStep /Function要求 Requirements潜在失效模式Potential Failure Mode潜在失效

44、后果Potential Effect of Failure严重度（S)Severity过程分类ProcessClassification产品分类ProductClassification潜在失效起因Potential Cause of Failure频度（O)Occurrence现行过程控制预防Current Process ControlsPrevention现行过程控制探测Current Process Controls delection探测度（D）DetectionRPN建议措施Recommended Action责任和目标完成日期Responsibility &Target

45、CompletionDate措施执行结果Action Results采取的措施及生效日期 Action Taken &Effective Date严重度Severuty频度Occyrance探测度DetectionRPN212Boring Hole 镗孔(30)0.1*45Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersper

46、iodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸345NANANANANANANA(13)2.5+0.2Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking d

47、imensions on line在线检查尺寸354NANANANANANANA(12)1.20.025Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life,change tools periodically1.估算刀具寿命,定时换刀2.Correct the toolingparameters periodically2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA(35)

48、Dimension out oftolerance尺寸超差Impact functionality影响使用性能6The machine centeroffset机床中心线偏移3Setup the machine centerperiodically定期调整机床中心Checking dimensions on line在线检查尺寸354NANANANANANANA(24)13 +0.04Dimension out oftolerance尺寸超差Impact assembly影响客户装配8Tools wear刀具磨损31.Estimate the tool life, changetools pe

49、riodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸4961.Determine the toolmaterial and enactmenttool life2.Determine theprocess parameters onthe machine3.SPC control1.确定刀具材质和设定刀具使用寿命2.确定过程参数3.SPC控制TechnologyDepartment技术部ProductionDepartme

50、nt 生产部11-171.Tool materialand tool lifeweredetermined.2.PPK1.67.1.刀具材质和刀具寿命已经确定2.PPK1.6782464213.TurningOutsideDiameter车外圆(6)14.6+0.11.Dimension out oftolerance2.Surface is rough1.尺寸超差2.表面粗糙Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the t

51、ooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA(29)0.20.1*45Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意4Tools wear刀具磨损21.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2

52、.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸324NANANANANANANA(9)3.8+0.1Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸3

53、54NANANANANANANA0.20.01*45Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸345NANANANANANANA过程步骤/功能 ProcessStep /Function要

54、求 Requirements潜在失效模式Potential Failure Mode潜在失效后果Potential Effect of Failure严重度（S)Severity过程分类ProcessClassification产品分类ProductClassification潜在失效起因Potential Cause of Failure频度（O)Occurrence现行过程控制预防Current Process ControlsPrevention现行过程控制探测Current Process Controls delection探测度（D）DetectionRPN建议措施Recommen

55、ded Action责任和目标完成日期Responsibility &Target CompletionDate措施执行结果Action Results采取的措施及生效日期 Action Taken &Effective Date严重度Severuty频度Occyrance探测度DetectionRPN213.TurningOutsideDiameter车外圆(27)0.30.05*20Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool lif

56、e, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸345NANANANANANANA(7)19.6+0.05/0Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the t

57、ooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA(28)0.20.05*45Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意5Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀

58、2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸345NANANANANANANA(3)27.3+0.06/+0.02Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意7Tools wear刀具磨损41.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on li

59、ne在线检查尺寸41121.Determine the toolmaterial and enactmenttool life2.Determine theprocess parameters onthe machine3.SPC control1.确定刀具材质和设定刀具使用寿命2.确定过程参数3.SPC控制TechnologyDepartment技术部ProductionDepartment 生产部11-171.Tool materialand tool lifeweredetermined.2.PPK1.67.1.刀具材质和刀具寿命已经确定2.PPK1.6772456(10)3.6+0.0

60、5Dimension out oftolerance尺寸超差Customer dissatisfaction客户不满意6Tools wear刀具磨损31.Estimate the tool life, changetools periodically2.Correct the tooling parametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正Checking dimensions on line在线检查尺寸354NANANANANANANA30Washing清 洗Different parts mixed不同的零件混合在一起Customer dissatisfaction客户不满意6The operater mix differentparts操作