FMEA潜在失效模式及分析标准表格模版

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潜在的失效模式及效应分析表POTENTIALFAILUREMODEANDEFFECTSANALYSIS,,,,,,,,,,,,,,,,,,

(过程PROCESSFMEA),,,,,,,,,,,,,,,,,,

项目名称Item:,,,,,过程责任部门ProcessResponsibility:质量部QADept.,,,,,FMEA编号Number:,,,,,页码Page:,,,

硅胶加热片类,,,,,关键日期KeyDate:2009.09.07,,,,,准备人PreparedBy:,,,,,,,,

主要参加人CoreTeam:QA部工程部Eng.Dept.,,,,,,,,,,FMEA日期Data(编制(orig):2010.01.25,,,,(修订REV)：,,,,

"序号

NO.","过程功能要求

ProcessFunctionRequirements","潜在的失效模式

PotentialFailureMode","潜在的失效后果

PotentialEffect(S)ofFailure","严

重

度Sev","级

别Class","潜在的失效原因/机理

PotentialCause(s)/Mechanism(s)ofFailure","频度

数Occ","现行过程预防控制

CurrentProcessControlsPrevention","现行过程检测控制

CurrentProcessControlsDetection","难检

度Det","风险优先指数

R.P.N.","建议的措施

Recommended

Action(S)",责任及目标完成日期Responsibility&TargetCompletionDate,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

In-comingRawMaterial","原材料规格错误

Materialspeciswrong","影响零件性能

affectparts'capability",4,,"供应商送原材料的规格有错

Thesuppliersendthewrongmaterial",1,"每批送货供应商附上材质证明书

Thesuppliersubmitthequalitycertificationeveryshipping","收料员检查送货单

Materialreceivercheckdeliveringlist",9,36,NA,NA,,,,,

20,"IQC检查

IQCInspection","尺寸检测有误差

measureerror","影响后续零件生产

affectpartsproductionnextprocess",3,,"供应商送原材料的规格有错

Thesuppliersendthewrongmaterial",2,"送货单标明材料尺寸规格

definetheSPEC.ofraw-materialinthediliveryBills","1.IQC按送货单核对原材料规格表

IQCconfirmtheRawMaterialSpecListaccordingtothedeliveryorder.

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

IQCcheckrawmaterialspecaccordingtotheRawMaterialSpecList,checkmaterial'sthicknessby3pointspercoil,2",8,48,NA,NA,,,,,

30,"移至原材料仓

MoveMaterialtoStore","材料转移错误

mistaketherawmaterial","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前材料上贴来料管理票

setthelabelontheRaw-materialbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

40,"存放

Storage","材料生锈

rustofthematerial","影响后续零件生产

affectpartsproductionnextprocess",2,,"1.材料入库、出库凌乱。

2.放置周期过长。

1.Un-sequenceinandoutstore.

2.longtermstore",4,"按照程序要求，材料先进先出。

Fristinfirstout

",QC复查在库re-checkthepartsinperiod.,8,64,NA,NA,,,,,

50,"移至生产线

MoveMaterial

toProductionLine","材料转移错误

mistaketherawmaterial","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前材料上贴来料管理票

setthelabelontheRaw-materialbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

60,"P200T冲压

P200TStamping","∮6.25±0.15

尺寸超差

isoutoftolerance",影响客户装配affectcustomerassembly,3,,"冲孔冲头磨损

Thetoolingpunchwearsaway",2,"定期维护保养模具

maintainthedieperiodically","PQC用通止规抽检

PQCcheckwithPingauge",8,48,NA,NA,,,,,

60,"P200T冲压

P200TStamping","∮78±0.25

尺寸超差

isoutoftolerance","1.影响客户使用。

2.后续磨削无法装夹。

1.affectcustomerassembly

2.Cannotputinthefixture.",3,,"1.冲孔冲头磨损

2.模具调试中，送料步距不对

1.Thetoolingpunchwearsaway

2.Non-conformingstampingstepinthetoolingadjustprocess.",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.maintainthedieperiodically

2.ContainthetoolingadjustpartsandaskoperatorsfollowtheWIintheproductionprocess.","PQC用卡尺抽检

PQCcheckwithVernierCaliper",8,48,NA,NA,,,,,

,,"翻边孔内径过大或者椭圆

flangingholebiggerorsmaller","1.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.Cause32.549outofdiemension.

2.Causetheroughnessof32.549holeoutofdimension.",3,,"1.合模高度不对

2.送料步距不对

1.Non-conformingshutterheight.

2.Non-conformingstampingstep.",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.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","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。

Addflangingholediameter31.8MaxandPQCcheckitwithverniercaliper.",8,48,NA,NA,,,,,

,,"翻边高度过低

tallerorshorteroftheblangingheight.","导致车削和磨削后7尺寸超差。

Causedimension7outofSPEC.afterturningandgrinding.",3,,"合模高度不到位

Non-conformingshutterheight.",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.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","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。

Addflangingholeheight7.5+/-0.3andPQCcheckitwithverniercaliper",8,48,NA,NA,,,,,

60,"P200T冲压

P200TStamping","37尺寸超差

37outofdimension",影响客户使用affectcustomerusing,3,,"1.合模高度不到位

2.来料较薄

1.Non-conformingshutterheight.

2.thinnerofthematerialthickness.",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.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.

","1.每卷材料上线时，检查材料厚度

1.PQCCheckthethicknessofmaterialwheneverycoilused.",8,48,NA,NA,,,,,

,,"材料厚度超差

materialthicknessoutofdimension.","导致磨削后3.0+/-0.15尺寸超差。

Causethedimension3.0+/-0.15outofSPEC.aftergrinding.",3,,"来料厚度超差

thethicknessofraw-materialoutofSPEC.",2,"将来料厚度控制在3.25+/-0.05。

Setthethicknessofraw-material3.25+/-0.05。","每卷材料上线时，PQC检查材料厚度

PQCCheckthethicknessofmaterialwheneverycoilused.",8,48,NA,NA,,,,,

,,"平面度超差

flatnessoutofdimension","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.Causetheflatnessafergrindingoutofdimension.

2.causethethicknessofthepartaftergrindingoutofdimension.",3,,"合模高度不到位

Non-conformingshutterheight.",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.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","增加冲压过程中的平面度0.15控制并且要求QC抽检。

AddflatnesscontrolinstampingprocessandPQCcheckitinperiod.",8,48,NA,NA,,,,,

60,"P200T冲压

P200TStamping","翻边孔与地面拐角过大

biggerradiusofthecrossingbetweentheflangingandtheflatness.","导致磨削后34.5MAX尺寸超差。

Cause34.5MAXaftergrindingoutofdimension.",3,,"合模高度不到位

Non-conformingshutterheight.",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.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","增加冲压过程中的尺寸34.5控制并且要求QC抽检。

Add34.5MAXcontrolinstampingprocessandPQCcheckitinperiod.",8,48,NA,NA,,,,,

,,毛刺过大largerburrs,"影响零件外观及客户使用

affectparts'appearanceandcustomers'usage",2,,"冲头或凹模镶块磨损

punchanddieinsertwearsaway",4,"定期维护保养模具

maintainthedieperiodically","操作工目视检查1pcs/15mins，PQC目视检查4pcs/h

OperatorcheckwithE,1pcs/15mins,PQCcheckwithE,4pcs/h",8,64,NA,NA,,,,,

70,"半成品包装

Packageinsemi-finishedproduct","包装错误

Non-conformingpackaging","造成零件表面的压伤。

Causethedentinthesurfaceofthepart.",3,,"包装方式不明确

Unknownofthepackagingmethods.",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.SetthePIsiteandasktheoperatorsfollowitafterstamping.","传送前PQC确认包装正确后才可以传送。

QCverifythepackagingbeforedelivery",8,48,NA,NA,,,,,

80,"移至半成品区

Movetosemi-finishedarea","零件转移错误

mistakethepart","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前每卡板贴上传送单核入库单。

setthedeliverynotesandreceiptsnoteslabelontheRaw-materialbeforestorepallet.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

90,"存放

Storage","零件生锈

rustofthepart.","影响后续零件生产

affectpartsproductionnextprocess",3,,"1.材料入库、出库凌乱。

2.放置周期过长。

1.Un-sequenceinandoutstore.

2.longtermstore",2,"按照程序要求，材料先进先出。

Fristinfirstout

",QC复查在库re-checkthepartsinperiod.,8,48,NA,NA,,,,,

100,"移至生产线

MoveMaterial

toProductionLine","材料转移错误

mistaketherawmaterial","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前材料上贴来料管理票

setthelabelontheRaw-materialbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

110,"机加工

machining","∮32.549±0.012

尺寸超差isoutoftolerance",影响客户装配affectcustomerassembly,4,,"1.车刀磨损

2.零件装夹不到位

1.Thelathetoolwearsaway

2.Non-confromingclampingarea",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.maintainthelatheperiodically

2.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.

","PQC和操作工用气动量仪抽检

PQCandoperatorscheckwithAIRgauge",8,96,NA,NA,,,,,

,,"内孔粗糙度不良

Non-conformingoftheroughnessintheinnerhole.","1.影响客户使用。

1.affectcustomerassembly",3,,"1.车刀磨损

1.Thelathetoolwearsaway",2,定期维护保养车床maintainthelatheperiodically,"PQC用粗糙度仪抽检

PQCandoperatorscheckwithroughnessmachine.",8,48,NA,NA,,,,,

,,"材料厚度超差

materialthicknessoutofdimension.","导致磨削后3.0+/-0.15尺寸超差。

Causethedimension3.0+/-0.15outofSPEC.aftergrinding.",5,,"进刀量过大

longerofthefeeding.",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。

SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","PQC用千分尺抽检

PQCandoperatorscheckwithmicrometer.",8,40,NA,NA,,,,,

110,"机加工

machining",尺寸超差isoutoftolerance,影响客户装配affectcustomerassembly,4,,"1.车刀磨损

2.零件装夹不到位

1.Thelathetoolwearsaway

2.Non-confromingclampingarea",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.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.

2.maintainthelatheperiodically

","PQC和操作工用检具抽检。

PQCandoperatorscheckwithgauge",8,64,NA,NA,,,,,

,,尺寸超差isoutoftolerance,影响客户装配affectcustomerassembly,4,,"1.车刀磨损

2.零件装夹不到位

1.Thelathetoolwearsaway

2.Non-confromingclampingarea",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.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.

2.maintainthelatheperiodically

","PQC和操作工用检具抽检。

PQCandoperatorscheckwithgauge",8,64,NA,NA,,,,,

120,"半成品包装

Packageinsemi-finishedproduct","包装错误

Non-conformingpackaging","造成零件表面的压伤。

Causethedentinthesurfaceofthepart.",3,,"包装方式不明确

Unknownofthepackagingmethods.",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.SetthePIsiteandasktheoperatorsfollowitafterstamping.","传送前PQC确认包装正确后才可以传送。

QCverifythepackagingbeforedelivery",8,48,NA,NA,,,,,

130,"移至半成品区

Movetosemi-finishedarea","零件转移错误

mistakethepart","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前每卡板贴上传送单核入库单。

setthedeliverynotesandreceiptsnoteslabelonthepalletbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

140,"存放

Storage","零件生锈

rustofthepart.","影响后续零件生产

affectpartsproductionnextprocess",3,,"1.材料入库、出库凌乱。

2.放置周期过长。

1.Un-sequenceinandoutstore.

2.longtermstore",2,"按照程序要求，材料先进先出。

Fristinfirstout

",QC复查在库re-checkthepartsinperiod.,8,48,NA,NA,,,,,

150,"移至生产线

MoveMaterial

toProductionLine","材料转移错误

mistaketherawmaterial","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前材料上贴来料管理票

setthelabelontheRaw-materialbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",4,24,NA,NA,,,,,

160,"倒角

chamfer","倒角大于0.5c

thechamfermorethan0.5","影响零件外观

affectparts'appearance",2,,"倒角限位移动

thelimitaway",5,"定期维护保养机床

maintainthemachineperiodically","PQC用投影仪抽检

PQCcheckwithprofileprojector.",3,30,NA,NA,,,,,

170,"半成品包装

Packageinsemi-finishedproduct","包装错误

Non-conformingpackaging","造成零件表面的压伤。

Causethedentinthesurfaceofthepart.",2,,"包装方式不明确

Unknownofthepackagingmethods.",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.SetthePIsiteandasktheoperatorsfollowitafterstamping.","传送前PQC确认包装正确后才可以传送。

QCverifythepackagingbeforedelivery",4,24,NA,NA,,,,,

180,"移至半成品区

Movetosemi-finishedarea","零件转移错误

mistakethepart","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前每卡板贴上传送单核入库单。

setthedeliverynotesandreceiptsnoteslabelonthepalletbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",4,24,NA,NA,,,,,

190,"存放

Storage","零件生锈

rustofthepart.","影响后续零件生产

affectpartsproductionnextprocess",3,,"1.材料入库、出库凌乱。

2.放置周期过长。

1.Un-sequenceinandoutstore.

2.longtermstore",4,"按照程序要求，材料先进先出。

Fristinfirstout

",QC复查在库re-checkthepartsinperiod.,8,48,NA,NA,,,,,

200,"移至生产线

MoveMaterial

toProductionLine","材料转移错误

mistaketherawmaterial","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前材料上贴来料管理票

setthelabelontheRaw-materialbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

210,"磨削

grinding","粗糙度超差

roughnessoftheflatoutofdimension.",影响客户使用affectcustomerusing,3,,"砂轮硬度以及颗粒度不适合。

Non-conformingofthehardnessandparticlegrindingwheel.",2,"选择合适的砂轮并将砂轮规格写入操作指导书

ChooseconforminggrindingwheelandwriteitintoWI",生产前，QC和操作工检查砂轮的规格。QCandoperatorschecktheSpec.ofthegrindingwheel.,8,48,NA,NA,,,,,

210,"磨削

grinding",outofdimension.,影响客户使用affectcustomerusing,4,,"1.磨床磁力过大

2.磨床工作台有异物

1.Biggermagneticforceofthegrindingmachine

2.Un-clearnoftheworkingflat.",2,"1.加工特殊的磨削夹具以减小磁力。

2.磨削前用切削液洗刷工作台面。

1.Machiningspecialgrindinggaugetoreducethemagneticforce.

2.Clearntheworkingflatbeforeproduction.","QC对每盘的零件平面度进行抽检

PQCcheckthesomesamplesofeveryplate.",8,96,NA,NA,,,,,

,,"3+/-0.15尺寸超差

3+/-0.15outofdimension",影响客户使用affectcustomerusing,3,,"车削不到位

moreornoenoughgrinding",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.SetthePIsiteandasktheoperatorsfollowitafterstamping.","QC对每盘的零件进行抽检

PQCcheckthesomesamplesofeveryplate.",8,48,NA,NA,,,,,

,,"7+/-0.3尺寸超差

7+/-0.3outofdimension",影响客户使用affectcustomerusing,3,,"车削不到位

moreornoenoughgrinding",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.SetthePIsiteandasktheoperatorsfollowitafterstamping.","QC对每盘的零件进行抽检

PQCcheckthesomesamplesofeveryplate.",8,48,NA,NA,,,,,

210,"磨削

grinding","34.5MAX尺寸超差。

34.5MAXoutofdimension",影响客户使用affectcustomerusing,3,,"磨削不到位

noenoughgrinding",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.SetthePIsiteandasktheoperatorsfollowitafterstamping.","QC对每盘的零件进行抽检

PQCcheckthesomesamplesofeveryplate.",8,48,NA,NA,,,,,

,,outofdimension,影响客户使用affectcustomerusing,3,,"磨床工作台有异物

Un-clearnoftheworkingflat.",2,"磨削前用切削液洗刷工作台面。

Clearntheworkingflatbeforeproduction.","QC对每盘的零件进行抽检

PQCcheckthesomesamplesofeveryplate.",8,48,NA,NA,,,,,

220,"半成品包装

Packageinsemi-finishedproduct","包装错误

Non-conformingpackaging","造成零件表面的压伤。

Causethedentinthesurfaceofthepart.",3,,"包装方式不明确

Unknownofthepackagingmethods.",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.SetthePIsiteandasktheoperatorsfollowit.","传送前PQC确认包装正确后才可以传送。

QCverifythepackagingbeforedelivery",8,48,NA,NA,,,,,

230,"移至半成品区

Movetosemi-finishedarea","零件转移错误

mistakethepart","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前每卡板贴上传送单核入库单。

setthedeliverynotesandreceiptsnoteslabelonthepalletbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

240,"外协清洗

cleanoutsource","零件表面未清洗干净

uncleanofthepart",影响客户使用affectcustomerusing,4,,"供应商对零件表面清洁度要求不明确

unknownofthesuppliertothecleanessrequiremnent.",3,"采购发图纸给供应商

Purchasepublishthedrawingtosupplier","每批来料QC对清洁度进行检测。

QCcheckthepartcleanessofeverylot.",8,96,NA,NA,,,,,

240,"外协清洗

cleanoutsource","零件表面有碰伤

dentinthesurfaceofthepart",影响客户使用affectcustomerusing,2,,"包装不合理

non-conformingpackaging",3,"与供应商沟通，制订合理包装方式。

CommunicatewithsupplierandmakerightPI.","每批来料QC对外观和包装进行检测。

QCcheckthepartappearanceandpackagingofeverylot.",8,48,NA,NA,,,,,

230,"移至包装区

Movepackagearea","零件转移错误

mistakethepart","影响后续零件生产

affectpartsproductionnextprocess",3,,"材料标识不明确

Un-clearlabel",2,"入库前每卡板贴上传送单核入库单。

setthedeliverynotesandreceiptsnoteslabelonthepalletbeforestore.","生产领料时，操作工和QC对材料进行确认

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

260,"包装全检

100%sortingandpackaging","零件外观项目检查有误

appearancesortingerror",影响客户使用affectcustomerusing,2,,"操作工对外观要求不明确

unknownoftheoperatortotheappearancerequirement.",3,"1.现场放置全检指导书，并且要求操作工严格按照全检指导书全检。

1.SettheInspectionInstructionsiteandasktheoperatorsfollowit.","QC对零件进行抽检

QCcheckthepartwitheyes.",8,48,NA,NA,,,,,

260,"包装全检

100%sortingandpackaging","包装有误

non-conformingpackaging","造成零件外观不良

causethenon-conformingofthepartappearance",3,,"操作工对包装要求不明确

Un-knownoftheoperatorsthethepackaginginstruction.",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.SetthePackagingInstructionsiteandasktheoperat