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PotentialFailureModeandEffectsAnalysis(ProcessFMEA),,,,,,,,,,,,,,,,,,
过程失效模式及后果分析,,,,,,,,,,,,,,,,,,
System系统,,"Enginesubsystems/
发动机分系统/",,,ProcessResponsibility过程责任,,,,,,FMEANumber编号,,,,,,,
Subsystem子系统,,,,,,,,,,,Page页码,,,共2页第1页,,,,
Component零部件,,,,,KeyDate关键日期,,,,,,PrepareBy编制,,,,,,,
ModelYear(s)/Vehicle(s)车型年/车辆类型,,,,,,,,,,,Date(Orig.)日期(最初),,,,,,,
CoreTeam核心小组成员,,,,,,,,,,,Rev.(修订),,,,,,,
"Serialnumber
序号","Item/Function
项目/功能",Requirements要求,PotentialFaisureMode潜在失效模式,PotentialEffect(s)ofFailure潜在失效后果,Sev.严重度,CLASS级别,PotentialCause(s)/Mechanism(s)ofFailure潜在失效的起因/机理,Occr.频度,"CurrentProcessControl
现行控制过程",Detec探测度,"RPN
风险度
",RecommendedAction(s)建议措施,Responsibility&TargetCompletionDate责任和目标完成日期,ActionResults措施结果,,,,
,,,,,,,,,,,,,,ActionsTaken采取的措施,Sev严重度,Occ频度,Det探测度,Rpn风险度
0--1,"ChemicalcompositionInspectionofrawmaterials(ADC12)
检验原材料化学成份(ADC12)","FollowtheincomingchemicalcompositionstandardproceduresofADC12
符合铝合金ADC12的进料化学成份标准","1Mistakenjudgments:
1.1qualifiedasunqualified;
1.2unqualifiedasqualified;
1误判断:
1.1合格判为不合格;
1.2不合格判为合格。
","1Purchasecostincreas(thepurchasepriceofdifferentgradesofaluminumaredifferent);
2Mechanicalpropertiesdifferent(mechanicalpropertiesofdifferentgradesofaluminumarebigdifferenct).
1采购成本增加(不同牌号铝材的采购价格有差价);
2力学性能差异(不同牌号铝材的机械性能差异大)。",6,,"1.1theWIofinspectionequipmentisunclear;
1.1检验设备操作书不明细;",2,"definetheoperationprocedure;
制订操作规程;",3,36,无,,,,,,
,,,,,5,,"1.2inspectortakeanwrongbatchofsamples
1.2检验人员取错批次样品",3,"definespecimenbatchmanagementprocedure
试块的批次管理",3,45,无,,,,,,
,,,,,3,,"1.3inspectionequipmenterror;
1.3检验设备误差;",2,"1.3.1regularcheck
1.3.2equipmentcheck
1.3.1定期校检
1.3.2设备点检",2,12,无,,,,,,
,,,,,3,,"1.4theenvironmenttemperatureandhumidityofinspectionequipmentisunstable
1.4检验设备使用环境温度湿度不稳定",2,"humidityandtemperaturemetercontrol
温度湿度计控制",2,12,无,,,,,,
,,,"2.Missinginspection
2.漏判","(Ibid.)
(同上)",5,,"Noinspectionrequestnote/notcheckallsample
未报检/少检",2,"incominginspectionprocedure
进料检验流程",4,40,无,,,,,,
0--2,"Ingotsstorage
铝锭入库","Seperatedqualifiedincomingaluminiumingot(Black)
合格铝锭用标识分开","1.notlabeledmaterial
1.未标示材质","materialwasmixedinmeltingoperation
混用",5,,"warehousekeeperforgetidentity
库管员忘记做标识",2,"checkingthelabelwhendrawing
领料时检查材料标识",3,30,无,,,,,,
,,,"2.surfacehalogenated
2.表面卤化","baddegassandmaycauseexcessiveinternalporosity
精炼效果不良,可能引起内部气孔超标",5,,2.1Humidityexceeded2.1环境湿度超标,2,"extendthedryingtimeofmelting
熔炼延长烘干时间",2,20,无,,,,,,
,,,,,,,"2.2Longtimestorage
2.2存放时间超长",,,,,无,,,,,,
0--3,"Transferfromstoragetofurnace
移送材料至熔炼炉","TankbowlwithblacktagfortransportationADC12
用有标记的铝缸来运ADC12","Errorgrade
牌号错误","mechanicalpropertiesofunquaified
力学性能不合格",5,,"Mixingdifferentbrandsofmaterial
物料混料",2,"requestorcheckthematerial
领用人核对",2,20,无,,,,,,
10--1,"melting
temperature:700~720℃
material:ADC12
熔炼
温度:700~720℃
材料:ADC12
","
60%ingot(Min)40%recycle(Max)ADC12.(ColorCode:Black)
75%铝锭(Min)25%回收铝(Max)ADC12.","1.Chemicalcompositionunqualified
1.化学成份不合格","Mechanicalpropertiesofunqualified
力学性能不合格",6,,"1.1Mixingdifferentbrandsofrecyclematerial
1.1不同牌号的回炉料混",3,"1.1.1recyclematerialmanagement
1.1.2chemistryinspection
1.1.1回炉料管理
1.1.2化学成份分析",2,36,无,,,,,,
,,,,,,,"1.2cleansingdidnotdoagoodjobrefiningfurnace
1.2熔炼炉未清理干净",3,"Cleanfurnacebeforedegass,Cleanfurnaceafterwork
精炼前清扫精炼炉,下班后清扫精炼炉",,,无,,,,,,
,,,"2.Temperatureoutofcontrol1
2.温度失控","2.1Thetemperatureistoohigh,causemoreinteralcastingdefects(porosityandshrinkage)
2.2Thetemperatureistoolow,causemoreexteralcastingdefects(coldshut)
2.1温度过高,铸件内部存在缺陷(气孔和缩孔)
2.2温度过低,铸件外部存在缺陷(冷隔)",6,,"2.1Equipmentfailure
2.1设备故障",3,"inspection:inspecttheAltemperature
点检:测铝水温度",2,36,无,,,,,,
,,,,,,,"2.2Extendeduseofcrucible
2.2钳锅超期使用",3,"replacethecrucibleregularly
定期更换坩埚",,,无,,,,,,
10--2,"reservemeltonanddegassing
精炼、除气","
用氮气除气机每炉进行一次.
","1.residualforeignsubstance
1.杂质残留","castingtrachoma
铸件沙眼",5,,"temperatureissetedtoolow
温度设置过低",3,"Requirements/Inspectionofequipment
规定/点检设备",3,45,无,,,,,,
,,,"2.degassingisnotfull
2.除气不充分","castingpore
铸件气孔",5,,"temperatureissetedtoolow
温度设置过低",3,"Requirements/Inspectionofequipment
规定/点检设备",3,45,无,,,,,,
,,,"3.Thetemperatureistoohigh
3.温度过高","Castingshrinkage
铸件缩孔",5,,"temperatureissetedtoohigh
温度设置过高",3,Requirements/InspectionofEquipment规定/点检设备,3,45,无,,,,,,
,,,"4.thetemperatureistoolow
4.温度过低","Castingscoldshut
铸件冷隔",4,,Furnacefailure电炉故障,2,"Requirements/Inspectionofequipment
规定/点检设备",3,24,无,,,,,,
,,,"5.reservetimeistoolong
5.静置时间过长","elementsisburned,segregation
元素烧损,偏析",4,,"Productioninterruption
生产中断",2,"re-degass
重新精炼",3,24,无,,,,,,
20--1,Insulation保温,MoltenAltemperatureintheHoldingfurnaceis620~660℃.铝液在保温炉温度620~660℃,1.Atemperaturetoohigh1.温度过高,"castingshrinkage
铸件缩孔",5,,"temperatureissetedtoohigh
温度设置过高",3,Requirements/PointInspectionEquipment规定/点检设备,4,60,无,,,,,,
,,,2.thetemperatureistoolow2.温度过低,castingscoldshut铸件冷隔,4,,"Furnacemalfunction
电炉故障",2,Requirements/PointInspectionEquipment规定/点检设备,4,32,无,,,,,,
,,,"3.standingtoolong
3.静置时间过长","elementsinburning,segregation
元素烧损,偏析",4,,"Productioninterruption
生产中断",2,"Ingots
铸锭",2,16,无,,,,,,
20--2,"die-casting
压型","Noseriousdefectsuchascracks,coldlap,deformationnonfills,porosityetc.
没有严重的缺陷,如开裂,冷格变形,压铸砂孔等","1.Appearancedefects
1.1notch
1.2dragmark,deformation,
1.3porosity
1.4ProductsCrack
2.Mechanicalpropertiesoutofspec
1.外观缺陷
1.1欠铸
1.2拉伤、变形
1.3气孔、
1.4产品裂纹
2.机械性能及功能能达不到要求",,8,,"1aluminumwater(moldtemperature)islow;
2Shotpressureislower.
1铝水(模温)度偏低;
2压射力低。",2,"Verifyprocessrationality,checksbeforeoperation;Scrapstandardnumberofpiecesmangement
验证工艺合理性,作业准备检查;冷模件管理",4,64,无,,,,,,
,,,"1.dimensionisoutofspec
1.尺寸不合格.
2.productdeformation.
2.产品变形。",,8,,"1cavitydeformation,
2coolingtimeisnotenough
1型腔变形,
2冷却时间不够",2,"1.checkthecavity
2.checktheprocessparametersbeforeoperation
1.模具型腔点检
2.作业前核对工艺参数",2,32,无,,,,,,
,,,"1.porosity.
1.气孔
2.notchdeformation
2.欠铸",,8,,"1Exhaustpoor
2Excessivespraying
1.排气不畅
2.喷涂过量",2,"1Regularlycleanuptherowoverflowtank;
2inspectasrequired
1定期清理排溢槽;
2按要求检查",4,64,无,,,,,,
,,,"1.porosity.
1.气孔.
",,8,,"1Aluminumwater(mold)temperatureistoohigh
2Productstructureisirrational
1铝水(模具)温度偏高
2产品结构不合理",2,"1checktheprocess
2measuretheALtemperatureregularly
1核对工艺
2定时测铝水温度",2,32,无,,,,,,
,,,"1.porosity
2.Mechanicalpropertiesoutofspec
1.气孔
2.机械性能及功能能达不到要求",,8,,"1Aluminum(mold)temperatureistoohigh
2risingpressureisplummeted
1铝水(模温)度偏高
2保压压力骤减",4,"1Checktheprocessbeforeoperation.
2Regularlycheckthetemperatureofaluminum.
1作业前对工艺进行点检.
2定时测铝水温度.",2,64,无,,,,,,
,,,"1.Appearancedefects
1.外观缺陷.",,8,,"Coldprocesspartsweremixedin
冷模件混入合格品中",4,Scrapstandardnumberofpieces规定开班前的冷模件数量,2,64,无,,,,,,
,,,"1.Appearancedefects
1.1notchdeformation,
1.2porosity
2.Mechanicalpropertiesoutofspec
1.外观缺陷
1.1欠铸
1.3气孔、
2.机械性能及功能能达不到要求",,8,,Castingparametersweresetedincorrectly压铸参数设置不正确,4,Checktheprocessbeforeoperation.开班根据压铸工艺校验压铸参数,2,64,无,,,,,,
,,,"2.dimensionisoutofspec
2.尺寸不合格","零件报废
Partsscrap",6,,"2.1diewear
2.2Revisedmodelbymistake
2.1模具磨损
2.2修模失误",2,"measuretherelateddimensionsby1/10000
1次/万件关重尺寸检测",2,24,无,,,,,,
30,"Trimmingbyhand
手工敲冒口",不能敲伤外观,"1.notchongate
2.Appearancehurt
1.去浇口溢料口缺料
2.外观敲伤","1.Partsscrap
2.badappearance,customercomplaints
1.零件报废
2.外观不良,客户不满",6,,"knockdirection,strength,location,tool
敲击方向,力量,位置,工具",3,"Operationinstructions(visual)
mastersample操作指导书(可视化),样件对比度",3,54,无,,,,,,
40,"Deburring
去毛刺",不能有挫伤,1.fileinjury1.锉伤,"1.impactthelocation2.customerdissatisfaction1.影响定位
2.客户不满意",5,,"Anoperator'soperationandtoolswerewrong
操作者操作工具及方法不对",2,"Operationinstructions(visual),mastersample
操作指导书(可视化),样件对比度",4,40,无,,,,,,
,,必须定置放置,2.missdeburrs2.漏去毛刺,"1.impactthelocation2.customerdissatisfaction1.影响定位
2.客户不满意",,,"partsbemixinprocess
产品流转时箱子混放",3,"Set-management,inspection定置管理,检查",,60,无,,,,,,
50,"roughcastinspection
毛坯检验",,"1Mistakenjudgments:
1.1qualifiedasunqualified;
1.2unqualifiedasqualified;
误判断:
1.1合格判为不合格;
1.2不合格判为合格。","Affecttheappearanceandmachineprocess
影响外观和后续的加工",5,,Burrisoutofspec毛刺不符合工艺要求,3,"Trainandevaluatetheinspector
对巡检员进行培训及考核",4,60,无,,,,,,
60,"roughcaststore
毛坯入库",,quantitydidnotconfrontwiththesheet数量与入库单不一致,"Cannotguaranteequantityinaccountsisthesamewithactualproducts
无法保证账本与实际产品相同数量",2,,"wrongAcceptance
验收错误",3,"Storagesheets,visualinspect
入库记录单,目测",3,18,无,,,,,,
70,Millingplane铣底平面,粗糙度在Ra3.2,"1.surfaceroughnessoutoftolerance
1.表面粗糙超差","themillingplaneandthecorrespondingsurfacecannotcompletelycloseafterassembly
基准A、C与相对应的装配面不能完全紧贴",6,,"1.1Cutterwear
1.1铣刀磨损",3,LifeManagement使用寿命管理,3,54,无,,,,,,
,,,,,,,"1.2Lowspeed
1.2转速低",3,"Confirmedbeforetheoperation
开班前转速确认",3,,无,,,,,,
,,,,,,,"1.3Fastfeed
1.3进给量快",3,confirmvalveoffeedbeforeoperation开班前进给量确认,3,,无,,,,,,
,,,,,,,"1.4bigdepthofcut
1.4切削深度大",3,Confirmedthedepthofcut开班前切削深度确认,3,,无,,,,,,
,,,,,,,"1.5Productsarenottightclamping
1.5产品装夹不紧",3,Checkwhethertheproductisqualified检查产品是否合格,3,,无,,,,,,
,,24mm±0.15,"2.24mm±0.15outofspec.
2.距离基准面A的高度24mm±0.15不合格
","Affectassemblyquality
影响装配质量",7,SC4,"theforeignmaterialonthesurfaceofFixtureandproduct
夹具,产品定位面有异物",3,"blowtheforeignmaterialonthesurfacebeforeclamping
装夹前气枪清除定位面异物.",4,84,无,,,,,,
,,,"3.MachinedsurfaceandthebaseB,A,C0.3degreeoutline
3.加工面与基准B、A、C的轮廓度0.3","Affectassemblyquality
影响装配质量",7,SC5,"theforeignmaterialonthesurfaceofFixtureandproduct
夹具,产品定位面有异物",3,"blowtheforeignmaterialonthesurfacebeforeclamping
装夹前气枪清除定位面异物.",4,84,无,,,,,,
,"drillingΦ22.2±0.15hole
镗Φ22.2±0.15孔",φ22.2±0.15,"1.holediameteroutofspec.
1.孔径不合格","Affectassemblyquality
影响装配质量",7,,"1.1wrongdrillbrand
1.1镗刀型号错误",4,CheckdiameterwithcalipersbeforeopeningandFirstpieceInspection开班前用卡尺检查直径大小和首件检查,3,84,无,,,,,,
,,,,,7,,"1.2thebladeofdrillwear
1.2镗刀磨损",4,Toollifemanagement:checkwhethertheproductisqualified刀具寿命管理:检查产品是否合格,3,84,无,,,,,,
,,,"2.位置度不合格
2.positionoutofspec.","Affectassemblyquality
影响装配质量",7,,"2.1wrongdrillbrand
2.1镗刀型号错误",3,CheckdiameterwithcalipersbeforeopeningandFirstpieceInspection开班前用卡尺检查直径大小和首件检查,3,63,无,,,,,,
,,,,,7,,2.2clamptheproductstiltlypositionisincorrect2.2装夹产品倾斜,位置不正确,5,Checkwhethertheproductisqualified检查产品是否合格,3,105,无,,,,,,
,,,,,7,,"2.3theforeignmaterialonthesurfaceofFixtureandproduct
2.3夹具,产品定位面有异物",3,"blowtheforeignmaterialonthesurfacebeforeclamping
装夹前气枪清除定位面异物.",4,84,无,,,,,,
,"drilling2-φ7.5±0.15hole
钻2×φ7.5±0.15孔",φ7.5±0.15,"1.holediameteroutofspec.
1.孔径不合格","Affectassemblyquality
影响装配质量",7,SC1,"1.1wrongdrillbrand
1.1钻花型号错误",4,CheckdiameterwithcalipersbeforeopeningandFirstpieceInspection开班前用卡尺检查直径大小和首件检查,3,84,无,,,,,,
,,,,,7,,"1.2thebladeofdrillwear
1.2钻花磨损",4,Toollifemanagement:checkwhethertheproductisqualified刀具寿命管理:检查产品是否合格,3,84,无,,,,,,
,,,"2.positionoutofspec.
2.位置度不合格","Affectassemblyquality
影响装配质量",7,SC2/SC3,"2.1wrongdrillbrand
2.1钻花型号错误",3,CheckdiameterwithcalipersbeforeopeningandFirstpieceInspection开班前用卡尺检查直径大小和首件检查,3,63,无,,,,,,
,,,,,7,,2.2clamptheproductstiltlypositionisincorrect2.2装夹产品倾斜,位置不正确,5,Checkwhethertheproductisqualified检查产品是否合格,3,105,无,,,,,,
,,,,,7,,"2.3theforeignmaterialonthesurfaceofFixtureandproduct
2.3夹具,产品定位面有异物",3,"blowtheforeignmaterialonthesurfacebeforeclamping
装夹前气枪清除定位面异物.",4,84,无,,,,,,
80,"Chamfer
倒角","partshavebevisualinspecteddoneaferimpregnation
产品补漏后进行目视检查","漏序
missingchamfer","Affectassemblyquality
影响装配质量",7,,Mixedproducts(processedandunprocessedproducts)混产品(加工与未加工产品),4,"定置管理
fixationmanage",4,112,无,,,,,,
90,Cleaning清洗,"Nogreaseandslagonproduct,partsnoscratch
产品上无油和铝屑,产品不可碰伤,划伤","1.productsaredirtandforeignmatteronit
1.产品有污垢和异物","Affectassemblyquality
影响装配质量",7,,cleaningisnotthorough清洗不彻底,2,"Comparedwiththemastersample
与样件比较",4,56,无,,,,,,
,,,"2.theproducthassurfacescratches
2.产品机加面有碰划伤","Affectproductappearanceandassemblyquality
影响产品外观和装配质量",7,,"bumpincleaningandtransferingprocess
周转和清洗过程中碰伤",3,"definethelayoutofthepart
产品规定摆放方式",3,63,无,,,,,,
100,"FinalInspection
终检",按照成品检验指导书进行检测,"1Mistakenjudgments:
1.1qualifiedasunqualified;
1.2unqualifiedasqualified;
误判断:
1.1合格判为不合格;
1.2不合格判为合格。
","1.Manufacturingcosts
2.Productisnotavailable
1.产品无法使用
",5,,"1.1usewrongcheckfixtur
1.1检具使用错误",3,"checkfixtureidentitymanagement
检具标识管理",3,45,无,,,,,,
,,,,,5,,1.2checkfixturewear1.2检具磨损,3,"Regularcalibration
定期校检",3,45,无,,,,,,
,,,,,5,,1.3Thespecisnotclear1.3检验标准不明确,3,"visualsample
可视标准",3,45,无,,,,,,
,,,"2.missedinspection
2.漏检,不合格品流出厂",2.theproductcannotbeused2.产品无法使用,7,,"SettingManagementisnotclear
定置管理混乱",3,"identificationininspectionarea
检验工位区域标识",3,63,无,,,,,,
110--1,Packingpart包装,"AccordingtoProductstructuralchart&packinginstruction
符合产品结构报表和包装指引",Wrongpartwaspacked包错工件,Customercomplain
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