DFMEA(大头带硅胶类)

,,PartNo零件編號:,,DesignFailureModeandEffectsAnalysis设计失效模式及后果分析(DFMEA),,,,,,,,,DocNo文件號:,,,,

,,PartName名稱:,大头带硅胶,,,,,,,,,,PreparedBy編制:,,,,

,,Project項目:,,,,,,,,,,,Revision版本:,,,,

,,Customer客戶:,,,,,,,,,,,FMEADate日期:,,,,

,,Process過程:,,,,,,,,,,,RevisionDate修訂日期:,,,,

,,CoreTeam核心團隊:,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,

,Item序,ProcessDescription過程名稱,PotentialFailureMode(s)潛在失效模式,PotentialEffect(s)ofFailure潛在失效后果,嚴重度Sev,PotentialCause(s)ofFailure潛在失效起因/機理,頻度Occ,"CurrentProcessControls

現行過程控制預防",探測度Det,風險順序數RPN,RecommendedAction(s)建議措施,Responsibility&TargetCompletionDate責任和目標完成日期,ActionsTaken采取的措施,嚴重度Sev,頻度Occ,探測度Det,風險順序數RPN

,,,,,,,,,,,,,,,,,,

,1,"來料检查

（塑胶）","塑胶原料

玷污/雜料","

外观缺陷",5,材料商及運輸員的不適當管理(控制),1,"1.要求每批來料提供COC/COA証明.2.檢查樹脂包裝情況,對來料進行抽樣檢查.",2,10,Norecommendedaction無建議,,,,,,

,,,ROHS检测不合规,客户投诉市场退货,7,供应商制程管控品质异常,1,来料ROHS机分析检测,6,42,Norecommendedaction無建議,,,,,,

,,,塑胶原料错误,造成無料可用及停产的危险,7,供應商發錯料或原料標識錯誤,1,"1.對每一批來料IQC根据随附出货检验报告進行检查

2.核對材質報告及原材料外箱標識",2,14,Norecommendedaction無建議,,,,,,

,,,来料包装破损、受潮、污染,影响使用,7,供应商运输或搬运损坏,1,IQC對每一批來料進行檢驗.,1,7,Norecommendedaction無建議,,,,,,

,,原料烘烤,烘烘时间&温度不符合WI,注塑成型后外观缺陷,6,参数设定未按WI执行,2,IPQC每2小时核查注塑参数,2,24,Norecommendedaction無建議,,,,,,

,,塑胶成型,毛边&缺料,注塑成型后外观缺陷,5,因磨損造成的模具匹配不當,2,1.每月下模進行定期保養.2..QC每2小時進行巡查.,2,20,Norecommendedaction無建議,,,,,,

,,,,,5,"注塑参数不当（成型压力）

80±20kg/c㎡",2,"1.按照试模完成的成型参数设定

2.IPQC每2小时核查注塑参数",2,20,Norecommendedaction無建議,,,,,,

,,,,,,,,,,,,,,,,,,

,2,來料检查（硅胶）,Silicone-硅胶原料Contamination玷污/Foreignmaterial雜料,"Cosmeticdefects

外观缺陷",7,Impropercontrolbymaterialsupplierandmaterialshandler材料商及運輸員的不適當管理(控制),1,"1.Certificateofcompliance(analysis)tobeprovidedwitheverylot.要求每批來料提供COC/COA証明.

2.Checkpackagingofresinandsamplingcheckforin-comingresin.檢查樹脂包裝情況,對來料進行抽樣檢查.",8,56,Norecommendedaction無建議,,,,,,

,,,"Silicone-硅胶原料

RoHSoutofspec

RoHS受限制物质超標.",Partsrejectedbycustomer產品被拒收.,7,Impropercontrolbymaterialsupplier材料商不適當管理(控制),1,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,5,35,Norecommendedaction無建議,,,,,,

,,,"Silicone-硅胶原料

Durometeroutspec

硬度超差

50A+/-3度",Partsrejectedbycustomer產品被拒收.,7,Impropercontrolbymaterialsupplier材料商不適當管理(控制),1,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,5,35,Norecommendedaction無建議,,,,,,

,,,硅胶原料错误,造成無料可用及停产的危险,7,供應商發錯料或原料標識錯誤,1,"1.對每一批來料IQC根据随附出货检验报告進行检查

2.核對材質報告及原材料外箱標識",2,14,Norecommendedaction無建議,,,,,,

,,,硅胶原料拉伸强度超差,影响产品成型及产品尺寸等问题,7,原料供应商制程管控品质异常,1,對每一批來料IQC根据随附出货检验报告進行检查,4,28,Norecommendedaction無建議,,,,,,

,,,硅胶原料伸长率超差,影响产品成型及产品尺寸等问题,7,原料供应商制程管控品质异常,1,對每一批來料IQC根据随附出货检验报告進行检查,4,28,Norecommendedaction無建議,,,,,,

,,,硅胶原料拉伸永久变形超差,影响产品成型及产品尺寸等问题,7,原料供应商制程管控品质异常,1,對每一批來料IQC根据随附出货检验报告進行检查,4,28,Norecommendedaction無建議,,,,,,

,,,硅胶原料撕裂强度超差,影响产品成型及产品尺寸等问题,7,原料供应商制程管控品质异常,1,對每一批來料IQC根据随附出货检验报告進行检查,4,28,Norecommendedaction無建議,,,,,,

,,,硅胶原料高低温不达标,影响产品使用寿命及性能,7,原料供应商制程管控品质异常,1,對每一批來料IQC根据随附出货检验报告進行检查,4,28,Norecommendedaction無建議,,,,,,

,,,来料包装破损、受潮、污染,材料污染后报废,7,供应商运输或搬运损坏,2,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,4,56,Norecommendedaction無建議,,,,,,

,,,硅胶原料缩水率不符,尺寸超差,7,Impropercontrolbymaterialsupplier材料商不適當管理(控制),1,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,5,35,Norecommendedaction無建議,,,,,,

,,來料检查（色膏）,"Colorpaste-色膏

Colordeviation

色差","Colordeviationonpart

零件色差",7,Impropercontrolbymaterialsupplier材料商不適當管理(控制),2,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,5,70,Norecommendedaction無建議,,,,,,

,,,色膏UV测试NG,影响产品颜色使用寿命,7,供应商使用搞UV等级低的原材料,3,对每一批来料IQC根据成品UV测试条件进行检验,4,84,Norecommendedaction無建議,,,,,,

,,,"Colorpaste-色膏

Contamination玷污/Foreignmaterial雜料","Cosmeticdefects

外观缺陷",7,Impropercontrolbymaterialsupplierandmaterialshandler材料商及運輸員的不適當管理(控制),1,"CheckpackagingofColorpasteandsamplingcheckforin-comingresin.檢查色膏包裝情況,對來料進行抽樣檢查.",8,56,Norecommendedaction無建議,,,,,,

,,,来料包装破损、受潮、污染,材料污染后报废,7,供应商运输或搬运损坏,2,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,4,56,Norecommendedaction無建議,,,,,,

,,,"色膏

RoHS受限制物质超標.",Partsrejectedbycustomer產品被拒收.,7,Impropercontrolbymaterialsupplier材料商不適當管理(控制),2,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,5,70,Norecommendedaction無建議,,,,,,

,,來料检查（包材）,包材破损,"對產品起不到防護作用,造成產品變形的可能",7,供應商運輸損壞,3,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,3,63,Norecommendedaction無建議,,,,,,

,,,包材受潮,"對產品起不到防護作用,造成產品變形的可能",5,供应商包装存储过程或进料运输等场所发生受潮现象,3,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,5,75,Norecommendedaction無建議,,,,,,

,,,包材尺寸不合格,影响包装效果，客户拒收,7,供应商制程管控品质异常,2,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,5,70,Norecommendedaction無建議,,,,,,

,,,包材来料材质不符,无法正使用，有运输隐患,7,供应商用错材料,2,IQC按工程规格书及样品进行验收,4,56,Norecommendedaction無建議,,,,,,

,,,包材信赖性测试不达标,无法正使用，有运输隐患,7,供应商选材错误,2,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,5,70,Norecommendedaction無建議,,,,,,

,,,包材条码失效,条码扫不出来，客户投诉,7,供应商制程管控品质异常,2,InspectedbyIQCeverylot/eachdelivery.IQC對每一批來料進行檢驗.,4,56,Norecommendedaction無建議,,,,,,

,,,,,,,,,,,,,,,,,,

,3,"Compounding

炼胶","Materialratioincorrect

材料配比错误

高拉1:5普通","Moldingdefects

各种成型缺陷",7,"OperatordidnotfollowWI

作业员没有按照WI配比",2,"IPQCcheckcompoundingrecordeachlot

IPQC每批确认材料配比记录",4,56,Norecommendedaction無建議,,,,,,

,,,"硬度不符

50A+/-3度",产品硬度不符合要求,7,生产时拿错原料,3,"1.不同硬度的原料做好标示公开存放

2.生产时做首件确认",2,42,Norecommendedaction無建議,,,,,,

,,,颜色不符,产品颜色不符合要求,6,".色膏用量出借

",3,"按工程WI用量进行比调配

",3,54,Norecommendedaction無建議,,,,,,

,,,,,6,色膏称重出错,3,"1.称料人员称料时注意精确到0.01g

2.生产时做首件确认",3,54,Norecommendedaction無建議,,,,,,

,,,"Unevencolorpastemixing

色膏混炼不均匀","Cosmeticdefects(flowmark,fogmark)

外观缺陷(流痕，雾斑）",7,"Compoundingtimeinsufficient

炼胶时间过短",2,"Changetoappropriatemixingtime

更改炼胶时间

IPQCcheckthemixingtimesettingatFAI

IPQC确认炼胶时间设定",4,56,Norecommendedaction無建議,,,,,,

,,,电子称不准,"1.配比错误

2.各种成型缺陷",7,计量工具未按时校准,2,按计量工具校准标准作业,4,56,Norecommendedaction無建議,,,,,,

,,,环境不达标(温湿度、污染),"1.降低原料存放有效期

2.延长成型硫化时间

3.产品外观不良",7,"1.空调设定异常

2.温湿计异常",2,"1.按要求设定空调参数

2.每班对相关设备及工具进行点检",3,42,Norecommendedaction無建議,,,,,,

,,,"Mixedsiliconeexpired（exceed12hours）

炼好的胶料超过12小时","Moldingdefects

各种成型缺陷",7,"Noclearmarkingonexpirationtime

没有明确标识到期时间",2,"IPQCcheckexpirationtimepershift

IPQC每班确认胶料有效时间",4,56,Norecommendedaction無建議,,,,,,

,4,"Cuttingintostrip

切片分条","Stripweightincorrect

单条料重错误

11.22g(±0.2g)","Onpart:shortshot/flash

零件缺料或者飞边",7,"Inappropriatesettingatcutting

分条机设定错误",2,"IPQCcheckthecuttingmachinesettingatFAI

IPQC确认分条机参数设定",4,56,Norecommendedaction無建議,,,,,,

,,,"胶条大小不一致

L:200±5mmH:3.0±0.2mm","Onpart:shortshot/flash

零件缺料或者飞边",7,分条机故障,2,每日点检,2,28,Norecommendedaction無建議,,,,,,

,,,,,,,,,,,,,,,,,,

,5,刷处理剂,处理剂刷不均匀,成型后硅胶松动影响使用,7,处理剂刷的不均匀,4,按WI进行标准作业,2,56,Norecommendedaction無建議,,,,,,

,,,刷处理剂时遮喷不当,塑胶端溢胶难清理,7,遮喷治具使用不当或损坏,4,定期检查遮喷治具,2,56,Norecommendedaction無建議,,,,,,

,,,,,,,,,,,,,,,,,,

6,,"Compressionmolding

固态成型",Flash毛边,"Cosmeticdefect

外观缺陷",6,Mis-matchofthemoldduetowear.因磨損造成的模具匹配不當,2,"1.Molddownforaperiodicmaintenanceeverymonth.每月下模進行定期保養.

2.InspectedbyQCevery2hours.QC每2小時進行巡查.",8,96,Norecommendedaction無建議,,,,,,

,,,,,6,"Excessivestripweight

料重过多

9.2g(±0.2g)",2,"1.100%scaletheweightatmoldingstation

在成型前100%称料重

2.QC100%checkonflash

对毛边进行外观全检",7,84,"Reviewlimitsampleswithcustomer

请客户签署限样","刘栋军

蔡嘉明",,6,2,5,60

,,,,,6,"Inappropriateparameters(moldingpressure)注塑参数不当（成型压力）

80±20kg/c㎡",4,"1.Followsettingatmoldtrial

按照试模完成的成型参数设定

2.IPQCcheckthemoldingparameterseverytwohours

IPQC每2小时核查注塑参数",4,96,"Optimizemoldingparameters

优化注塑参数","刘栋军

蔡嘉明",,6,2,4,48

,,,"Shortshot

缺料","Moldingdefect

成型缺陷",4,"Insufficientstripweight

料重不够

9.2g(±0.2g)",3,"1.100%scaletheweightatmoldingstation

在成型前100%称料重

2.QC100%check

QC进行全检",7,84,Norecommendedaction無建議,,,,,,

,,,"Notcured

料不熟","Moldingdefect

成型缺陷",7,"Actualmoldtemp.toolow

实际模温偏低

上模温：120±5℃

下模温：120±5℃",3,"IPQCmeasuremoldtemp.evary4hours

IPQC每4小时确认模温",4,84,"Reducethetimeoftakingproductsoutofmold.

减少模外取产品的时间",刘栋军,,7,3,4,84

,,,,,7,"Lesscuringtime

硫化时间：150±10sec",3,"IPQCcheckcuringtimepershift

IPQC每班确认硫化时间",4,84,,,,7,2,4,56

,,,,,7,"SB-511硫化剂比例过少

A剂0.8%，B剂2.3%",3,按工程WI用量进行比调配,4,84,Norecommendedaction無建議,,,,,,

,,,过熟,"Moldingdefect

成型缺陷",7,"Actualmoldtemp.tooHigh

实际模温偏高

上模温：120±5℃

下模温：120±5℃",3,"IPQCmeasuremoldtemp.evary4hours

IPQC每4小时确认模温",4,84,"Optimizemoldingparameters

优化注塑参数","刘栋军

蔡嘉明",,7,3,4,84

,,,,,7,"Lesscuringtime

硫化时间太长",3,"IPQCcheckcuringtimepershift

IPQC每班确认硫化时间",4,84,,,,7,2,4,56

,,,色差,影响外观,5,"模温过高

上模温：120±5℃

下模温：120±5℃",4,IPQC每4小时确认模温,4,80,减少模外取产品的时间,刘栋军,,5,3,4,60

,,,,,5,色膏颜色差异,4,IPQC做首件确认,4,80,生产严格按比例调配，精度精确到0.01g,刘栋军,,5,2,4,40

,,,"Brokenathole

孔洞处破损",Partsrejectedbycustomer產品被拒收.,7,"Undercutathole,difficulttode-mold

孔洞处倒扣，难以脱模",3,"QC100%checkaftermolding

QC在成型后全检",4,84,"Moldplatingforeasyde-molding

模具表面电镀",齐银,,7,3,4,84

,,,,,7,"Inappropriatede-moldsetting(angle,speed)

机台脱模的参数设定不合适（角度，速度）",3,"QC100%checkaftermolding

QC在成型后全检",4,84,"Optimizede-moldsetting

优化脱模参数设定",,,7,3,4,84

,,,,,7,高拉力原料比例太少,2,按工程WI进行比调配,5,70,Norecommendedaction無建議,,,,,,

,,,"Dirt/contaminationonAsurface

A级面的脏污，杂质","Cosmeticdefects

外观缺陷",5,"Dirtinenvironment

环境中的灰尘脏污",4,"1.FollowWItomaintainthecleannessofmoldingworkshop

按照WI要求维护成型车间的清洁

2.QC100%check

QC进行外观全检",4,80,"Addprotectivefilmonsiliconestrip

在硅胶条料上加保护膜",刘栋军,,5,3,4,60

,,,,,5,"Fiber/dirtfromoperator'sglove

作业员手套上的脏污，毛丝",4,"1.FollowWItoreplaceglovepershift

按照WI要求每班更换新手套

2.QC101%check

QC进行外观全检",4,80,"Changetomicro-fiberglove

更改为无纺布手套",刘栋军,,5,3,4,60

,,,"Criticaldimensionoutofspec:长度

144.74+/-0.5

关键尺寸超差",影响装配,7,"Excessivestripweight

料重过多",2,"1.Followsettingatmoldtrial

按照试模完成的成型参数设定

2.IPQCsamplingcheckeverytwohours

IPQC每2小时抽检",6,84,Norecommendedaction無建議,,,,,,

,,,,,7,"Inappropriatemoldingparameters(pressure)

成型参数不当（压力）",3,"1.Followsettingatmoldtrial

按照试模完成的成型参数设定

2.IPQCsamplingcheckeverytwohours

IPQC每2小时抽检",4,84,"IPQCmonitorsparametertime,pressureandtemperature.

IPQC监控参数时间、压力、温度

",陈善双,,7,3,3,63

,,,,,,,,,,,,,,,,,,

,7,"Deflashing

拆边","FlashonAsurface

A级面的毛边","Cosmeticdefectsrejectedbycustomer

外观缺陷，客户拒收",7,"Poorhandlingbymanualdeflashing

员工没有完全修剪毛边",3,按工程WI指导进行操作,4,84,"QC100%checkflash

QC对毛边做100%全检",谢军,,7,3,4,84

,,,"OvercutonAsurface

A级面的剪缺","Cosmeticdefectsrejectedbycustomer

外观缺陷，客户拒收",7,"Poorhandlingbymanualdeflashing

员工修剪毛边时造成",2,按工程WI指导进行操作,7,98,"QC100%checkflash

QC对毛边做100%全检",谢军,,7,2,5,70

,,,"Scratch/abrasionmarkonsurface

表面刮花和磨痕","Cosmeticdefectsrejectedbycustomer

外观缺陷，客户拒收",7,员工去毛边中操作不慎摩擦造成,2,按工程WI指导进行操作,7,98,"Changetomicro-fiberglove

更改为无纺布手套",谢军,,7,2,5,70

,,,,,,,,,,,,,,,,,,

,8,"Paintpreparation

调油漆","Paintformulaiswrong

油漆配比错误

","Paintingdefects

喷涂缺陷",7,"Donotfollowrecommendationfrompaintvendor

没有按照油漆物料的推荐值",2,"1.FollowWIbasedonrecommendationfrompaintvendor

按照油漆物料的推荐值准备调油漆的WI

2.IPQCcheckrecordforeachlot

IPQC每批检查油漆配比记录",4,56,Norecommendedaction無建議,,,,,,

,,,"Viscosityoutofspec

油漆粘度不符合规格","Paintingdefects

喷涂缺陷",7,"Donotfollowrecommendationfrompaintvendor

没有按照油漆物料的推荐值",3,"IPQCcheckviscosityforeachlot,rangexxxxs

IPQC每批检查粘度，范围8.5±0.5秒",4,84,Norecommendedaction無建議,,,,,,

,,,调好的油漆超过24小时,"Paintingdefects

喷涂缺陷",7,"Donotfollowrecommendationfrompaintvendor

没有按照油漆物料的推荐值",2,IPQC每班确认油漆有效时间,4,56,Norecommendedaction無建議,,,,,,

,,,"Colordeviation

色差","Colordeviationonpart

零件色差",7,"Impropercontrolfrompaintvendor

油漆来料色差",3,"IPQCcheckcoloratFAI,foreveryshift

IPQC每班检测颜色",4,84,Norecommendedaction無建議,,,,,,

,,,,,,,,,,,,,,,,,,

9,,"Paintspraying

喷漆","Particle,dirt,speck,dot,fiber

尘点，脏污，黑点，异色点,毛丝","Cosmeticdefectsonsurface

外观缺陷",7,"Particleinpaint

油漆中的杂质颗粒",2,"1.Usemesh#300forfiltering

用300目滤网过滤油漆

2.Cleanmeshpershift

每班清洁滤网",7,98,"Changemesh#

更改滤网目数",朱伟贞,,7,2,5,70

,,,,,7,"Particle/dirtinsprayinggun/tube

喷枪，管路中的杂质",3,"Cleanspraygun/tubepershift

每周清洁喷枪，管道",4,84,"Reviewlimitsampleswithcustomer

请客户签署限样",朱伟贞,,7,3,4,84

,,,,,7,"Dirtfromsprayroom/container&tray

来自喷漆房，托盘，周转箱的灰尘",3,"Cleansprayroom/container&trayweekly

每周清洁喷漆房，托盘，周转箱",4,84,"Reviewlimitsampleswithcustomer

请客户签署限样",朱伟贞,,7,3,4,84

,,,"Blister/bubbleonsurface

表面气泡","Cosmeticdefectsonsurface

外观缺陷",7,"Oil/contaminationonsurfacebeforepainting

零件表面脏污，喷漆前没有清洁干净",2,"100%cleanpartsurfacebeforepainting

100%清洁零件表面",5,70,Norecommendedaction無建議,,,,,,

,,,,,7,"Bakingtemptoohigh,ortemp.risingtoofast

烘烤温度过高或升温过快",3,"1.IPQCcheckoventemp.pershift

IPQC每班检查温度

2.Measuretemp.profileweekly

每周测量温度曲线",4,84,Norecommendedaction無建議,,,,,,

,,,"Wrinkle/orangepeel

起皱，橘皮","Cosmeticdefectsonsurface

外观缺陷",7,"Coatingthicknesstoothick

喷涂太厚",3,"IPQCmeasurethicknesspershift，rangeXXX

IPQC每班测量膜厚，范围",4,84,Norecommendedaction無建議,,,,,,

,,,,,7,"Toobigviscocityofpaint

油漆太粘",3,"IPQCmeasurepaintviscocityperlot

IPQC每批测量粘度，范围",4,84,Norecommendedaction無建議,,,,,,

,,,,,7,"Inappropriatesprayingsetting(toolowspraypressure,etc)

喷涂参数不合适（比如喷枪压力太低）",3,"IPQCchecksprayingsettingbasedonWIpershift

IPQC每班检查喷涂参数",4,84,Norecommendedaction無建議,,,,,,

,,,表面手感不符合要求,"Rejectedbycustomer

客户拒收",7,油墨型号及配比不正确,2,IPQC每班检查油墨型号与配比,4,56,Norecommendedaction無建議,,,,,,

,,,调好的油墨超过24小时,各种喷油缺陷,7,"Noclearmarkingonexpirationtime

没有明确标识到期时间",2,"IPQCcheckexpirationtimepershift

IPQC每班确认胶料有效时间",4,56,Norecommendedaction無建議,,,,,,

,,,"Adhesion/cleaning/abrasiontestfailed

表面可靠性测试失败","Reliabilityfailedandrejectedbycusomter

可靠性测试失败，客户拒收",7,"Coatingthicknesstoothin

喷涂膜厚太薄",3,"IPQCmeasurethicknesspershift，rangeXXX

IPQC每班测量膜厚，范围",4,84,Norecommendedaction無建議,,,,,,

,,,,,7,"Paintformulaincorrect(toomu