机械加工PFMEA案例

Issue Material 发料
Issue wrong material 发错材料
parts 1.影响后续加工
6
2.影响产品使用功能
201. Turning Facing 光平面
Face is not flat
Impact machining
端面不平整
影响后续加工
3
202.
Drilling hole Φ5.4 钻孔
n
n
潜在失效起因 Potential Cause of Failure
频度
（O)O
现行过程控制预防
ccurre Current Process Controls Prevention
nce
现行过程控制探测 Current Process Controls delection
探测
度
（D ）
RPN
Dete
Checking dimensions on line 在线检查尺寸
3 54
NA
1.估算刀具寿命,定时换刀
2.定期对刀具参数进行补正
NA
NA
NA NA NA NA
NA
NA
NA NA NA NA
NA
NA
NA NA NA NA
NA
NA
NA NA NA NA
过程步骤/功 能 Process
Step / Function
NA
1.估算刀具寿命,定时换刀
2.定期对刀具参数进行补正
NA
NA
NA NA NA NA
204 Reamering
hole 铰孔
（21）Φ5.5
+0.02/-0.005
Dimension out of tolerance
Impact assembly 影响客户装配
8
尺寸超差
Tools wear 刀具磨损
Effective Date ruty ce ction
RPN
10.Raw material in coming来料
Surface crash 表面碰伤
Impact machining 影响后续加工
4
transit method was unreasonable 搬运方法不合理
2
Transit way was regulated 规定搬运方法
ction
建议措施 Recommended Action
措施执行结果
责任和目标完成日期
Action Results
Responsibility & Target Completion
Date
采取的措施及生 严重 频度 探测
效日期
度 Occ 度
Action Taken & Seve yran Dete
要求 Requirements
潜在失效模式 Potential Failure Mode
潜在失效后果 Potential Effect of Failure
过程 产品
严重 分类 分类
度 Proce Produ
（S) ss ct
Seve Classi Classi
rity ficatio ficatio
Checking dimensions on line 在线检查尺寸
3 18
NA
1.估算刀具寿命,定时换刀
2.定期对刀具参数进行补正
1.Estimate the tool life, change
2
tools periodically 2.Correct the tooling parameters periodically
检查材质证明与原材料
11-15
certification
标识一致
库管员确认送货
单和材质证明
6
96
Send the material to the third party to conduct an overall checking once a
year 每年一次第三方原材料
检测
Quality department 质量保证部 11-19
Dimension out of tolerance 尺寸超差
Impact machining 影响后续加工
6
203.
Dimension out of
Brilling Hole （20）Φ5.6 +0.2 tolerance
镗孔
尺寸超差
Customer dissatisfaction 客户不满意
6
Supplier delivery wrong material 供应商送错材料
Operator and warehouse keeper check each other 操作员人员和仓库管理员互相检验
3
18
NA
1.Estimate the tool life, change
2
tools periodically 2.Correct the tooling parameters periodically
Supplier provide material
2 certification 供应商提供材质证书
1.Incoming inspection engineer
check with material certification 2.Send the material to the third party to conduct an overall checking once three years 1.来料检验核对材料证书 2.每3年一次第三方原材料检测
The material's chemical composition are all according
with Spec. 确定化学成份符 合规定
8
1
6
48
1
Paint the different color at the bar end to manage different raw material 材料进行颜色管理
要求 Requirements
潜在失效模式 Potential Failure Mode
潜在失效后果 Potential Effect of Failure
过程 产品
严重 分类 分类
度 Proce Produ
（S) ss ct
Seve Classi Classi
rity ficatio ficatio
material
Warehouse keeper checks the
2.Supplier should inform us before raw material according with
2 delivery
delivery list
1.材料订购进行审核
仓库人员按送货单检查原材料
2.供应商送货之前提前通知
3
tools periodically 2.Correct the tooling parameters periodically
Checking dimensions on line 在线检查尺寸
3 45
NA
1.估算刀具寿命,定时换刀
2.定期对刀具参数进行补正
NA
NA
NA NA NA NA
Dimension out of
8
incoming inspection 来料检验
The material's chemical composition are out of spec.
Impact the functionality of parts 影响零件使用性能
8
材料成份超差
1.Impact machining
2.Impact function of
Checking dimensions on line 在线检查尺寸
3 45
NA
1.估算刀具寿命,定时换刀
2.定期对刀具参数进行补正
NA
NA
NA NA NA NA
（15）14.5+0.2
Dimension out of tolerance 尺寸超差
Customer dissatisfaction
客户不满意
1.Estimate the tool life, change
4
tools periodically 2.Correct the tooling parameters periodically
Checking dimensions on line 在线检查尺寸
Potential Failure Mode and Effects Analysis (Process FMEA) 潜在的失效模式及后果分析
****-FMEA-******
零件名称 /客户图号 /版本： Part Name /Drawing No. / Rev.
零件程序编号 /版本号 Part Program No./Rev.
n
n
潜在失效起因 Potential Cause of Failure
频度
（O)O
现行过程控制预防
ccurre Current Process Controls Prevention
nce
现行过程控制探测 Current Process Controls delection
探测
度
（D ）
R源自文库N
Dete
Supplier production control out of spec. 供应商材质成份控制超 差
Warehouse keeper issue wrong material 仓库发料错误
Tools wear 刀具磨损
Tools wear 刀具磨损
Tools wear 刀具磨损
1.Check purchasing order of raw
Effective Date ruty ce ction
RPN
203.
Brilling Hole （32,42）20° 镗孔
Dimension out of tolerance 尺寸超差
Customer dissatisfaction
客户不满意
5
Tools wear 刀具磨损
1.Estimate the tool life, change
of spec
3 certification
供应商生产尺寸超差
供应商提供材质证书
Incoming Inspection 料检验
来
3 54
NA
NA
NA
NA NA NA NA
American code:AISI 1215
Material type wrong 材料牌号不对
Impact the functionality of parts 影响零件使用性能
Incoming Inspection 来料检验
6 48
NA
NA
NA
NA NA NA NA
Ф28 -0.03
Dimension out of spec 尺寸超差
Can't be machined 无法加工
6
Supplier's dimension out
Supplier provide material
ction
建议措施 Recommended Action
措施执行结果
责任和目标完成日期
Action Results
Responsibility & Target Completion
Date
采取的措施及生 严重 频度 探测
效日期
度 Occ 度
Action Taken & Seve yran Dete
核心小组 Core Team
过程责任 Process Responsibility
初始生产日期 Orignal Production Date
FMEA日期（原始） Date (Orig.)
编制者 Prepared By
日期(修订) Revised date
过程步骤/功 能 Process
Step / Function
Warehouse
Check certificate of raw
keeper confirm
materials in line with the Warehouse keeper delivery list and
6 96 label of raw materials
仓库管理员
the raw material 8 1 6 48
（19）Φ5.9±0.1 tolerance 尺寸超差
Customer dissatisfaction
客户不满意
5
Tools wear 刀具磨损
1.Estimate the tool life, change
3
tools periodically 2.Correct the tooling parameters periodically
Checking dimensions on line 在线检查尺寸
3 36
NA
1.估算刀具寿命,定时换刀
2.定期对刀具参数进行补正
1.Estimate the tool life, change
3
tools periodically 2.Correct the tooling parameters periodically
6
Tools wear 刀具磨损
1.Estimate the tool life, change
tools periodically
3
2.Correct the tooling parameters periodically
Checking dimensions on line 在线检查尺寸
3 54