塑胶行业PFMEA案例

功能
要求 Requirement
潜在失效模式 Potential Failure
Mode
失效的模式潜在后果 Potential Effect(s) of Failure
严 重分 度类 S
失效的潜在要因 Potential Causes of Failure
现行过程控制 Current process controls
材料错误 Wrong part No.of material
产品性能达不到预定要求 Products' performance fail
8
颗粒受潮
产品性能达不到预定要求 外观不良
Affected with Products' performance and
6
damp
appearance fail
领错料 Get wrong material
54
Clear mould surface once/4hrs
of product
6
模具设计不合理Mould design not
模具设计时考虑 Need consider this issue when
suitable
design the mould
OP/QC 抽检产品外观 3 OP/QC check appearance 2
36
of product
4
注塑速度偏快 The speed of injection is too fast
依据《标准注塑工艺》生产 According to <<injection standard parameter>> to set
OP/QC 抽检产品外观 2 OP/QC check appearance 2
项目
Aggy
过程责任
注塑生产部
型号年/项目
N/A
关键日期
2010.03.18
核心小组 Project: Kary Xu / Molding:Xiongwe / TQM: Michael / Tooling: Young Jiang / Material: Zoe Hu
潜在失效模式及后果分析 (过程FMEA)
Responsible & Completion Date
采取措施和生效 日期
Action taken
严 重 度
S
发 生 率
O
探 测 度
D
RPN
10 收料 Receiving material 20 原料储存 material store
30 领料 Get the material
40 烘料 drying material
控制预防 Prevention
发
生 频
控制探测
率
Detection
O
措施结果
责任&目标完
建议措施
成日期
探 测 度 D
RPN
Recommended Action
Responsible & Completion Date
采取措施和生效 日期
Action taken
严 重 度
S
发 生 率
O
探 测 度
D
RPN
warehouse keeper distribute material
填错料号 Fill in wrong part number
岗位培训，主管确认
核对领料单
Training the related people and the ticket must approved by supervisor
2
Warehouse keep double check the apply form
2
24
库房发错料
岗位培训
Warehouse keeper issued the wrong material
Training the related people
核对领料单 2 Applier double check the 4 48
can not finished on time
干燥不充分 Drying material is not enough
产品外观不良和性能不良 Products' performance and appearance fail
6
烘料过头
产品外观不良和性能不良
Drying material Products' performance and
OP/QC 抽检产品外观 2 OP/QC check appearance 2
16
machine
of product
8
□ 模具尺寸NG ◇ The dimension of mould is NG
产品功能不良，影响装配，
尺寸不良
客户抱怨
Products' performance and
dimension defect appearance fail and it
12
machine
of product
排气不良
2
Venting not good
注塑技术员每4小时清理模面 Clear mould surface once/4hrs
3
OP/QC 抽检产品外观 OP/QC check appearance of product
3
18
Page 1 of 2
Rev:A
过程步骤 Process
12
machine
of product
模温太低 The mould temperature is too low
依据《标准注塑工艺》生产 According to <<injection standard parameter>> to set
OP/QC 抽检产品外观 2 OP/QC check appearance 3
parts when receive material
填错数量 Fill in wrong part amount
核对领料单
2
Applier double check the parts when receive
7
42
material
库房发错料 Warehouse keeper issued the wrong parts
不能生产 影响产品性能 We Can not use it to produce 6 and it will influence the function of product
数量不对
生产计划不能按时完成
Wrong amount of It may cause the production 3
material
3
产品变形 product deformed
产品外观不良和性能不良 6 Products' performance and appearance fail
客户抱怨 Customer complain
3
清点错误
Make a mistake when count
依据包装作业指导书作业
3 FQC抽检
Follow the packing instruction
FQC sampling check
3 27
标识错误
客户抱怨
Mark incorrectly Customer complain
核对工艺卡参数 Check the parameter
3 36
熔融温度不足 The melt temperature is too lower
依据《标准注塑工艺》生产 According to <<injection standard parameter>> to set
OP/QC 抽检产品外观 2 OP/QC check appearance 3
2 尺寸 X-R
3 48
IPQC measure dimension
machine
once/4H by X-R
检查原材料 Check the raw material
IPQC每4小时检查1shot
1 尺寸 X-R
3 24
IPQC measure dimension
once/4H by X-R
数量有误 The quantity is incorrect
核对工艺卡参数 Check the parameter
3 36
烘料温度偏高，时间偏长 The temperature of drying material is too higher or drying time is too longer
物料员依据《烘料工艺卡》烘 料 According to <<material drying 2 parameter>> to set machine
6
overdo
appearance fail
2
结合线 weld line
产品外观不良
2
Products' appearance fail
提供原料牌号不正确 The part No. of material is wrong
要求供应商提供每批次的材料
证明
1 进料检验
Require supplier offer material
OP/QC 抽检产品外观 2 OP/QC check appearance 2
of product
16
4
注塑压力偏高 The pressure of moulding is too high
依据《标准注塑工艺》生产 According to <<injection standard parameter>> to set