塑胶行业PFMEA案例

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
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
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
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
核对领料单
2
Applier double check the parts when receive
7
42
material
烘料温度偏低，时间偏短 The drying temperature is too lower or drying time is too short
物料员依据《烘料工艺卡》烘 料 According to <<material drying 2 parameter>> to set machine
3
产品变形 product deformed
产品外观不良和性能不良 6 Products' performance and appearance fail
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)
FMEA编号: PFMEA-CA044 页码 1 编制 Soochow FEMA日期(原始) 2010.03.18
(修订) 2010.03.18
过程步骤 Process
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
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
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
16
machine
of product
毛刺飞边 flash
产品外观不良，客户抱怨
Products' appearance fail
4
熔融温度偏高 The temperature of unfreezing rosin is too high
依据《标准注塑工艺》生产 According to <<injection standard parameter>> to set machine
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
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
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
8
□ 注塑工艺原因 ◇ Caused by moulding parameter
setting
influence assembly
8
□ 原料变化原因 ◇ Caused by raw material
试模人员试模时发现问题，解 IPQC每4小时检查1shot
决问题 Solve problem on time once
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
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
1 尺寸 X-R
3 24
IPQC measure dimension
detect the issue in try run
once/4H by X-R
依据《标准注塑工艺》生产
IPQC每4小时检查1shot
According to <<injection standard parameter>> to set
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
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
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
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
of product
短射 short shot
产品外观及功能不良，客户
抱怨
Products' performance and
6
appearance fail
排气不良 Venting not good
注塑技术员每4小时清理模面 3
OP/QC 抽检产品外观 OP/QC check appearance
3
Responsible & Completion Date
采取措施和生效 日期
Action taken
Fra Baidu bibliotek
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
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
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
50 注塑 moulding
60 包装 Packing 70 产品储存 Product store
成型参数不合理Molding
6
parameter is not optimized
优化成型参数 Optimize molding parameter
OP/QC 抽检产品外观 2 OP/QC check appearance 2 24
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
Incoming inspection
certificate every batch
2 16
包装破损 Package damaged
堆高限制，防止破损 Define a limit of stacking highness to avoid damage
发料时检查是否破损 2 Check the packing when 2 24
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
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
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