机械加工pfmea案例

罗信精密零件（上海）有限公司LXPrecision(Shanghai)Co.,Ltd.ThomasMagneteGMBH448817/02A01-002Coneng2009/11/16Rev.DateRevisedbyB10/DecLuXianming潜在的失效模式及后果分析PotentialFailureModeandEffectsAnalysis(Process)FMEARevisedMinutesRevisedItemThedocumentformathasbeenchanged初始制定日期OriginalMakedDate：客户名称CustomerName：客户零件图号/版本CustomerPartNo./Rev.罗信零件图号LXPartNo..零件名称PartName/Description：日期(修订)Reviseddate采取的措施及生效日期ActionTaken&EffectiveDate严重度Severuty频度Occyrance探测度DetectionRPN10.Rawmaterialincoming来料4transitmethodwasunreasonable搬运方法不合理2648NANANANANANANAФ28-0.036Supplier'sdimensionoutofspec供应商生产尺寸超差3354NANANANANANANAAmericancode:AISI12158Supplierdeliverywrongmaterial供应商送错材料2696Checkcertificateofrawmaterialsinlinewiththelabelofrawmaterials检查材质证明与原材料标识一致Warehousekeeper仓库管理员11-15Warehousekeeperconfirmdeliverylistandtherawmaterialcertification库管员确认送货单和材质证明816488Supplierproductioncontroloutofspec.供应商材质成份控制超差2696Sendthematerialtothethirdpartytoconductanoverallcheckingonceayear每年一次第三方原材料检测Qualitydepartment质量保证部11-19Thematerial'schemicalcompositionareallaccordingwithSpec.确定化学成份符合规定81648IssueMaterial发料6Warehousekeeperissuewrongmaterial仓库发料错误1318NANANANANANANA201.TurningFacing光平面3Toolswear刀具磨损2318NANANANANANANA202.Drillinghole钻孔Φ5.46Toolswear刀具磨损2336NANANANANANANA203.BrillingHole镗孔（20）Φ5.6+0.26Toolswear刀具磨损3354NANANANANANANACan'tbemachined无法加工Impactthefunctionalityofparts影响零件使用性能Impactthefunctionalityofparts影响零件使用性能1.Impactmachining2.Impactfunctionofparts1.影响后续加工2.影响产品使用功能Impactmachining影响后续加工Impactmachining影响后续加工Customerdissatisfaction客户不满意Supplierprovidematerialcertification供应商提供材质证书1.Checkpurchasingorderofrawmaterial2.Suppliershouldinformusbeforedelivery1.材料订购进行审核2.供应商送货之前提前通知Supplierprovidematerialcertification供应商提供材质证书Paintthedifferentcoloratthebarendtomanagedifferentrawmaterial材料进行颜色管理1.Estimatethetoollife,changetoolsperiodically2.Correctthetoolingparametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正1.Estimatethetoollife,changetoolsperiodically2.Correctthetoolingparametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正1.Estimatethetoollife,changetoolsperiodically2.Correctthetoolingparametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正1.Incominginspectionengineercheckwithmaterialcertification2.Sendthematerialtothethirdpartytoconductanoverallcheckingoncethreeyears1.来料检验核对材料证书2.每3年一次第三方原材料检测Operatorandwarehousekeepercheckeachother操作员人员和仓库管理员互相检验Checkingdimensionsonline在线检查尺寸Checkingdimensionsonline在线检查尺寸Checkingdimensionsonline在线检查尺寸RPN建议措施RecommendedAction责任和目标完成日期Responsibility&TargetCompletionDate措施执行结果ActionResultsIncomingInspection来料检验Warehousekeepercheckstherawmaterialaccordingwithdeliverylist仓库人员按送货单检查原材料潜在失效起因PotentialCauseofFailure频度（O)Occurrence产品分类ProductClassification现行过程控制预防CurrentProcessControlsPrevention现行过程控制探测CurrentProcessControlsdelection探测度（D）Detection初始生产日期OrignalProductionDate编制者PreparedBy过程责任ProcessResponsibility零件程序编号/版本号PartProgramNo./Rev.核心小组CoreTeam零件名称/客户图号/版本：PartName/DrawingNo./Rev.incominginspection来料检验Materialtypewrong材料牌号不对Impactmachining影响后续加工过程步骤/功能ProcessStep/Function要求Requirements潜在失效模式PotentialFailureMode潜在失效后果PotentialEffectofFailureThematerial'schemicalcompositionareoutofspec.材料成份超差Issuewrongmaterial发错材料Faceisnotflat端面不平整严重度（S)Severity过程分类ProcessClassificationDimensionoutoftolerance尺寸超差Dimensionoutofspec尺寸超差Dimensionoutoftolerance尺寸超差****-FMEA-******PotentialFailureModeandEffectsAnalysis(ProcessFMEA)潜在的失效模式及后果分析FMEA日期（原始）Date(Orig.)Transitwaywasregulated规定搬运方法IncomingInspection来料检验Surfacecrash表面碰伤采取的措施及生效日期ActionTaken&EffectiveDate严重度Severuty频度Occyrance探测度DetectionRPNRPN建议措施RecommendedAction责任和目标完成日期Responsibility&TargetCompletionDate措施执行结果ActionResults潜在失效起因PotentialCauseofFailure频度（O)Occurrence产品分类ProductClassification现行过程控制预防CurrentProcessControlsPrevention现行过程控制探测CurrentProcessControlsdelection探测度（D）Detection过程步骤/功能ProcessStep/Function要求Requirements潜在失效模式PotentialFailureMode潜在失效后果PotentialEffectofFailure严重度（S)Severity过程分类ProcessClassification203.BrillingHole镗孔（32,42）20°5Toolswear刀具磨损3345NANANANANANANA（19）Φ5.9±0.15Toolswear刀具磨损3345NANANANANANANA（15）14.5+0.26Toolswear刀具磨损3354NANANANANANANA204Reameringhole铰孔（21）Φ5.5+0.02/-0.0058Toolswear刀具磨损441281.Determinethetoolmaterialandenactmenttoollife2.Determinetheprocessparametersonthemachine3.SPCcontrol1.确定刀具材质和设定刀具使用寿命2.确定过程参数3.SPC控制TechnologyDepartment技术部ProductionDepartment生产部11-171.Toolmaterialandtoollifeweredetermined.2.PPK≥1.67.1.刀具材质和刀具寿命已经确定2.PPK≥1.6782464205.Dillinghole钻孔Φ104Toolswear刀具磨损2324NANANANANANANA206.Boringhole镗孔（18）Φ12.2+0.04/08Toolswear刀具磨损441281.Determinethetoolmaterialandenactmenttoollife2.Determinetheprocessparametersonthemachine3.SPCcontrol1.确定刀具材质和设定刀具使用寿命2.确定过程参数3.SPC控制TechnologyDepartment技术部ProductionDepartment生产部11-171.Toolmaterialandtoollifeweredetermined.2.PPK≥1.67.1.刀具材质和刀具寿命已经确定2.PPK≥1.6782464（16）17.5+0.02/-0.036Toolswear刀具磨损3354NANANANANANANAImpactassembly影响客户装配Customerdissatisfaction客户不满意Impactassembly影响客户装配Impactmachining影响后续加工1.Estimatethetoollife,changetoolsperiodically2.Correctthetoolingparametersperiodically1.估算刀具寿命,定时换刀2.定期对刀具参数进行补正1.Estimatethetoo