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园螺母PFD+FMEA+CP


POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS 潜在失效模式分析 (PROCESS FMEA)

Description/Part Name: φ2.4*0.92钛螺母 Process Responsibility: Part Number: SIT-2028A Prepared By:

贺赛明 蒋

祖安

Date: Rev :

Process Step 工序号

Process Function / Potential Requirements Failure Mode 过程描述/要求 潜在失效模式

Potential Effect(s) of Failure 失效的潜在 影响

S E V

Potential Cause(s) / Mechanism(s) of Failure 失效 的潜在 原因/机 理

Current Process Controls O C C D E T R P N

Prevention 预防

Detection 探测

Dimension inspection 尺寸检验: a.0.30±0.05 b.0.11+0.04/-0 c.φ2.4±0.03 d.齿数:22-25

Dimenstion out of Spec. 尺寸不符合规 格

Possible assembly problem and customer usage 影响加工及客户 使用

4

Supplier product issue 供应商产品问题

6

Only purchase from approved supplier 1从有资质供应商处采购 IQC incoming inspection with the supplier quality instruction assurance agreement 按进料检验标准进行检查 2.与供应商签订《质量保 证协议》

2

48

Check material specification 材质确认 material Ti 材质Ti

Wrong material 错误材质

Product performance failure 影响产品机械性 能

1

Supplier product issue 供应商产品问题

9

Only purchase from approved supplier 1.从有资质供应商处采购 with the supplier quality assurance agreement 2.与供应商签订《质量保 证协议》

The supplier Provides a material certificate 供应商提供材质证明文件

2

18

Raw material inspection 1. 原材进料检

Raw material inspection 1. 原材进料检 验

Low hardness Function failure 硬度偏低 功能失效 Hardness 275HV320HV 硬度检测275HV— 320HV Possible High hardness assembly 硬度偏高 problem 影响生产加工

2

Supplier product issue 供应商产品问题

6

Only purchase from approved supplier 从有资质供应商处采购 with the supplier quality assurance agreement 2.与供应商签订《质量保 证协议》 Only purchase from approved supplier 从有资质供应商处采购 with the supplier quality assurance agreement 2.与供应商签订《质量保 证协议》

IQC incoming inspection instruction 按进料检验标准 The supplier Provides a material certificate 供应商提供材质证明文件 IQC incoming inspection instruction 按进料检验标准 The supplier Provides a material certificate 供应商提供材质证明文件

2

24

2

Supplier product issue 供应商产品问题

6

2

24

Material apprearance 材料外观 Possible assembly problem 影响生产加工 Supplier product issue 供应商产品问题 transport 运输中造成 Only purchase from approved supplier 从有资质供应商处采购 Define the packaging method 规定包装方式

material bended 材料弯曲

2

7

IQC incoming inspection instruction 按进料检验标准

3

42

Determine the location 挡料打中心

Hole deviation 偏孔

The size is not qualified 影响功能尺寸

2

Center offset 1.中心点偏移 Tool adverse 2.中心钻不利 Fastening bolt failure 3.扭紧螺丝松动

5

Regularly check the running status of the machine by technician 1.技师定时检查机器运行 按作业指导书要求执行 状况 The timing of replacing the drill bit 2.定时更换中心钻

2

20

Profile-lathing 车外形

Lathe knife worned out 车刀磨损 调机不精准

1.披锋( burrs) 2.尺寸超规 (Dimension out of Spec.) a.1.97+0/-0.03 b.0.35±0.02

4

Tool work too long 刀具工作时长过 长 机器不稳定

5

Manage tool life 管控车刀使用寿命 技师定时检查机器运行 状况

First article inspectin 5pcs,IPQC 5pcs/H, Finished Goods CCD full check 首件5pcs,IPQC5pcs/H 制程产品分时段隔离 成品CCD全检

1

20

drill worned out 钻头磨损 Drill、Thread tapping 钻孔、攻牙

hole dimension out of Spec. slid thread 孔径超规 φ 1.085±0.02 牙紧

5

Tool work too long 钻头工作时长过 长

6

Manage tool life 管控钻头使用寿命 定时更换被磨损的钻头

First article inspectin 5pcs,IPQC 5pcs/H, Finished Goods CCD full check 首件5pcs,IPQC5pcs/H 成品CCD全检

1

30

Lathing 2. 车削 Thread tap wear 牙针磨损

The thread is not qualified 牙规不过 M1.2*0.25

2

Not timely replacement of thread tap 牙针未及时更换

5

Manage tool life 管控牙针的使用寿命 定时更换被磨损的牙针

First article inspectin 5pcs,IPQC 5pcs/H, Finished Checks according to sampling plan 首件5pcs,IPQC5pcs/H 成品按抽样方案抽检

2

20

Smoothing Smoothing end face tool worned 修面 out 修面刀磨损

The surface is not smooth 1.表面刀纹 Dimension out of Spec. 2.尺寸超规 0.92±0.02 0.35±0.02

4

Tool work too long 刀具工作时长过 长

5

Manage tool life 管控修面刀使用寿命

IPQC inspction, 5pcs/machine/H IPQC巡检,5PCS/机/H Product use magnifying glass to full check 成品用放大镜全检

1

20

Slot knife broken 插槽刀断 Rabbetting 插槽 Slot knife worned out 插槽刀磨损

No slot 无槽

1

Knife shelf loosed 刀架松动

9

Machine verifiaction 开机前点检机台

First article inspectin 5pcs,IPQC 5pcs/H 首件5pcs,IPQC5pcs/H

1

9

槽尺寸超规 a.φ1.78+0/-0.05 b.0.25±0.03

3

Tool work too long 插槽刀工作时间 过长

6

Manage tool life 管控插槽刀使用寿命

First article inspectin 5pcs,IPQC 5pcs/H 首件5pcs,IPQC5pcs/H

1

18

Cutting off 切断

material carrying not in place 送料不到位 The cutter wear 切刀磨损 not clean burrs,oil or dirty 毛刺、油污未 去除 Time and temperature control is not accurate 烘干时间及温 度控制不精准

material shortage 短料 Dimension out of Spec 尺寸超规 0.92±0.02 C0.1±0.04

3

material bend 材料弯曲 Tool work too long 切刀工作时间过 长

6

Incoming material inspection 原材进料时检验 Manage tool life 管控切刀使用寿命

First article inspectin 5pcs,IPQC 5pcs/H 首件5pcs,IPQC5pcs/H Finished Goods CCD full check 成品用CCD全检

1

18

Clean Magnetic grinding 5.清洗 磁力研磨

Clean Magnetic grinding 清洗 磁力研磨

Affect apprearance/Pos sible assembly problem 影响组装或影响 功能 Bad appearance 影响外观

2

Cleaning and grinding parameter incorrect 清洗、研磨参数 不正确

5

Define cleaning and grinding SOP 制定清洗、研磨的SOP

Operator self-inspection FQC samplin Full inspection hole burrs with CCD 作业员自检 FQC抽检 CCD全检孔内毛刺

2

20

Check tapping hole 抽查牙纹及孔 径

0.93/0.985塞棒 M1.2*0.25牙规

Affect Aperture apprearance/Pos deviation sible assembly Thread tight problem 孔径偏差、牙 影响组装或影响 紧 功能

5

Screw thread gauge is worn Sampling inspection can not completely guarantee 牙规磨损、抽检 风险

6

Regularly check the thread gage Select the AQL0.07 sampling inspection plan 定时校验牙规,选择 AQL0.07方案检查

Sampling inspection by FQC FQC抽检

1

30

6. CCD全检 CCD full check

CCD full check CCD全检

not detect dimensation out of spec. 尺寸超差未检 出

Affect function/Possibl e assembly problem 影响组装或影响 功能

2

CCD not detect CCD机未能探测 并隔离不良品

8

Calibrate machine at beginning of each shift 1.换班时对机器进行校验 The machine operator every 2 hours, good and bad products, artificial sampling verification 2.机器操作者每2小时, 对机器检出的良品和不 良品,进行人工抽样验 证 AQL Sampling Plan in SOP SOP中制定AQL抽样计 划

Sampling inspection AQL0.4 post optical sorting 按AQL0.4对挑选后产品抽 样

1

16

2

AQL sample not effective 抽样风险 Measuring instrument is not accurate 测量仪器失准

3

According to the sampling plan inspection 根据抽样计划检查 The FQC themselves check test instrument, before work, 检验前FQC自校

4

24

7. 终检 Final Inspection

dimensation & apprearance inspection 尺寸与外观检查

Out-of-Spec 超规

Affect function/Possibl e assembly problem 影响组装或影响 功能

2

7

Regular inspection
定期校验

2

28

7. 终检 Final Inspection

dimensation & apprearance inspection 尺寸与外观检查

Out-of-Spec 超规

Affect function/Possibl e assembly problem 影响组装或影响 功能 2

Inspector Skill deviation 检验员判别水平 的差异

5

Inspectors are trained & ceritifed 检验员需培训并持证上 岗

Line test on operators periodically to ensure compliance 定期对操作员进行测试

2

20

Mixed parts 混料

Customer complaint, affect customer usage 客诉,影响客户 使用

1

Poor 5-S, did not follow SOP, operators mistakes, no lot information 5S管理不到位; 未按SOP执行; 作业员失误;无 批次

8

Procedure in place, 5-S practices, lot travelers tag with lot 提供适当的流程; 实施5S 管理; 批次标签

Regular inspection of the implementation of 5S 对“5S”的管理执行情况定 期检查

2

16

8. 包装出货 Packing and Ship

Packing inspection 包装核查

Customer complaint, affect wrong quantity customer usage 数量错误 客诉,影响客户 使用

2

Electronic balance is not accurate,The weight of a single product is not the same 电子天平失准; 单重有差别

4

Before packing, calibration of electronic balance and To formulated a SOP for check the individual 3 product packaging weight of each batch 制定包装的《作业指导书》 of products 包装前先校准电子天平和 每批产品的单重

24

wrong label 标签错误

Customers receive the product specification error 出货规格错误

2

Electronic document not classified management 1.标签的电子文 档未分类管理 2.多种产品同时 包装时标签贴错

8

Electronic document classification management for label To formulated a SOP for 1.标签的电子文档分类管 1 product packaging 理。 制定包装的《作业指导书》 不同类别的产品和对应 的标签,分不同时段包 装贴标。

16

2014.08.23 A01

Evaluate the QA capabilities of suppliers 1.审核材料供应商品质保 证能力 with the supplier quality assurance 蒋祖安& 9月5日 agreement 2.签订品质保证协议 3.审核不通过对供应商暂 停采购 4.每支料的前5个产品检 测尺寸,每批料发现3支 以上材料不良,整批退换

8月30日

2

6

2

24

New RPN

New SEV

New DET

Recommended Action (s) 行动计划

Responsibility Action Results 行动结果 & Target Actions Completion Completion Date Date 行动完 责任人& 预计 成日期 完成日期 New OCC

Evaluate the QA capabilities of suppliers 1.审核材料供应商品质保 证能力 with the supplier quality assurance 蒋祖安& 9月5日 agreement 2.签订品质保证协议 3.审核不通过对供应商暂 停采购 4.每支料的前5个产品检 测尺寸,每批料发现3支 以上材料不良,整批退换

8月30日

2

6

2

24

Change the drill drill sizes 1.钻头规格将原用的φ 1.087改为φ 1.085 The service life of the bit is 12000 times 2.钻头使用寿命定为1.2万 贺赛明&8月27 /支 日 3.丝攻外径选定为φ 1.255至φ 1.258 The Thread tap life of the bit is 8000 times 2.钻头使用寿命定为1.2万 /支4.丝攻使用寿命定为 8K/支

8月27日

3

6

1

18

Change the drill drill sizes 1.钻头规格将原用的φ 1.087改为φ 1.085 The service life of the bit is 12000 times 2.钻头使用寿命定为1.2万 贺赛明&8月27 /支 日 3.丝攻外径选定为φ 1.255至φ 1.258 The Thread tap life of the bit is 8000 times 2.钻头使用寿命定为1.2万 /支4.丝攻使用寿命定为 8K/支

8月27日

3

6

1

18


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