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机械加工pfmea案例

日期(修订)Revised date

采取的措施及生效日期

Action Taken &Effective Date

严重度Seve ruty

频度Occ yran ce

探测度Dete ction

RPN

10.Raw material in coming 来料

transit method was

unreasonable 搬运方法不合理

648NA NA

NA NA NA NA

Ф28

-0.03

Supplier's dimension out of spec

供应商生产尺寸超差

354

NA NA NA NA NA NA NA

American

code:AISI 12158

Supplier delivery wrong material

供应商送错材料

96Check certificate of raw materials in line with the label of raw materials

检查材质证明与原材料标识一致

Warehouse keeper

仓库管理员11-15

Warehouse keeper confirm delivery list and the raw material certification 库管员确认送货单和材质证明81648

Supplier production control out of spec.

供应商材质成份控制超差

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

The material's chemical

composition are all according with Spec.

确定化学成份符合规定

81648

Issue Material 发料

Warehouse keeper issue wrong material 仓库发料错误

318NA NA NA NA NA NA NA

201.Turning Facing 光平面

Tools wear 刀具磨损

318

NA NA NA NA NA NA NA

202.

Drilling hole 钻孔

Φ5.46

Tools wear 刀具磨损

336

NA NA NA NA NA NA NA

203.

Brilling Hole 镗孔

（20）Φ5.6 +0.2

Tools wear 刀具磨损

354

NA NA NA NA NA NA NA

Can't be machined 无法加工

Impact the functionality of parts

影响零件使用性能

Impact the functionality of parts 影响零件使用性能1.Impact machining

2.Impact function of parts

1.影响后续加工

2.影响产品使用功能

Impact machining 影响后续加工

Customer dissatisfaction 客户不满意

Supplier provide material certification

供应商提供材质证书

1.Check purchasing order of raw material

2.Supplier should inform us before

delivery

1.材料订购进行审核

2.供应商送货之前提前通知

Supplier provide material certification

供应商提供材质证书

Paint the different color at the bar end to manage different raw material

材料进行颜色管理

1.Estimate the tool life, change tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

2.Correct the tooling parameters periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

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Operator and warehouse keeper check each other

操作员人员和仓库管理员互相检验

Checking dimensions on line 在线检查尺寸

RPN 建议措施

Recommended Action

责任和目标完成日期

Responsibility & Target Completion Date 措施执行结果Action Results

Incoming Inspection 来料检验

Warehouse keeper checks the raw

material according with delivery list

仓库人员按送货单检查原材料

潜在失效起因

Potential Cause of Failure

频度（O)O ccurre nce

产品分类

Produ

Classif ication

现行过程控制预防

Current Process Controls Prevention 现行过程控制探测

Current Process Controls delection 探测度（D

）Dete ction

初始生产日期

Orignal Production Date

编制者 Prepared By

过程责任

Process Responsibility 零件程序编号 /版本号Part Program No./Rev.核心小组Core Team

零件名称 /客户图号 /版本：Part Name /Drawing No. / Rev. incoming inspection 来料检验

Material type wrong 材料牌号不对

Impact machining 影响后续加工

过程步骤/功能 Process Step /Function

要求

Requirements 潜在失效模式Potential Failure Mode 潜在失效后果

Potential Effect of Failure The material's chemical composition are out of spec.材料成份超差

Issue wrong material 发错材料

Face is not flat 端面不平整严重

度

（S)S

everit

过程分类Proce ss Classif ication Dimension out of tolerance 尺寸超差

Dimension out of spec 尺寸超差

Dimension out of tolerance 尺寸超差

****-FMEA-******

Potential Failure Mode and Effects Analysis (Process FMEA)

潜在的失效模式及后果分析

FMEA 日期（原始）

Date (Orig.)Transit way was regulated 规定搬运方法

Incoming Inspection 来料检验

Surface crash 表面碰伤

Effective Date ruty ce ction 203.

Brilling Hole

镗孔（32,42）20°5

Tools wear

刀具磨损

3345NA NA NA NA NA NA NA （19）Φ5.9±0.15

Tools wear

刀具磨损

3345NA NA NA NA NA NA NA （15）14.5+0.26

Tools wear

刀具磨损

3354NA NA NA NA NA NA NA

204 Reamering

hole

铰孔

（21）Φ5.5 +0.02/-0.0058

Tools wear

刀具磨损

44128

1.Determine the tool

material and enactment

tool life

2.Determine the process

parameters on the

machine

3.SPC control

1.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

Technology

Department

技术部

Production

Department

生产部

11-17

1.Tool material

and tool life were

determined.

2.PPK≥1.67.

1.刀具材质和刀

具寿命已经确定

2.PPK≥1.67

82464

205. Dilling hole 钻

孔

Φ104Tools wear

刀具磨损

2324NA NA NA NA NA NA NA

206. Boring hole

镗孔

（18）

Φ12.2+0.04/08

Tools wear

刀具磨损

44128

1.Determine the tool

material and enactment

tool life

2.Determine the process

parameters on the

machine

3.SPC control

1.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

Technology

Department

技术部

Production

Department

生产部

11-17

1.Tool material

and tool life were

determined.

2.PPK≥1.67.

1.刀具材质和刀

具寿命已经确定

2.PPK≥1.67

82464

（16）17.5 +0.02/-0.03

Tools wear

刀具磨损

3354NA NA NA NA NA NA NA Impact assembly

影响客户装配

Customer dissatisfaction

客户不满意

Impact assembly

影响客户装配

Impact machining

影响后续加工

1.Estimate the tool life, change

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

Customer dissatisfaction

客户不满意

1.Estimate the tool life, change

tools periodically

2.Correct the tooling parameters

periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

Checking dimensions on line

在线检查尺寸

Effective Date ruty ce ction 206.

Boring hole

镗孔

（37）61,Tools wear

刀具磨损

2,The machine center line

offset 机床中

心线偏移

3354NA NA NA NA NA NA NA

207. Turning Outside

Diameter车

外圆（4）Φ14.035

Tools wear

刀具磨损

3345NA NA NA NA NA NA NA （5）Φ12.6±0.035

Tools wear

刀具磨损

3345NA NA NA NA NA NA NA

（1）Φ16.18 0/-

0.04

Tools wear

刀具磨损3354NA NA NA NA NA NA NA （25）45.6°±5°4

Tools wear

刀具磨损3336NA NA NA NA NA NA NA

208.Groovin g 割槽

（2）Ф 14+0.057Tools wear

刀具磨损44112

1.Determine the tool

material and enactment

tool life

2.Determine the process

parameters on the

machine

3.SPC control

1.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

Technology

Department

技术部

Production

Department

生产部

11-17

1.Tool material

and tool life were

determined.

2.PPK≥1.67.

1.刀具材质和刀

具寿命已经确定

2.PPK≥1.67

72456

（11）2.2 +0.2/06Tools wear

刀具磨损3354NA NA NA NA NA NA NA

（26）R0.1 +0.1(2X)

Tools wear

刀具磨损3345NA NA NA NA NA NA NA Impact assembly

影响客户装配

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Impact functionality

影响使用性能

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

1.Estimate the tool life, change

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

3,Setup the machine center line

periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

3.定期调整机床中心

1.Estimate the tool life, change

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Dimension out of

tolerance

尺寸超差

1.Dimension out of

tolerance

2.Surface is rough

1.尺寸超差

2.表面粗糙

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

1.Dimension out of

tolerance

2.Surface is rough

1.尺寸超差

2.表面粗糙

Dimension out of

tolerance

尺寸超差

Effective Date

ruty

ction

212

Boring Hole 镗孔

(30)0.1*45°

Tools wear 刀具磨损

345NA NA NA NA NA NA NA

(13)2.5

+0.2

Tools wear 刀具磨损

354NA NA NA NA NA NA NA

(12)1.2

±0.025

Tools wear 刀具磨损

354NA NA NA NA NA NA NA

(35)

The machine center offset

机床中心线偏移

354

NA NA NA NA NA NA NA

(24)Φ13

+0.04

Tools wear 刀具磨损

96 1.Determine the tool material and enactment tool life

2.Determine the process parameters on the machine

3.SPC control

1.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

Technology Department 技术部Production Department 生产部11-17 1.Tool material and tool life were determined.2.PPK ≥1.67.1.刀具材质和刀具寿命已经确定2.PPK ≥1.67

82464

213.Turning Outside Diameter 车外圆

(6)Φ14.6

+0.1

Tools wear 刀具磨损

354

NA NA NA NA NA NA NA

(29)0.2±0.1

*45

Tools wear 刀具磨损

324

NA NA NA NA NA NA NA

(9)3.8

+0.1

Tools wear 刀具磨损

354

NA NA NA NA NA NA NA

0.2

±0.01

*45°

Tools wear 刀具磨损

345

NA NA NA NA NA NA NA

Impact functionality 影响使用性能

Impact assembly 影响客户装配

Customer dissatisfaction 客户不满意

Setup the machine center periodically

定期调整机床中心

1.Estimate the tool life, change tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

2.Correct the tooling parameters periodically

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 tools periodically

1.估算刀具寿命,定时换刀

2.Correct the tooling parameters periodically

2.定期对刀具参数进行补正Checking dimensions on line 在线检查尺寸

Checking dimensions on line 在线检查尺寸

Dimension out of tolerance 尺寸超差

1.Dimension out of tolerance

2.Surface is rough 1.尺寸超差2.表面粗糙

Dimension out of tolerance 尺寸超差

Checking dimensions on line 在线检查尺寸

Effective Date ruty ce ction 213.Turning

Outside

Diameter车

外圆(27)0.3±0.05*20°5Tools wear

刀具磨损

3345NA NA NA NA NA NA NA

(7)19.6+0.05/06Tools wear

刀具磨损

3354NA NA NA NA NA NA NA

(28)0.2±0.05*45°5

Tools wear

刀具磨损

3345NA NA NA NA NA NA NA

(3)Φ27.3 +0.06/+0.027

Tools wear

刀具磨损

44112

1.Determine the tool

material and enactment

tool life

2.Determine the process

parameters on the

machine

3.SPC control

1.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

Technology

Department

技术部

Production

Department

生产部

11-17

1.Tool material

and tool life were

determined.

2.PPK≥1.67.

1.刀具材质和刀

具寿命已经确定

2.PPK≥1.67

72456

(10)3.6+0.056Tools wear

刀具磨损

3354NA NA NA NA NA NA NA

30Washing

清洗

The operater mix different

parts

操作员将不同零件混合清

洗

2336NA NA NA NA NA NA NA 6

The operater mix the

different batch parts

操作员将不同批次混合清

洗

2224NA NA NA NA NA NA NA 6

Washing too many

pieces one time results in

parts colliding each other

清洗数量太多导致零件堆

积相互碰撞

2336NA NA NA NA NA NA NA

Washing solution is durty,

parts are not cleaned up

completely

清洗液脏,零件清洗不干净

2336NA NA NA NA NA NA NA

Washing time short

清洗时间短

2116NA NA NA NA NA NA NA

The concentration and

temperature don't meet

the requirements

清洗液浓度,温度未达指定

要求

2336NA NA NA NA NA NA NA Impact functionality

影响功能

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Parts can not be

traceable

零件无法追溯

Check washing solution's

concentration and temperature

periodically

定期检查清洗液浓度与温度

1.Estimate the tool life, change

tools periodically

2.Correct the tooling parameters

periodically

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

tools periodically

2.Correct the tooling parameters

periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

Use the dempty washing basket

使用空的清洗篮

1.Estimate the tool life, change

tools periodically

2.Correct the tooling parameters

periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

https://www.sodocs.net/doc/988122515.html,ing different color of flow sheet

to distinguish shifts of every day

2.Put the machine no. card on the

washing basket

Put only one layer of parts on the

washing basket

清洗篮内只能放一层零件

Periodically change washing

solution

定期更换清洗液

Set up the washing time

设定清洗时间

Visual checking

目视检查

Visual checking

目视检查

Checking dimensions on line

在线检查尺寸

Visual checking

目视检查

Check the quantity after washing

清洗完后核对数量

Visual checking

目视检查

Visual checking

目视检查

Checking dimensions on line

在线检查尺寸

Checking dimensions on line

在线检查尺寸

Part Surface crash

零件表面碰伤

Cuting oil not clean

油污没有清洗干净

Dimension out of

tolerance

尺寸超差

Different batches are

mix

不同批次混在一起

Different parts mixed

不同的零件混合在一

起

Dimension out of

tolerance

尺寸超差

Dimension out of

tolerance

尺寸超差

1.Estimate the tool life, change

tools periodically

2.Correct the tooling parameters

periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

Checking dimensions on line

在线检查尺寸

Dimension out of

tolerance

尺寸超差

Customer dissatisfaction

客户不满意

1.Estimate the tool life, change

tools periodically

2.Correct the tooling parameters

periodically

1.估算刀具寿命,定时换刀

2.定期对刀具参数进行补正

Checking dimensions on line

在线检查尺寸

Dimension out of

tolerance

尺寸超差

Effective Date ruty ce ction 40

Surface of part

plate Zn 5~10μm 表面镀Zn5~10μm 6

1.The concentration of

liquor is low

溶液浓度低

2.Voltage instability

电压不稳定

4372NA NA NA NA NA NA NA

Salt Spray Test

198H

盐雾试验198小时6

1.The concentration of

liquor is low

溶液浓度低

2.Voltage instability

电压不稳定

4372NA NA NA NA NA NA NA

50Final Inspection

成品检查

Measure tools not precise

测量工具不精确

4248NA NA NA NA NA NA NA 6

Parts accumulate collide

one another

零件堆积相互碰撞

4248NA NA NA NA NA NA NA 6

Working environment not

clean

工作环净不干净

4248NA NA NA NA NA NA NA

60Packaging

包装

72.The intensity of packing

material is not strong

enough

包装材料强度不够

3484

Inspection packaging

material

包装材料进货检验

Quality department

质量保证部

11-17

Packaging

material were

inspected 包装材

料进货检验

71428

6Package people is

careless

包装人员疏忽

3590NA NA NA NA NA NA NA

6Package people is

careless

包装人员疏忽

3590NA NA NA NA NA NA NA

61.Have chips adhere on

the packing material

2.Packaging environment

not clean

1.包装材料上粘有碎屑

2.包装环境不干净

3236NA NA NA NA NA NA NA

70检验/入库

Inspection / Storing 6

Package people is

careless

包装人员疏忽

3236NA NA NA NA NA NA NA

80检验/出货

Dock audit /

Shipment

Shipping people are

careless

出货人员疏忽

3672NA NA NA NA NA NA NA 4

Wrong handling method

during transportation

运输中不正确的搬运方法

3672NA NA NA NA NA NA NA Approval

Delivery not in time

不能准时交货

Can't be assembled

不能客户装配

Product characteristic or process parameter which affects a product's safety or compliance with regulatory requirements.

影响产品的安全性或法规要求的符合性的产品特性或过程参数。

Product characteristic or process parameter which affects a product's fit/function or has other reasons for control and documentation such as customer requirements.

影响产品的配合/功能或关于控制和文件化有其它原因（如客户特殊要求）的产品特性或过程参数。

Parts are damaged

零件损坏

Parts can not be

traceable

零件无法追溯

Ship wrong parts

出错货

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Customer dissatisfaction

客户不满意

Parts damage

零件损坏

Impact the functionality of

parts

影响零件使用性能

https://www.sodocs.net/doc/988122515.html,e new packing material

2.Packaging in appointed

packaging area

1.每次包装使用新的包装材料

2.在指定的包装区域包装

Use the special packing material

使用专用的包装材料进行包装

Label on every tray

每盘贴标签

Confirm parts in conform with label

确认零件与标签是否一致

Requirement the supplier keep all

records and we would confirm it

periodically

要求供应商保留记录,并定期进行确

认

periodically calibration

量具定期计量

Check parts in despatching area

before delivery

出货前将零件放在待发货区审核

Use the high strength packing

material

使用强度高的包装材料

Inspection in appoint inspection

area

在指定的检验区域检验

Putting part in the tray after

inspection

检查好的零件放在吸塑盘内,

Dock audit

出货检查

Dock audit

出货检查

Packaging inspection

包装检验

Packaging inspection

包装检查

Packaging inspection

包装检查

Packaging inspection

包装检验

1.Check the supplier's thickness

report 检查供应商的镀层厚度报告

2.Send the parts to third party to

checking the thickness periodically.

定期第三方检测。

Check if the calibration label is in

validity period

检查量具标签是否在有效期内

标签错误

The labels were

affixed wrong

Delivery wrong parts

零件发错

https://www.sodocs.net/doc/988122515.html,bel on every box 每箱贴标签

2.Confirm parts in conform with

label确认零件与标签是否一致

Packaging inspection

包装检验

Package material is

damaged

包装材料损坏

The measurements

are incorrect

测量结果不准确

Different batches are

mix

不同批次混在一起

Label not in conform

with parts

标识与零件不符

Delivery wrong parts

零件发错

Part surface crash

零件表面碰伤

Part surface is dirty

零件表面粘有脏物

Package damaged

包装损坏

Part surface is dirty

零件表面粘有脏物

Visual checking

目视检查

Visual checking

目视检查

Plating layer out of

tolerance

尺寸超差

The test was unfail

试验不合格

Impact the functionality of

parts

影响零件使用性能

1.Check the supplier's test report

检查供应商的测试报告

2.Send the parts to third party to

checking the thickness periodically.

定期第三方检测。

Requirement the supplier keep all

records and we would confirm it

periodically

要求供应商保留记录,并定期进行确

认

Effective Date

ruty

ction

Team Member/ Title Team Member/ Title Team Member/ Title

Team Member/ Title

Team Member/ Title Team Member/ Title

机械加工pfmea案例

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