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机械加工pfmea案例GOOD

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

4transit method was unreasonable 搬运方法不合理

648NA NA NA NA NA NA NA

Ф28

-0.03

Supplier's dimension out of spec

供应商生产尺寸超差

354NA 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

96Send 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

318NA NA NA NA NA NA NA

202.

Drilling hole 钻孔

Φ5.46

Tools wear 刀具磨损

336NA NA NA NA NA NA NA

203.

Brilling Hole 镗孔（20）Φ5.6 +0.26

Tools wear 刀具磨损

354NA 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

Classi

ficatio n

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)Seve rity

过程分类Proce ss Classi ficatio n

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

n 203.

Brilling Hole 镗孔

（32,42）20°5

Tools wear 刀具磨损

345NA NA NA NA NA NA NA

（19）Φ5.9

±0.1

Tools wear 刀具磨损

345NA NA NA NA NA NA NA

（15）14.5+0.2

Tools wear 刀具磨损

354NA NA NA NA NA NA NA

204Reamering hole 铰孔

（21）Φ5.5

+0.02/-0.005

Tools wear 刀具磨损

1281.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

Φ10

Tools wear 刀具磨损

324NA NA NA NA NA NA NA

206.Boring hole

镗孔

（18）

Φ12.2

+0.04/0

Tools wear 刀具磨损

1281.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

354NA 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

Customer dissatisfaction 客户不满意

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

n 206.Boring hole

镗孔

（37）

1,Tools wear 刀具磨损

2,The machine center line offset

机床中心线偏移

354NA NA NA NA NA NA NA

207.Turning Outside

Diameter 车外圆

（4）Φ14.035

Tools wear 刀具磨损

345NA NA NA NA NA NA NA

（5）Φ12.6

0.03

Tools wear 刀具磨损

345NA NA NA NA NA NA NA

（1）Φ16.18

0/-

0.04

Tools wear 刀具磨损

354NA NA NA NA NA NA NA

（25）45.6°

±5

Tools wear 刀具磨损

336NA NA NA NA NA NA NA

208.Groovin g 割槽

（2）Ф 14

+0.05

Tools wear 刀具磨损

1121.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

+0.2/0

Tools wear 刀具磨损

354NA NA NA NA NA NA NA

（26）R0.1+0.1

(2X)

Tools wear 刀具磨损

345NA NA NA NA NA NA NA

Impact assembly 影响客户装配

Customer dissatisfaction 客户不满意

Impact functionality 影响使用性能

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

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

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

(36)tolerance

尺寸超差

Effective Date ruty ce

ction

n 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

354NA 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

354NA NA NA NA NA NA NA

(29)0.2±0.1

*45

Tools wear 刀具磨损

324NA NA NA NA NA NA NA

(9)3.8

+0.1

Tools wear 刀具磨损

354NA NA NA NA NA NA NA

0.2

±0.01

*45°

Tools wear 刀具磨损

345NA 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

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

n 213.Turning Outside Diameter 车外圆

(27)0.3±0.05

*20

Tools wear 刀具磨损

345NA NA NA NA NA NA NA

(7)19.6

+0.05/0

Tools wear 刀具磨损

354NA NA NA NA NA NA NA

(28)0.2±0.05*45°

Tools wear 刀具磨损

345NA NA NA NA NA NA NA

(3)Φ27.3

+0.06/+0.02

Tools wear 刀具磨损

1121.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

+0.05

Tools wear 刀具磨损

354NA NA NA NA NA NA NA

Washing 清洗

The operater mix

different parts

操作员将不同零件混合清洗

336NA NA NA NA NA NA NA

The operater mix the different batch parts 操作员将不同批次混合清洗

224NA NA NA NA NA NA NA

6Washing 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

336NA 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2

336NA 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

336NA 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

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.doczj.com/doc/2f13520032.html,ing different color of flow

sheet to distinguish shifts of every day

2.Put the machine no. card on the

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

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 up

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

6Dimension 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

n 40

Surface of part

plate Zn 5~10μ

m 表面镀

Zn5~10μm

1.The concentration of liquor is low 溶液浓度低

2.Voltage instability 电压不稳定

372NA 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

Final Inspection

成品检查

6Measure tools not precise

测量工具不精确4248NA NA NA NA NA NA NA

6Parts accumulate collide one another

零件堆积相互碰撞4248NA NA NA NA NA NA NA

6Working environment not clean

工作环净不干净4

248NA NA NA NA NA NA NA

Packaging 包装

7 2.The intensity of

packing material is not strong enough 包装材料强度不够3

84Inspection 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3

590NA NA NA NA NA NA NA

6Package people is careless

包装人员疏忽

590NA NA NA NA NA NA NA

6 1.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3

236NA NA NA NA NA NA NA

检验/入库Inspection /Storing 6Package people is careless

包装人员疏忽3

236NA NA NA NA NA NA NA

检验/出货Dock audit /Shipment

4Shipping people are careless

出货人员疏忽

3672NA NA NA NA NA NA NA

4Wrong 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

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

Parts damage 零件损坏

Impact the functionality of parts

影响零件使用性能

https://www.doczj.com/doc/2f13520032.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.doczj.com/doc/2f13520032.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 ce

ction

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

Team Member/ Title

Team Member/ Title Team Member/ Title