PFMEA-失效模式分析案例.xls

Page 1 of 19有有限限公公司司工工 程程 潜潜 在在 的的 失失 效效 模模 式式 与与 效效 果果 分分 析析Co.,Ltd.Co.,Ltd.(PROCESS(PROCESS FMEA)FMEA)Item项目名称:Page no.页码：共19页Model Year/Vehicle:Responsibility责任部门：Prepared by制作：Core Team核心小组:Key Date关键日期：FMEA date日期（编制）：过程项目潜在的潜在的严S级CLASS潜在的频O现行制程预防控制现行制程侦测措施难D风险优先率R建议的措施责任与目标效果确认Action Results&功能要求失效模式失效结果重E失效原因与机理度CCurrent ControlCurrent Control检ePRecommended完成日期SODRProcess DescpriptionPotentialPotential度V别Potential数CPreventionDetection度tNAction(s)Res.&Tar.采取的措施eceP&Process Purpose Failure ModeEffect(s)of FailureCause(s)of FailureCompletion DateAction TakenvctNPartsParts incomingincoming部部品品受受入入过过程程1.Receiving partspoor appearancefunction error 7handling carelessly by2None1 visual check by warehouseman&IQA228None1.接收部品on cartonor packing NGoperator or due to delivery无1 由仓管员及IQA目视检查无纸箱的有形损坏功能或装置不良操作或运输过程中的过失操作2 visual check by PK01 station72 包装工位目视检查actual qty unmatched withcant complete this lot7handling carelessly by2Nonecheck by warehouseman&IQA456Nonesuppliers invoice无法完成该批量的产品operator or due to delivery无由仓管员及IQA核对发票上的数量6无部品数量与供应商操作或运输过程中的过失操作的发票不符2.Incoming inspectionoversight on inspectionNG parts released to 6incoming part released to2rule of incoming inspection1 check by part using station224None2.受入检查漏检product line4warehouse without release 受入检查规定1 部品使用工位来料检查7无(IQC)错误或不良品stamp of IQA2 cosmetic check 100%流到生产线无受入检查印章部品入了库2 100%进行外观检查overview NG未检出不良NG parts released to 61 miss operating2qualification training on 100%fuction check后段工位多重100%进行功能测试448Noneproduct line41 操作失误inspection3无错误或不良品流到生产线检查员资格培训2 dont point out inspectionitem in inspection document2 检验指导书没有明确的指出检测点21 add inspection items in document1 追加检验指导书中没有的检验点2 IQC re-inspect all parts inwarehouse2 在库品IQC全部重检3 refer detail in report SCAR 07-OM-005 and SCAR 07-OM-0033 详见编号为SCAR 07-OM-005 andSCAR 07-OM-003中的报告100%fuction check后段工位多重100%进行功能测试396None无3 tester failure2emendation on equipments yearly仪器校正每年一次equipments maintain monthly设备的月度保养check equipments at the begin of work作业准备时测量336None3 测定器失效4无3.Part storagePart Shortagecant complete this lot7mistake input by warehouseman2Nonecheck parts list by warehouse456None3.部品入库/储藏缺少部品无法完成该批量的产品1仓管员输入错误无仓库核对入库清单6无check parts list by materiel people物料员核对入库清单part rustinessfunction error7temperature/humidity out of 21.temperature/humidity controlcheck temperature/humidity at thebegin of work228None/ESD destroy功能不良standard1.温湿度管理规定4无部品生锈/ESD破坏温湿度超标2.ESD control 作业准备时点检温湿度表2.静电管理规定4.Part supplyed to part supplyed wronglyproduct line stop7mistake parts by warehouseman2mark part location and makingcheck part list and BOM456None product line发错料生产线停产1or part list wrongspecial control on similar parts 检查发料清单,核对BOM表无4.发料到生产线发料员在仓库拿错料对部品放置区域作相关标识发料单制作错误对类似品作特殊管理partsurface scrape intransport process部品刮伤poor appearance外观不良(面板,旋钮表面刮伤)641 rub between parts and packingmateriel1 部品在运输过程中与自身的包装材料摩擦21 requset vender improve packingmateriel1 要求供应商修改部件的包装材料2 refer detail in report PR-07-082 详见PR-07-08报告1 inspect parts before assemble1 部品组装前检验2 cosmetic check 100%2 外观100%检验4796None无6 66 6Sev:Severity Occ:Occurance Det:Detection R.P.N.:Risk Priority Number (*:公司内部重要管理项目;SC:客户要求重要管理项目)样式:RF-PT-03,050705Page 2 of 195.Label printprint badnessdifficult to trace4operating NG2training operatorlabel scan.条码扫描比对216None5标签打印打印不良批量不易追溯1作业不良培训作业员无equipment NG2check and maintain equipmentdaily check216None设备故障点检,保养日常点检无label scan.条码扫描比对CDRCDR MECHAMECHA准准备备工工程程6.inspect main PCB(ST:PT01)6.main PCB部件检验PCBs surface scrape主基板表面划伤function error功能不良87PCB scrape by hardness inprocess作业过程中硬物刮伤2forbid operator wear ring or otherhardness作业员禁止带戒指等硬物作业1 100%visual check1 100%目视检查2 next station 100%function check2 后续多层工位100%功能视检查4364none无ESD destroyelectrical function7operator not wearing 2use ESD cleaner to get rid of ESD1.daily check before line start228NoneESD破坏failuredESD band使用离子风机消除静电1.每天开始生产前检查4无电器性能破坏作业员没有佩带静电带2.check ESD of operating areas2.作业区域静电检查oversight on inspection漏检NG parts released to productline,result in productionfunction fail as cantworkable or instability不良品流到生产线,造成产品功能不良87parts put into next stationwithout inspection because ofmiss operating of operator作业员失误,部件没有检查就流到下个工位2dispart the checked parts andwithout check parts检查过和未检查的部品分开放置if parts have checked,will make amark on it在已经检查过的部品上打点确认100%fuction check后续多层功能测试工位100%检查100%visual check on parts usingstation在部件的使用工位100%检验有无该标识4364none无overview NG未检出不良NG parts released to 61 miss operating2qualification training on 100%fuction check后段多层工位100%进行功能测试448Noneproduct line41 操作失误inspection3无错误或不良品流到生产线,检查员资格培训2 tester failure2emendation on equipmentsemendation list of equipments336None2 测定器失效仪器校正仪器校正清单无100%fuction check后段100%进行功能测试FT测试搜索敏感性的参数设置不正确产品误判(搜索不停台)2参数设置过严,造成产品在正常的状态下无法实现搜索停台的功能2搜索停台的控制规格设定为35.3dbuvemffuction check后续工位功能检查456搜索停台的控制规格更改设定为36.7dbuvemf生技日期:2007/06/20完成负载盒上开关位置拨错产品误判(搜索不停台)2作业员误操作将负载盒上的TNS开关由on拨到OFF造成产品在正常的状态下无法实现搜索停台的功能2生技设备月度保养工作准备时作业员的点检4161 负载盒上追加开关位置标识2 将负载盒上的ACC开关移到治具上,避免作业员在负载盒上作业生技日期:2007/06/11完成7.fix main PCB to chassismodule chassis is NG assembly7handling carelessly by2Nonevisual check by warehouseman&IQA228None&screwingout of shape错误装配4operator or due to delivery无7无(ST:A-01)模块变形操作或运输过程中的过失操作由仓管员及IQA目视检查7.组装主基板至五金支架check by hisself&打螺丝对来料进行自检查NG assemblyfixing NG7pressure not enough 2use cylinder jigcheck pressure daily and when456None错误装配组装不到位4压力不够用气缸治具model changed无每天或换机种时检查气压fixing to wrong location2training operator100%visual double check 456None放入位置不正确培训作业员100%双重目视检查7无screw loose/tightenrattle noise heard when6screw driver torque too small2use torque meter to control check torque daily and when448None螺丝松动或过紧shaking due to loose4螺丝刀扭力过小torquemodel changed无松动，摇晃时有杂音用扭力计控制扭力每天或换机种时检查扭力slide occurred due to 6screw driver torque too big2use torque meter to control check torque daily and when448Nonetighten4螺丝刀扭力过大torquemodel changed无过紧，滑牙用扭力计控制扭力每天或换机种时检查扭力stick sheet to wrongcant load CD7miss operating21.training operator100%visual double check 456Nonelocation不能进碟操作错误1.培训作业员100%双重目视检查7无碟仓绒布贴附位置不正确2.process sheet2.作业指导书6 6有有限限公公司司工工 程程 潜潜 在在 的的 失失 效效 模模 式式 与与 效效 果果 分分 析析Co.,Ltd.Co.,Ltd.(PROCESS(PROCESS FMEA)FMEA)Item项目名称:Page no.页码：共19页Model Year/Vehicle:Responsibility责任部门：Prepared by制作：Core Team核心小组:Key Date关键日期：FMEA date日期（编制）：过程项目潜在的潜在的严S级CLASS潜在的频O现行制程预防控制现行制程侦测措施难D风险优先率R建议的措施责任与目标效果确认Action Results&功能要求失效模式失效结果重E失效原因与机理度CCurrent ControlCurrent Control检ePRecommended完成日期SODRProcess DescpriptionPotentialPotential度V别Potential数CPreventionDetection度tNAction(s)Res.&Tar.采取的措施eceP&Process Purpose Failure ModeEffect(s)of FailureCause(s)of FailureCompletion DateAction TakenvctNSev:Severity Occ:Occurance Det:Detection R.P.N.:Risk Priority Number (*:公司内部重要管理项目;SC:客户要求重要管理项目)样式:RF-PT-03,050705Page 3 of 19PCB crack/scratchfunction error7miss operating21.training operator100%visual check 456NonePCB 断裂/划伤功能不良操作失误1.培训作业员100%目视检查3无2.jig for avoiding missing100%check fuction repeatedly后段多层工位100%进行功能测试2.防呆治具incoming part NG2PCB cosmetic checkincoming inspection228None来料不良PCB板外观检查受入检查3无100%check fuction repeatedly后段多层工位100%进行功能测试forget to stick heatNG assembly7miss operating21.manage by quantity100%visual check by hisself456Nonesink sheet to PCB错误装配4操作错误1 数量管理100%目视自检8无漏贴散热胶布至PCB2.process sheet2.作业指导书ESD destroyelectrical function7operator not wearing 2use ESD cleaner to get rid of ESD1.daily check before line start228NoneESD破坏failuredESD band使用离子风机消除静电1.每天开始生产前检查4无电器性能破坏作业员没有佩带静电带2.check ESD of operating areas2.作业区域静电检查space between panelfixing NG3block of fixing jig shifted21.check this item when monthly1 visual check by hisself after318Nonebottom and chassis组装不到位面板底盖定位块的位置发生偏移maintenance assemble7无is too big when 1.治工具月度维护时重点检查此项目1 组装后自检assembly2 next station check组装时面板底盖与五金支架2 后工位检查之间间隙过大screw of jig loosedNG assembly3the screw is used to fix the 21.check this item when monthly1 visual check by hisself after318None治具螺丝松动错误装配pillar of cylinder and pillar maintenance assemble7无of press,its easy to become1.治工具月度维护时重点检查此项目1 组装后自检loose when using2 next station check该螺丝用于连接汽缸杆与受力杆,2 后工位检查使用中易松动post beside sheet leatherNG assembly3this item is not treated as2None1.IQC added this item to inspection424Noneplate of bottom panel错误装配important item when inspection无process sheet无is anamorphicIQC检查时未将此项列入重点检查1.IQC将此项列入受入检查的重点检查项目面板底盖贴附碟仓绒布处项目2.100%visual inspection支柱变形2.100%目视检查螺丝刀碰伤主基板回路功能不良(AM无反应)7治具上有多余的孔,作业员锁螺丝时打错位置,将主基板上的回路钻断2治具上的螺丝孔位有标识100%function check100%功能检查456治具改造,将治具上多余的孔位去除生技日期:2007/08/07完成3 3有有限限公公司司工工 程程 潜潜 在在 的的 失失 效效 模模 式式 与与 效效 果果 分分 析析Co.,Ltd.Co.,Ltd.(PROCESS(PROCESS FMEA)FMEA)Item项目名称:Page no.页码：共19页Model Year/Vehicle:Responsibility责任部门：Prepared by制作：Core Team核心小组:Key Date关键日期：FMEA date日期（编制）：过程项目潜在的潜在的严S级CLASS潜在的频O现行制程预防控制现行制程侦测措施难D风险优先率R建议的措施责任与目标效果确认Action Results&功能要求失效模式失效结果重E失效原因与机理度CCurrent ControlCurrent Control检ePRecommended完成日期SODRProcess DescpriptionPotentialPotential度V别Potential数CPreventionDetection度tNAction(s)Res.&Tar.采取的措施eceP&Process Purpose Failure ModeEffect(s)of FailureCause(s)of FailureCompletion DateAction TakenvctNSev:Severity Occ:Occurance Det:Detection R.P.N.:Risk Priority Number (*:公司内部重要管理项目;SC:客户要求重要管理项目)样式:RF-PT-03,050705Page 4 of 198.inspect SCD module(ST:PT-02)8.CD机芯部件的检查test CD can not insertinto SCD moduleCD机芯不入碟function errer功能不良871 shock top cover byoperators mistake and makedistortion of CD module1 作业动作过失磨擦上盖导致机芯变形4can not superpose CD module incheck process检测过程中不能叠放1 100%function check2 100%visual check1 100%功能检查2 100%目视检查2364None无2 Test CD dirty2 碟片赃污4check and maintain Test CDbefore operation作业员作业前先进行光盘点检function check功能检查2364None无CD moduleaxes lock CD机芯前轴卡住CD碟function errer(CD is notworkable and feedback)功能不良(无法读碟)87shock parts and makedistortion of CD module部品碰撞变形4check appearance检查确认外观100%function check功能检查2364None无oversight on inspection漏检NG parts released to productline,result in productionfunction fail as cantworkable or instability不良品流到生产线,87parts put into next stationwithout inspection because ofmiss operating of operator作业员失误,部件没有检查就流到下个工位2dispart the checked parts andwithout check parts检查过和未检查的部品分开放置if parts have checked,will make amark on it在已经检查过的部品上打点确认100%fuction check后续功能测试工位100%检查100%visual check on parts usingstation在部件的使用工位100%检验有无该标识364none无overview NG未检出不良NG parts released to 61 miss operating2qualification training on 100%fuction check后续功能测试工位100%检查448Noneproduct line41 作业员失误,inspection3无错误或不良品流到生产线,检查员资格培训22 tester failure2emendation on equipments yearly仪器校正每年一次equipments maintain monthly设备的月度保养check equipments at the begin of work始业点检336None2 测定器失效4无not fix FFC steadyfunction error8miss operating21.make jig to insert FFC1.100%visual inspection after FFC wasinserted,and add mark on FFC cable,1.FFC插入后100%目视检查,检查ok后在FFC排线上打点做标识,2 check mark 100%next station2 后工位在100%目测检查标识360NoneFFC未固定(没有扣上固定FFC排线的固定扣)功能不良(FR,RR声道无输出)7作业员过失1.制做FFC排线插入治具6无2.add the correct method ofinsertting FFC into process sheet2.在作业指导书内追加FFC排线的正确插入方法insert FFC flatlyfunction error7miss operating21.training operator100%visual check 456NoneFFC未水平插入功能不良作业员过失1.培训作业员100%目视检查并打点确认6无2.process sheet2.作业指导书治具排线端子与机芯接触不良产品误判(按出碟键无反应)7治具上的FFC排线多次使用后磨损,造成与机芯接触不良2将FFC排线列为易损件,每月进行更换fuction check后续工位功能检查356治具改造,在治具上追加FFC排线快速夹子生技日期:2007/06/18完成1.training operator9.insert FFC&SCD modulespring of mecha fall off function error7miss operating21.培训作业员100%visual inspection456Nonepreparation&bracket screwing 机芯弹簧脱落功能不良操作错误2.add correct method to carry CDmodule process sheet2.作业指导书追加机芯的正确握取方法100%目视检查3无(ST:A-02)fuction check9.FFC排线插入&机芯准备&后续工位功能检查 机芯支架打螺丝incoming part NG2Noneincoming inspection228None来料不良无受入检查无100%fuction check后续工位功能检查ESD destroyelectrical function8Operator not wearing 2use ESD cleaner to get rid of ESDcheck ESD of operating areas beforline start232NoneESD破坏failured7ESD band使用离子风机消除静电4无电器性能破坏作业员没有佩带静电带作业前检查静电screw loose/tightenrattle noise heard when6screw driver torque too small2use torque meter to controlcheck torque daily and when448None螺丝松动/过紧shaking due to loose4螺丝刀扭力过小torquemodel changed无松动，摇晃时有杂音用扭力计控制扭力每天或换机种时检查扭力6 64 4有有限限公公司司工工 程程 潜潜 在在 的的 失失 效效 模模 式式 与与 效效 果果 分分 析析Co.,Ltd.Co.,Ltd.(PROCESS(PROCESS FMEA)FMEA)Item项目名称:Page no.页码：共19页Model Year/Vehicle:Responsibility责任部门：Prepared by制作：Core Team核心小组:Key Date关键日期：FMEA date日期（编制）：过程项目潜在的潜在的严S级CLASS潜在的频O现行制程预防控制现行制程侦测措施难D风险优先率R建议的措施责任与目标效果确认Action Results&功能要求失效模式失效结果重E失效原因与机理度CCurrent ControlCurrent Control检ePRecommended完成日期SODRProcess DescpriptionPotentialPotential度V别Potential数CPreventionDetection度tNAction(s)Res.&Tar.采取的措施eceP&Process Purpose Failure ModeEffect(s)of FailureCause(s)of FailureCompletion DateAction TakenvctNSev:Severity Occ:Occurance Det:Detection R.P.N.:Risk Priority Number (*:公司内部重要管理项目;SC:客户要求重要管理项目)样式:RF-PT-03,050705Page 5 of 19slide occurred due to 6screw driver torque too big2use torque meter to controlcheck torque daily and when448Nonetighten4螺丝刀扭力过大torquemodel changed无过紧，滑牙用扭力计控制扭力每天或换机种时检查扭力can not fix screw tofixing NG7torque is to small(52kgf)3increase torque to 6.751.25 1.check torque daily and when242Nonebracket 组装不到位4螺丝刀设定力矩规格过小kgf base on technical spc and model changed3无机芯防尘支架螺丝打不进test result,and revised CP and 1.每天或换机种时检查扭力process sheet2.operator confirms screwing well根据设计规格和实际打螺丝测试结after fixing结果,将力矩调至.751.25 kgf,并2.作业员组装完毕后100%目视检查螺丝修订控制计划和作业指导书打入良好10.bracket-m screwing&fix螺丝松动/过紧shaking due to loose6螺丝刀扭力过小torquemodel changed4Noneshield case&fix FFC holder&松动，摇晃时有杂音4用扭力计控制扭力每天或换机种时检查扭力无stick cushion dustproof(ST:A-03)slide occurred due to 6screw driver torque too big2use torque meter to controlcheck torque daily and when448None10.机芯支架打螺丝&防护盖组装&tighten4螺丝刀扭力过大torquemodel changed无 FFC支架组装&防尘胶布贴附过紧，滑牙用扭力计控制扭力每天或换机种时检查扭力ESD destroyelectrical function8operator not wearing 2use ESD cleaner to get rid of ESD1.daily check before line start232NoneESD破坏failured7ESD band使用离子风机消除静电1.每天开始生产前检查4无电器性能破坏作业员没有佩带静电带2.check ESD of operating areas2.作业环境静电检查forget to fix FFC holder NG assembly7miss operating21.training operator100%visual double check 456NoneFFC支架漏装错误装配4操作错误1.培训作业员100%双重目视检查7无2.process sheet2.作业指导书forget to stick cushionNG assembly7miss operating21.training operator100%visual check 456Nonedustproof to bracket错误装配4操作错误1.培训作业员100%目视检查8无漏贴防尘胶布至机芯支架2.process sheet2.作业指导书not combine two of NG assembly7miss operating操作错误21.training operator100%visual check 456Nonedustproof completely错误装配4操作错误,操作后未做压紧动作1.培训作业员100%目视检查8无防尘胶布接合处不紧密2.process sheet update2.修改作业指导书(追加NG和OK品FFC fixing NGfunction error7miss operating2None100%double visual check and make amark on ok product双重目视检查和打点确认check by fixture用治具检查456None排线组装不到位功能不良操作错误无2无not fix FFC steadyfunction error7miss operating21.training operator100%double visual check and make amark on ok product双重目视检查和打点确认456NoneFFC未固定功能不良操作错误1.培训作业员6无2.process sheet2.作业指导书check by fixture用治具检查FFC holderNG fixing7miss operating21.培训作业员100%目视检查456None排线未放入排线支架错误装配4操作错误2.process sheet8无2.作业指导书3 using fixture3 应用治具进行固定sheet which is used tofunction error8miss operating2training operator100%visual inspection464noneconnect FFC and main PCB功能不良(机芯不动作)7操作错误,操作后未做压紧动作培训作业员100%目视检查8无is not sticked firmlyadd this item as notice pointFFC与基板连接