PFEMA-中文格式

1、 東風(fēng)汽車公司商用車鑄造一廠DFM foundry #1. 潛在失效模式及影響分析（PFMEA） PPAP-3Page 10 of 10Supplier Part No.供應(yīng)商零件號：3970955-00Part Name零件名稱：CAP, MAIN BEARINGFMEA & Rev FMEA編號及版本：S8Z0622-2005 00Part No. & Rev.零件號和級別：3970955-00Key Date 關(guān)鍵日期：2005/6/22Prepared By 編制人：楊士周 Yang shi zhouCore Team 核心小組： Product Development

2、 team for CAP,MAIN BEARINGProcess Responsibility 過程責(zé)任部門： Technique departmentDate(Orig.) 編制日期：2005/6/22Date(Rev) 修改日期：Part/Process Function產(chǎn)品/過程功能PCID/描述Potential FailureMode潛在失效模式Potential Effects Of Failure潛在失效影響Sev嚴(yán)重度Class級別Potential Causes Of Failure潛在的失效原因Occu頻度數(shù)CurrentProcessControls現(xiàn)行控制方法Dete

3、c不可探測數(shù)RPN風(fēng)險序數(shù)Recommend-Ed Corrective Actions建議采取措施responsibility & Target Completion Date責(zé)任和目標(biāo)完成日期Actions Taken采取的措施Occu頻度數(shù)Sev.嚴(yán)重度Detec不可探測數(shù)RPN風(fēng)險序數(shù)10A金屬材料進(jìn)廠驗收Acceptance Inspection Of Metal MaterialG1:分供方質(zhì)保書Quality Guarantee From Sub-Supplier無質(zhì)保書No Quality warrant拒收Rejection6分供方質(zhì)量體系不完善Imperfect S

4、ub-Suppliers Quality System1檢查Inspection16G2:進(jìn)廠檢驗合格單Qualification Sheet Of Acceptance Inspection無檢驗單No Check Sheet混料Materials mixed6檢驗滯后Inspection Delay2檢驗報告Inspection report11210B非金屬材料進(jìn)廠驗收Acceptance Inspection Of Nonmetal MaterialG1: 分供方質(zhì)保書Sub-Suppliers Quality Guarantee無質(zhì)保書No Quality Warrant拒收Reje

5、ction6分供方質(zhì)量體系不完善imperfect Sub-suppliersquality system1檢查Inspection16G2:進(jìn)廠檢驗合格單Qualification Sheet Of Acceptance Inspection無檢驗單No Check Sheet混料Materials mixed6檢驗滯后Inspection Delay2檢驗報告Inspection report11220A室內(nèi)存放Ware-House StoringG3:存放時間Storing Time過長Too Long品質(zhì)變差Quality Variation6庫存周期長Too LongStock Cy

6、cle1先進(jìn)先出First in , first out21220A室內(nèi)存放Ware-House StoringG4:存放標(biāo)識Storing Identification錯誤標(biāo)識Wrong identification無標(biāo)識No identification用錯料Material Used Wrongly6失誤miscarriage1定期檢查check termly21220B室外存放Outdoor StoringG3:存放時間Storing Time過長Too Long品質(zhì)變差Quality Variation6庫存周期長Too Long Stock Cycle2先進(jìn)先出First in ,

7、 first out224G4:存放標(biāo)識Storing Identification錯誤標(biāo)識Wrong identification無標(biāo)識No identification用錯料Material Wrongly Used6失誤miscarriage1定期檢查check termly21230A配型砂prepara-tion Of Molding SandP1:濕壓強度Green Compressive Strength過低Too Low型廢多Too Many Scrap Moulds5粘土量低Low Clay Content21次/小時測定Determining Once/h SPC110P2

8、:緊實率Compactability過高Too High鑄件氣孔Casting Blow-Hole4*水份含量低Low Moisture Content21次/小時測定Determining Once/h SPC18過低Too Low鑄件砂眼Casting Sand Hole5*水份含量高High Moisture Content21次/小時測定Determining Once/h SPC110P3:透氣性Permeability過低Too Low鑄件氣孔Casting Blow-Hole5有效煤粉含量高High Effective Coal Dust Content21次/班測定Determ

9、ining Once/shift330粘土量過高TooHigh Clay Content21次/班測定Determining Once /shift33030B配芯砂Preparation of Core SandP6:常溫抗拉強度Normal Temperature Tensile Strength過低Too Low斷芯裂紋Core Rupture or Crack4*過燒Over Burnt21次/2小時檢測Inspection Once/2h324覆膜不均勻Resin-Coated Inhomogenously21次/2小時檢測Inspection Once/2h324P7:熔點Fusi

10、on Point過高Too High結(jié)殼過薄Too Thin Shell7烏洛托品超量Too Much Urotropine11次/2小時檢測Inspection Once/2h321過低Too Low脫殼Shell Peeling Off6烏洛托品不足Shortage of Urotropine11次/2小時檢測Inspection Once/2h31830C化料MeltingR1:含碳量C%過低Too low縮松porosity8*爐料定量不準(zhǔn)Inexact Furnace Charges Ration1爐前成分分析Pretreatment Chemical Composition Ana

11、lysis21630C化料MeltingR1:含碳量C%過高Too high強度偏低8*爐料定量不準(zhǔn)Inexact Furnace Charges Ration1爐前成分分析Pretreatment Chemical Composition Analysis216R2:含硅量Si%過低Too low鑄件白口8*爐料定量不準(zhǔn)Inexact Furnace Charges Ration1爐前成分分析Pretreatment Chemical Composition Analysis216過高Too High鐵素體量高too much Ferrite8*爐料定量不準(zhǔn)Inexact Furnace C

12、harges Ration1爐前成分分析Pretreatment Chemical Composition Analysis216R3:含錳量Mn%過低Too Low珠光體量低too much pearlite8*爐料定量不準(zhǔn)Inexact Furnace Charges Ration1爐前成分分析Pretreatment Chemical Composition Analysis216R6:含鉻量Cr%過低Too Low珠光體量低too much pearlite8*爐料定量不準(zhǔn)Inexact Furnace Charges Ration1爐前成分分析Pretreatment Chemica

13、l Composition Analysis216R8:取樣品質(zhì)Quality Of Samples白口化不足Insufficient White Fracture成分測量不準(zhǔn)Inaccurate Chemical CompositionAnalysis7光譜樣激冷不足Insufficient Chilling Of Spectographic Specimen3水冷Water Cooling1217碳片質(zhì)量差 Poor Quality Of Carbon Flake3清潔激冷鐵板Cleaning Refrigeration Iron Board12135C爐前處理pre-treatmentC

14、1:出爐溫度Tapping Temperature過高Too High孕育不良Poor Inoculation6未按時測溫temperature measurement not on schedule2每半小時測 溫Once / 30 Minutes224過低Too Low鑄件冷隔或澆不足Coldshut or Misrun7未按時測溫temperature measurement not on schedule2每半小時測 溫Once / 30 Minutes228C2:孕育劑量Inoculant Quantity過多Too High終硅超量Last Silicon Content Too

15、Much4臺秤失準(zhǔn)Inaccurate Bench Scales2稱量weigh216過少Too Low白口組織White fracture4臺秤失準(zhǔn)Inaccurate Bench Scales2稱量weigh21640A造型MoldingZ1:鑄造日期標(biāo)識Casting Identification標(biāo)識錯誤indistinct or wrong identification鑄件報廢casting be scrapped8操作失誤miscarriage operation2首檢Initial Inspection116Z2:模板加熱溫度Heating Of Pattern Plate過低To

16、o Low起型不良Withdrawing The Pattern Difficulty3斷電Power Supply Failure3加熱Heating118Z3:砂型硬度Sand Mold Hardness過低Too Low脹箱Swell4壓實壓力不足Insufficient Squeezing Force2調(diào)整Adjusting21640A造型MoldingZ5:模板銷子銷套Status Of Pin And pin bush of Pattern Plate錯型Shift尺寸錯誤dimensional errors不能加工will not machine6磨損過量wear damage2

17、定檢Regular Inspection224量規(guī)special gage下不到位Incorrectly偏芯Core Shift5操作不熟練Poor Skill1目視檢查VisualInspection21050澆注PouringJ1:澆注溫度Pouring Temperature過低Too Low冷隔澆不足Cold Shut or Misrun7等待時間過長Waiting Time Too Long2每包測溫Determining Temperatureevery ladle228J2:孕育Inoculation衰退Fading出現(xiàn)碳化物Carbide Appears8*有效時間短Short

18、 Effective Time2三次孕育Three Batches Of Inoculation being Used232J3:可澆注時間Pourable Time過長Too Long孕育衰退Inoculation Fading6型廢多Too Many Scrap Molds3報警裝置Alarm device118設(shè)備故障Equipment Breakdown2報警裝置Alarm device112J4:澆試塊Pouring Test Specimen品質(zhì)不良Poor Quality材質(zhì)判斷不準(zhǔn)Material Deciding Inexactly7取樣時間不正確Improper Time

19、For Making Sample2結(jié)合破壞性檢查判定Judgement By Destroying inspection11460落砂ShakeoutL1:堆積Heaping過多Too Many壓壞鑄件Product Damage7鑄件卡住Castings Jammed2隨時鉤出被卡住的鑄件Taking Out Jammed Castings Timely22870清理CleaningL2:去澆口Remov-ing Gates殘余過長Remains Too Much余量過大 too much stock4失誤miscarriage2100% visual inspection目測216缺肉I

20、usuffici-ent Metal不被加工will not machine4失誤miscarriage2100% visual inspection目測216S:表面粗糙度Surface Finish太粗糙Too rough加工問題machine problems6鋼丸不足lack of Steel Grit2首檢Initial Inspection112Q5:毛坯清整Casting Finishing缺肉Iusufficient Metal鑄件報廢casting be scrapped6失誤miscarriage2100% visual inspection目測112不足Insuffici

21、ency多肉Surplus Metal4失誤miscarriage2100% visual inspection目測216Q6: 飛邊殘余joint flash remains過長too long鑄件不合格Unqualified Products未磨到位grinding not to position100% visual inspection目測Q7: 定位點pick up point不平整accident-ed影響加工affect machining缺陷或清理損傷defect or cleaning damage100% visual inspection目測80鑄件檢查Inspectio

22、nH1:力學(xué)性能Mechanics performance錯判Wrong Decision不合格品出廠Unqualified Products8*操作技能差Poor Skill Of Operator2試驗報告experiment report232H7:金相Microstructure錯判Wrong Decision不合格品出廠Unqualified Products8*技能差Poor Skill Of Operator2檢驗報告Inspection report232H2:外觀判定Surface Check漏檢Failing To Inspection不合格品出廠Unqualified P

23、roducts8*技能差Poor Skill Of Operator2目視全檢Full Visual Inspection232錯判Wrong Decision內(nèi)廢率高High Internal Scrap Rate6技能差Poor Skill Of Operator1目視全檢Full Visual Inspection212H3:標(biāo)識狀態(tài)Status of Identification標(biāo)識不清indistinct identification鑄件報廢casting be scrapped8*起模不良 withdrawing difficult2目視全檢Full Visual Inspection116H6:全尺寸檢查Full dimension inspection超出鑄件尺寸公差overtop castings tolerances鑄件報廢casting be scrapped8*模具磨損mould abrasion2定檢模具Regular Inspection mould116H8：關(guān)鍵尺寸key dimension超出鑄件尺寸公差overtop castings tolerances鑄件報廢casting be scrapped8*模具磨損mouldabrasion2定檢模具Regular Inspection mould116H9:壁厚Wall thi