,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

潛在的失效模式及效應分析表POTENTIALFAILUREMODEANDEFFECTSANALYSIS,,,,,,,,,,,,,,,,,,

(過程PROCESSFMEA),,,,,,,,,,,,,,,,,,

項目名稱Item:,,,,,過程責任部門ProcessResponsibility:質量部QADept.,,,,,FMEA編號Number:,,,,,頁碼Page:,,,

硅膠加熱片類,,,,,關鍵日期KeyDate:2009.09.07,,,,,準備人PreparedBy:,,,,,,,,

主要參加人CoreTeam:QA部工程部Eng.Dept.,,,,,,,,,,FMEA日期Data(編制(orig):2010.01.25,,,,(修訂REV)：,,,,

"序號

NO.","過程功能要求

ProcessFunctionRequirements","潛在的失效模式

PotentialFailureMode","潛在的失效后果

PotentialEffect(S)ofFailure","嚴

重

度Sev","級

別Class","潛在的失效原因/機理

PotentialCause(s)/Mechanism(s)ofFailure","頻度

數Occ","現行過程預防控制

CurrentProcessControlsPrevention","現行過程檢測控制

CurrentProcessControlsDetection","難檢

度Det","風險優先指數

R.P.N.","建議的措施

Recommended

Action(S)",責任及目標完成日期Responsibility&TargetCompletionDate,措施結果Result,,,,

,,,,,,,,,,,,,,,"嚴重度

Sev",頻度數Occ,難檢度Det,風險優先指數R.P.N.

10,"原材料進廠

In-comingRawMaterial","原材料規格錯誤

Materialspeciswrong","影響零件性能

affectparts'capability",4,,"供應商送原材料的規格有錯

Thesuppliersendthewrongmaterial",1,"每批送貨供應商附上材質證明書

Thesuppliersubmitthequalitycertificationeveryshipping","收料員檢查送貨單

Materialreceivercheckdeliveringlist",9,36,NA,NA,,,,,

20,"IQC檢查

IQCInspection","尺寸檢測有誤差

measureerror","影響后續零件生產

affectpartsproductionnextprocess",3,,"供應商送原材料的規格有錯

Thesuppliersendthewrongmaterial",2,"送貨單標明材料尺寸規格

definetheSPEC.ofraw-materialinthediliveryBills","1.IQC按送貨單核對原材料規格表

IQCconfirmtheRawMaterialSpecListaccordingtothedeliveryorder.

2.IQC按原材料規格表檢查原材料尺寸規格,以每批2卷，每卷3個點檢查料厚

IQCcheckrawmaterialspecaccordingtotheRawMaterialSpecList,checkmaterial'sthicknessby3pointspercoil,2",8,48,NA,NA,,,,,

30,"移至原材料倉

MoveMaterialtoStore","材料轉移錯誤

mistaketherawmaterial","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前材料上貼來料管理票

setthelabelontheRaw-materialbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

40,"存放

Storage","材料生銹

rustofthematerial","影響后續零件生產

affectpartsproductionnextprocess",2,,"1.材料入庫、出庫凌亂。

2.放置周期過長。

1.Un-sequenceinandoutstore.

2.longtermstore",4,"按照程序要求，材料先進先出。

Fristinfirstout

",QC復查在庫re-checkthepartsinperiod.,8,64,NA,NA,,,,,

50,"移至生產線

MoveMaterial

toProductionLine","材料轉移錯誤

mistaketherawmaterial","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前材料上貼來料管理票

setthelabelontheRaw-materialbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

60,"P200T沖壓

P200TStamping","∮6.25±0.15

尺寸超差

isoutoftolerance",影響客戶裝配affectcustomerassembly,3,,"沖孔沖頭磨損

Thetoolingpunchwearsaway",2,"定期維護保養模具

maintainthedieperiodically","PQC用通止規抽檢

PQCcheckwithPingauge",8,48,NA,NA,,,,,

60,"P200T沖壓

P200TStamping","∮78±0.25

尺寸超差

isoutoftolerance","1.影響客戶使用。

2.后續磨削無法裝夾。

1.affectcustomerassembly

2.Cannotputinthefixture.",3,,"1.沖孔沖頭磨損

2.模具調試中，送料步距不對

1.Thetoolingpunchwearsaway

2.Non-conformingstampingstepinthetoolingadjustprocess.",2,"1.定期維護保養模具

2.隔離調模品，并要求操作工嚴格按照操作指導書操作。

1.maintainthedieperiodically

2.ContainthetoolingadjustpartsandaskoperatorsfollowtheWIintheproductionprocess.","PQC用卡尺抽檢

PQCcheckwithVernierCaliper",8,48,NA,NA,,,,,

,,"翻邊孔內徑過大或者橢圓

flangingholebiggerorsmaller","1.車削后導致32.549尺寸超差。

2.內孔車削后無法滿足粗糙度要求。

1.Cause32.549outofdiemension.

2.Causetheroughnessof32.549holeoutofdimension.",3,,"1.合模高度不對

2.送料步距不對

1.Non-conformingshutterheight.

2.Non-conformingstampingstep.",2,"1.現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

2.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","增加翻邊孔控制尺寸31.8最大并要求操作工按照此尺寸卡尺控制。

Addflangingholediameter31.8MaxandPQCcheckitwithverniercaliper.",8,48,NA,NA,,,,,

,,"翻邊高度過低

tallerorshorteroftheblangingheight.","導致車削和磨削后7尺寸超差。

Causedimension7outofSPEC.afterturningandgrinding.",3,,"合模高度不到位

Non-conformingshutterheight.",2,"1.現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

1.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","增加翻邊孔高度尺寸控制7.5+/-0.3并要求操作工按照此尺寸卡尺控制。

Addflangingholeheight7.5+/-0.3andPQCcheckitwithverniercaliper",8,48,NA,NA,,,,,

60,"P200T沖壓

P200TStamping","37尺寸超差

37outofdimension",影響客戶使用affectcustomerusing,3,,"1.合模高度不到位

2.來料較薄

1.Non-conformingshutterheight.

2.thinnerofthematerialthickness.",2,"1.現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

1.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.

","1.每卷材料上線時，檢查材料厚度

1.PQCCheckthethicknessofmaterialwheneverycoilused.",8,48,NA,NA,,,,,

,,"材料厚度超差

materialthicknessoutofdimension.","導致磨削后3.0+/-0.15尺寸超差。

Causethedimension3.0+/-0.15outofSPEC.aftergrinding.",3,,"來料厚度超差

thethicknessofraw-materialoutofSPEC.",2,"將來料厚度控制在3.25+/-0.05。

Setthethicknessofraw-material3.25+/-0.05。","每卷材料上線時，PQC檢查材料厚度

PQCCheckthethicknessofmaterialwheneverycoilused.",8,48,NA,NA,,,,,

,,"平面度超差

flatnessoutofdimension","1.導致磨削后的平面度超差。

2.導致磨削后的材料厚度超差。

1.Causetheflatnessafergrindingoutofdimension.

2.causethethicknessofthepartaftergrindingoutofdimension.",3,,"合模高度不到位

Non-conformingshutterheight.",2,"1.現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

1.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","增加沖壓過程中的平面度0.15控制并且要求QC抽檢。

AddflatnesscontrolinstampingprocessandPQCcheckitinperiod.",8,48,NA,NA,,,,,

60,"P200T沖壓

P200TStamping","翻邊孔與地面拐角過大

biggerradiusofthecrossingbetweentheflangingandtheflatness.","導致磨削后34.5MAX尺寸超差。

Cause34.5MAXaftergrindingoutofdimension.",3,,"合模高度不到位

Non-conformingshutterheight.",2,"1.現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

1.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","增加沖壓過程中的尺寸34.5控制并且要求QC抽檢。

Add34.5MAXcontrolinstampingprocessandPQCcheckitinperiod.",8,48,NA,NA,,,,,

,,毛刺過大largerburrs,"影響零件外觀及客戶使用

affectparts'appearanceandcustomers'usage",2,,"沖頭或凹模鑲塊磨損

punchanddieinsertwearsaway",4,"定期維護保養模具

maintainthedieperiodically","操作工目視檢查1pcs/15mins，PQC目視檢查4pcs/h

OperatorcheckwithE,1pcs/15mins,PQCcheckwithE,4pcs/h",8,64,NA,NA,,,,,

70,"半成品包裝

Packageinsemi-finishedproduct","包裝錯誤

Non-conformingpackaging","造成零件表面的壓傷。

Causethedentinthesurfaceofthepart.",3,,"包裝方式不明確

Unknownofthepackagingmethods.",2,"1.現場放置包裝指導書，并且要求操作工嚴格按照包裝指導書包裝。

1.SetthePIsiteandasktheoperatorsfollowitafterstamping.","傳送前PQC確認包裝正確后才可以傳送。

QCverifythepackagingbeforedelivery",8,48,NA,NA,,,,,

80,"移至半成品區

Movetosemi-finishedarea","零件轉移錯誤

mistakethepart","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前每卡板貼上傳送單核入庫單。

setthedeliverynotesandreceiptsnoteslabelontheRaw-materialbeforestorepallet.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

90,"存放

Storage","零件生銹

rustofthepart.","影響后續零件生產

affectpartsproductionnextprocess",3,,"1.材料入庫、出庫凌亂。

2.放置周期過長。

1.Un-sequenceinandoutstore.

2.longtermstore",2,"按照程序要求，材料先進先出。

Fristinfirstout

",QC復查在庫re-checkthepartsinperiod.,8,48,NA,NA,,,,,

100,"移至生產線

MoveMaterial

toProductionLine","材料轉移錯誤

mistaketherawmaterial","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前材料上貼來料管理票

setthelabelontheRaw-materialbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

110,"機加工

machining","∮32.549±0.012

尺寸超差isoutoftolerance",影響客戶裝配affectcustomerassembly,4,,"1.車刀磨損

2.零件裝夾不到位

1.Thelathetoolwearsaway

2.Non-confromingclampingarea",2,"1.定期維護保養車床

2.現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

1.maintainthelatheperiodically

2.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.

","PQC和操作工用氣動量儀抽檢

PQCandoperatorscheckwithAIRgauge",8,96,NA,NA,,,,,

,,"內孔粗糙度不良

Non-conformingoftheroughnessintheinnerhole.","1.影響客戶使用。

1.affectcustomerassembly",3,,"1.車刀磨損

1.Thelathetoolwearsaway",2,定期維護保養車床maintainthelatheperiodically,"PQC用粗糙度儀抽檢

PQCandoperatorscheckwithroughnessmachine.",8,48,NA,NA,,,,,

,,"材料厚度超差

materialthicknessoutofdimension.","導致磨削后3.0+/-0.15尺寸超差。

Causethedimension3.0+/-0.15outofSPEC.aftergrinding.",5,,"進刀量過大

longerofthefeeding.",1,"現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.","PQC用千分尺抽檢

PQCandoperatorscheckwithmicrometer.",8,40,NA,NA,,,,,

110,"機加工

machining",尺寸超差isoutoftolerance,影響客戶裝配affectcustomerassembly,4,,"1.車刀磨損

2.零件裝夾不到位

1.Thelathetoolwearsaway

2.Non-confromingclampingarea",2,"1.定期維護保養車床

2.現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

1.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.

2.maintainthelatheperiodically

","PQC和操作工用檢具抽檢。

PQCandoperatorscheckwithgauge",8,64,NA,NA,,,,,

,,尺寸超差isoutoftolerance,影響客戶裝配affectcustomerassembly,4,,"1.車刀磨損

2.零件裝夾不到位

1.Thelathetoolwearsaway

2.Non-confromingclampingarea",2,"1.定期維護保養車床

2.現場放置操作指導書，并且要求操作工嚴格按照操作指導書操作。

1.SettheWIsiteandasktheoperatorsfollowitintheproductionprocess.

2.maintainthelatheperiodically

","PQC和操作工用檢具抽檢。

PQCandoperatorscheckwithgauge",8,64,NA,NA,,,,,

120,"半成品包裝

Packageinsemi-finishedproduct","包裝錯誤

Non-conformingpackaging","造成零件表面的壓傷。

Causethedentinthesurfaceofthepart.",3,,"包裝方式不明確

Unknownofthepackagingmethods.",2,"1.現場放置包裝指導書，并且要求操作工嚴格按照包裝指導書包裝。

1.SetthePIsiteandasktheoperatorsfollowitafterstamping.","傳送前PQC確認包裝正確后才可以傳送。

QCverifythepackagingbeforedelivery",8,48,NA,NA,,,,,

130,"移至半成品區

Movetosemi-finishedarea","零件轉移錯誤

mistakethepart","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前每卡板貼上傳送單核入庫單。

setthedeliverynotesandreceiptsnoteslabelonthepalletbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

140,"存放

Storage","零件生銹

rustofthepart.","影響后續零件生產

affectpartsproductionnextprocess",3,,"1.材料入庫、出庫凌亂。

2.放置周期過長。

1.Un-sequenceinandoutstore.

2.longtermstore",2,"按照程序要求，材料先進先出。

Fristinfirstout

",QC復查在庫re-checkthepartsinperiod.,8,48,NA,NA,,,,,

150,"移至生產線

MoveMaterial

toProductionLine","材料轉移錯誤

mistaketherawmaterial","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前材料上貼來料管理票

setthelabelontheRaw-materialbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",4,24,NA,NA,,,,,

160,"倒角

chamfer","倒角大于0.5c

thechamfermorethan0.5","影響零件外觀

affectparts'appearance",2,,"倒角限位移動

thelimitaway",5,"定期維護保養機床

maintainthemachineperiodically","PQC用投影儀抽檢

PQCcheckwithprofileprojector.",3,30,NA,NA,,,,,

170,"半成品包裝

Packageinsemi-finishedproduct","包裝錯誤

Non-conformingpackaging","造成零件表面的壓傷。

Causethedentinthesurfaceofthepart.",2,,"包裝方式不明確

Unknownofthepackagingmethods.",3,"1.現場放置包裝指導書，并且要求操作工嚴格按照包裝指導書包裝。

1.SetthePIsiteandasktheoperatorsfollowitafterstamping.","傳送前PQC確認包裝正確后才可以傳送。

QCverifythepackagingbeforedelivery",4,24,NA,NA,,,,,

180,"移至半成品區

Movetosemi-finishedarea","零件轉移錯誤

mistakethepart","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前每卡板貼上傳送單核入庫單。

setthedeliverynotesandreceiptsnoteslabelonthepalletbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",4,24,NA,NA,,,,,

190,"存放

Storage","零件生銹

rustofthepart.","影響后續零件生產

affectpartsproductionnextprocess",3,,"1.材料入庫、出庫凌亂。

2.放置周期過長。

1.Un-sequenceinandoutstore.

2.longtermstore",4,"按照程序要求，材料先進先出。

Fristinfirstout

",QC復查在庫re-checkthepartsinperiod.,8,48,NA,NA,,,,,

200,"移至生產線

MoveMaterial

toProductionLine","材料轉移錯誤

mistaketherawmaterial","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前材料上貼來料管理票

setthelabelontheRaw-materialbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

210,"磨削

grinding","粗糙度超差

roughnessoftheflatoutofdimension.",影響客戶使用affectcustomerusing,3,,"砂輪硬度以及顆粒度不適合。

Non-conformingofthehardnessandparticlegrindingwheel.",2,"選擇合適的砂輪并將砂輪規格寫入操作指導書

ChooseconforminggrindingwheelandwriteitintoWI",生產前，QC和操作工檢查砂輪的規格。QCandoperatorschecktheSpec.ofthegrindingwheel.,8,48,NA,NA,,,,,

210,"磨削

grinding",outofdimension.,影響客戶使用affectcustomerusing,4,,"1.磨床磁力過大

2.磨床工作臺有異物

1.Biggermagneticforceofthegrindingmachine

2.Un-clearnoftheworkingflat.",2,"1.加工特殊的磨削夾具以減小磁力。

2.磨削前用切削液洗刷工作臺面。

1.Machiningspecialgrindinggaugetoreducethemagneticforce.

2.Clearntheworkingflatbeforeproduction.","QC對每盤的零件平面度進行抽檢

PQCcheckthesomesamplesofeveryplate.",8,96,NA,NA,,,,,

,,"3+/-0.15尺寸超差

3+/-0.15outofdimension",影響客戶使用affectcustomerusing,3,,"車削不到位

moreornoenoughgrinding",2,"1.現場放置包裝指導書，并且要求操作工嚴格按照包裝指導書包裝。

1.SetthePIsiteandasktheoperatorsfollowitafterstamping.","QC對每盤的零件進行抽檢

PQCcheckthesomesamplesofeveryplate.",8,48,NA,NA,,,,,

,,"7+/-0.3尺寸超差

7+/-0.3outofdimension",影響客戶使用affectcustomerusing,3,,"車削不到位

moreornoenoughgrinding",2,"1.現場放置包裝指導書，并且要求操作工嚴格按照包裝指導書包裝。

1.SetthePIsiteandasktheoperatorsfollowitafterstamping.","QC對每盤的零件進行抽檢

PQCcheckthesomesamplesofeveryplate.",8,48,NA,NA,,,,,

210,"磨削

grinding","34.5MAX尺寸超差。

34.5MAXoutofdimension",影響客戶使用affectcustomerusing,3,,"磨削不到位

noenoughgrinding",2,"1.現場放置包裝指導書，并且要求操作工嚴格按照包裝指導書包裝。

1.SetthePIsiteandasktheoperatorsfollowitafterstamping.","QC對每盤的零件進行抽檢

PQCcheckthesomesamplesofeveryplate.",8,48,NA,NA,,,,,

,,outofdimension,影響客戶使用affectcustomerusing,3,,"磨床工作臺有異物

Un-clearnoftheworkingflat.",2,"磨削前用切削液洗刷工作臺面。

Clearntheworkingflatbeforeproduction.","QC對每盤的零件進行抽檢

PQCcheckthesomesamplesofeveryplate.",8,48,NA,NA,,,,,

220,"半成品包裝

Packageinsemi-finishedproduct","包裝錯誤

Non-conformingpackaging","造成零件表面的壓傷。

Causethedentinthesurfaceofthepart.",3,,"包裝方式不明確

Unknownofthepackagingmethods.",2,"1.現場放置包裝指導書，并且要求操作工嚴格按照包裝指導書包裝。

1.SetthePIsiteandasktheoperatorsfollowit.","傳送前PQC確認包裝正確后才可以傳送。

QCverifythepackagingbeforedelivery",8,48,NA,NA,,,,,

230,"移至半成品區

Movetosemi-finishedarea","零件轉移錯誤

mistakethepart","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前每卡板貼上傳送單核入庫單。

setthedeliverynotesandreceiptsnoteslabelonthepalletbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

240,"外協清洗

cleanoutsource","零件表面未清洗干凈

uncleanofthepart",影響客戶使用affectcustomerusing,4,,"供應商對零件表面清潔度要求不明確

unknownofthesuppliertothecleanessrequiremnent.",3,"采購發圖紙給供應商

Purchasepublishthedrawingtosupplier","每批來料QC對清潔度進行檢測。

QCcheckthepartcleanessofeverylot.",8,96,NA,NA,,,,,

240,"外協清洗

cleanoutsource","零件表面有碰傷

dentinthesurfaceofthepart",影響客戶使用affectcustomerusing,2,,"包裝不合理

non-conformingpackaging",3,"與供應商溝通，制訂合理包裝方式。

CommunicatewithsupplierandmakerightPI.","每批來料QC對外觀和包裝進行檢測。

QCcheckthepartappearanceandpackagingofeverylot.",8,48,NA,NA,,,,,

230,"移至包裝區

Movepackagearea","零件轉移錯誤

mistakethepart","影響后續零件生產

affectpartsproductionnextprocess",3,,"材料標識不明確

Un-clearlabel",2,"入庫前每卡板貼上傳送單核入庫單。

setthedeliverynotesandreceiptsnoteslabelonthepalletbeforestore.","生產領料時，操作工和QC對材料進行確認

OperatorsandQCverifythematerialinproductionline.",8,48,NA,NA,,,,,

260,"包裝全檢

100%sortingandpackaging","零件外觀項目檢查有誤

appearancesortingerror",影響客戶使用affectcustomerusing,2,,"操作工對外觀要求不明確

unknownoftheoperatortotheappearancerequirement.",3,"1.現場放置全檢指導書，并且要求操作工嚴格按照全檢指導書全檢。

1.SettheInspectionInstructionsiteandasktheoperatorsfollowit.","QC對零件進行抽檢

QCcheckthepartwitheyes.",8,48,NA,NA,,,,,

260,"包裝全檢

100%sortingandpackaging","包裝有誤

non-conformingpackaging","造成零件外觀不良

causethenon-conformingofthepartappearance",3,,"操作工對包裝要求不明確

Un-knownoftheoperatorsthethepackaginginstruction.",2,"1.現場放置包裝指導書，并且要求操作工嚴格按照包裝指導書包裝。

1.SetthePackagingInstructionsiteandasktheoperat