制程失效模式及效应分析(PFMEA)表

Current Process Control 2009/08/20
Draft
文嘉偉 Ray Man 陳穩華 Daniel Tan 版本﹕ Rev.: 版本﹕ Rev.: A
Plating Plus Panyu Company Limited
跨部門小組: Team: Daniel Tan; Tang Wing Kin; Wang Jin Tao; Ray Man; Liu Hai Bin; Cheng Hua Tie; He Shi Han.
2
Display of process parameters instructions 展示注塑參數 Trained & Skilled operators to set machine 培訓操作員工調機 Preventive maintenance of Machine 預防性保養機器 mould design;add venting loacation 改善工模﹐增加排氣
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Mould surface scratch mark 模具上有花痕
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Polish mould 拋光模具
Training records 培訓記錄 100% visual inspection by operators 100%操作人員全檢 Training records 培訓記錄 100% visual inspection by operators 100%操作人員全檢 Sampling inspection by IPQA per control plan IPQA 抽樣檢查參照控制計划
2
Display of process parameters instructions 展示注塑參數 Trained & Skilled operators to set machine 培訓操作員工調機 Preventive maintenance of Machine 預防性保養機器
Training records 培訓記錄 100% visual inspection by operators 100%操作人員全檢 Sampling inspection by IPQA per control plan IPQA 抽樣檢查參照控制計划
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56
3050
Pre drying of 3001M 焗乾膠料 3001M
High Moisture content in raw material. 膠料濕度過高
Moulded part with void,bubble,silver streakes,delayering. 膠件有空隙, 膠泡 Coustomer dissatisfaction 客戶不滿
C l a s s
Potential Cause(s)/Mechanism(s) of failure
O c c (O)
Preventive
Detective
Recommended Action
Action Taken
(S)
(O)
(D)
1000
Incoming inspection of raw Material ABS(3001M) 原材料來料檢查 ABS(3001M)
Action Results D e t (D) R. P. N. Responsibility and Target Date R. P. N.
Operation Process function Potential Failure Mode No. requirement
S e Potential Effect(s) Of failure v (S)
3
1) Predrying mechanism is not working. 1) 焗乾機器壞掉 2) Predrying time & Temp not set as per MI 2)焗乾時間及溫度不是按作業指 示書 3) Unskilled operators. 3) 操作員工未有培訓
1
Display of predrying process instruction/process parameters. 於操作地方展示焗乾程序及指示 Trained and skilled operator. 培訓操作員工
4
72
Mould rust 模具生鏽
7
2
Routine maintenance of Mould 日常保養維修模具 Clean Mould before Molding 啤塑前清潔模具
Check Mould before assembly 模具師裝模前檢查
5
70
Mould Spot/Mould scratch 模點/模面刮花
制程失效模式及效應分析(PFMEA)表 制程失效模式及效應分析 表 Failure Mode and Effects Analysis(Process FMEA)
Prototype 样件
圖紙編號﹕ Print # : W10144038 產品名稱: 面框 Item: COVER-FRONT, FLAT, MYTG 產品電碼﹕ Product code: JWPU4091-PSS-FC
7
Less clamping tonnage. 鎖模力不足 Mould spotting is improper. 模具定位不合適 Injection pressure too high. 注塑力太大 Material feeding too much. 射膠量太多 Mould edge (Parting line worn out) 模邊磨損 melt temprature too high. 料溫太高
6
1)Variation in Polymerization process at material manufacturing end 1) 材料於塑化過程中出現偏差 2) MFR equipment error 2) MFR 機器偏差 Mould not clean. 模具不清潔 Water mark 模具有水痕
1
Proper Work Instruction of Handling & Storage of packaging material. 適當地處理及儲放的工作指引 Skill Operators. 已培訓的操作員
Sampling inspection by IQC IQC抽樣檢查 Sorting by operators 操作員工分類
5
70
Burn 燒膠
Apperance reject 外觀退貨 Customer dissatisfaction 客戶不滿
7
Injection speed high 射速太快 Venting no engough 排氣不良 Large capacity machine used for moulding 鎖模 力太大
Training records 培訓記錄 100% visual inspection by operators 100%操作人員全檢 Sampling inspection by IPQA per control plan IPQA 抽樣檢查參照控制計划
5
70
3100
Injection Molding 注塑 Flashes 披鋒 Apperance reject 外觀退貨 Customer dissatisfaction 客戶不滿
Resin Pre-drying time and temperature is controlled by injection. 注塑部控制焗料時間及溫度 Shiftwise perdrying process parameter recording 每班記錄局爐參數
6
18
Page 1 of 5
FM-PG-0201-01
3
COC with every batch of raw material. 每批原料要求COC Calibration of MFR equipment 檢查溶流指數的機器教正
COC cross checking at receving 來貨時核對COC MFI, Charpy impact and Rockwell hardness checking at receiving. 來貨時檢查溶流指數,沖擊及硬度
Pre-Launch 试生产
Production 生产
圖紙版本: Print Rev.: 過程責任: Process Responsibility: 產品編號﹕ Product No.: W10144091 關鍵日期: Key Date:
文件控制印章: Control Stamp: H 編號﹕ Doc. No.: 編寫人: Prepare by: 審批人﹕ Approved by: 日期（初稿): Date(Orig): 日期（修訂）﹕ Date(Rev):
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49
Processing Difficulty MFR & Other properties not 生產過程困難 as per specification Functional Problem 不能符合熔流指數及其他特性 shrinkage vary 與標準 功能性的問題 , 縮水不一致 Cause part Visual problem 影響產品外觀 Mould reject 模具退回 Apperance reject 外觀退貨 Customer dissatisfaction 客戶不滿
Sink Marks 縮水
7
2
5
70
Short shot 走膠不齊
Apperance reject 外觀退貨 Customer dissatisfaction 客戶不滿
7
Injection speed is too slow 射速太慢 Injection perssure less 注塑壓力不足 Melt temprature low 料溫太低