制程失效模式及效应分析(PFMEA)表

喷涂制程

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

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): 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.

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)

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)

Final product damage. Damaged Packaging material 完成品受損 Customer dissatisfaction 損壞的包裝材料 客戶不滿

7

1)Improper material handling 1) 不適當既物料處理 2)Improper storage 2) 不適當既儲存 3)Wrong packaging material 3) 錯誤的包裝材料 4)No FIFO. 4)未有先入先出

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

7

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

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

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

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

7

Mould surface scratch mark 模具上有花痕

2

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

5

70

1500

Mould 模具

Flashes/parting line not smooth. 披鋒/合模線不平順

Apperance reject 外觀退貨 Customer dissatisfaction 客戶不滿

7

Mould edge (Parting line worn out) 模邊磨損

2

Polish part line of mould 改善模具PL

5

70

Wrong dimensions 尺寸不合格

Assembly reject 裝配不良 Customer dissatisfaction 客戶不滿

7

Wrong of tooling dimension 模具尺寸不合格

2

Modify mould dimension 修整模具尺寸

Sampling inspection by IPQA per control plan IPQA 抽樣檢查參照控制計划

4

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

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

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

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