最新第五版FMEA模板-AP值自动计算(带实际案例).xls

最新第五版FMEA模板-AP值自动计算(带实际案例).xls

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FAILUREMODEANDEFFECTSANALYSIS失效模式及后果分析范围定义：

确认项目结构分析功能分析产品、元素或过程的系统结构产品或过程的功能概述系统（项目）系统要素/相关接口零部件要素（项目/接口）系统的功能，要求及预期输出系统要素的功能，要求及预期输出胶壳外形CPK支撑，定位，保护背光；组装、保护客户LCD决定产品形状外形尺寸支撑，定位，保护背光；组装、保护客户LCD决定产品形状结构外观支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构LCD沉槽支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构水口避让位支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构凸包支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构凸包支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构排气槽支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构胶壳壁支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构胶壳壁支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构灯槽位支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构镶螺母牙孔支撑，定位，保护背光；组装、保护客户LCD利于配套，注塑所需，符合图纸结构镶螺母牙孔支撑，定位，保护背光；组装、保护客户LCD定位，配套，客用结构镶螺母牙孔支撑，定位，保护背光；组装、保护客户LCD定位，配套，客用失效分析建立失效链（针对每一个产品或过程功能，分析潜在失效后果,失效模式,失效原因）零部件的功能，要求，预期输出及特性失效影响严重度失效模式确保生产稳定影响制程能力7CPK不达标确保装配合格与其他零件干涉，无法正常组装8尺寸超差符合图纸影响装配，影响外观8外形不符，无标示字符，不清晰，或错误定位保护LCD与LCD干涉，无法正常组装7LCD沉槽四角避空位做偏确保内部配套合格导光板装配干涉5胶壳槽与导光板水口位不匹配配套铁框扣位防脱离组装胶壳干涉异物隐患7凸包不合理，与铁框组装掉屑配套铁框扣位防松脱胶壳与铁框松脱8凸包不合理，与铁框配套脱离解决困气影响产品效果6下胶壳内部排气槽凸起顶起反光膜FAILUREMODEANDEFFECTSANALYSIS失效模式及后果分析配套铁框，配套客户模组铁框，模组松脱，可靠性不良。

7中胶壳整体外扒、挡墙边外扒，通框胶壳外扒配套铁框，配套客户模组影响尺寸精度和配套性能6脱模斜度过大灯条放置位影响配套7灯槽位倒角过大客户使用螺丝打不进去8螺丝孔不符合图纸无毛刺影响打螺丝6镶螺母牙孔毛刺不良无滑牙螺丝打滑8镶螺母牙孔滑牙失效原因工艺参数不合理注塑设备选择不合理原料问题测量误差1.多件组合件的配套尺寸多，管控位置多，造成不达标2.测量误差3.柱子勾子无加强筋，垂直度不够。

4.模具精度不足1.2D或3D零件图纸与客户成品图纸不符合。

2.模具结构设计失误1.模具精度影响2.未按照图纸制作1.导光板水口位置不平整2.设计不合理1.配套过紧，凸包位置太靠边角，塑胶与铁框组装困难2.设计不合理，凸包凸出高度太大3.铁框毛刺方向设计不合理1.铁框和胶壳间隙设计太大，导致凸包扣合量过小2.凸包高度设计过小3.凸包的方向做反了排气槽实际制作出来效果不好，产生的飞边，毛刺顶起反光膜FAILUREMODEANDEFFECTSANALYSIS失效模式及后果分析失效分析建立失效链（针对每一个产品或过程功能，分析潜在失效后果,失效模式,失效原因）设计不合理，挡墙壁厚不均、产品大壁厚过薄（0.5以下）、中间有开到底的缺口、缩水槽设计不合理等均会存在不同程度的变形外扒现象塑胶为满足成型脱模斜度设计过大塑件形状复杂，壁厚较厚，收缩率较大，相对应的加大了脱模斜度设计不合理，灯与灯槽位间隙小，导致倒角后组装干涉未按照图纸制作来料不良（攻牙丝攻异常）1.本身来料不良2.螺丝止规不止3.牙径偏小强度不够4.扭矩过大启动准备工作：

项目计划，分析边界，经验教训，结构基础，分析步骤风险评估识别针对失效原因和失效模式的控制方法现行预防控制发生度1.规范尺寸公差滿足CPK的能力标准，前期与客户定出合理标准；2.与供方讨论达成方案，监督供方规范达成标准；3.同客户沟通CPK调整所需時間（首次较难满足）；4.组合尺寸分解分级管控51.按规范合理评估尺寸公差2.规范测试规范和手法，做到供方、我司、客户统一特殊结构前期与客户统一量测方法3.薄弱结构设计考量增加强度，如柱子，勾子可适当加加强筋、倒角4.公差精度要求较严的产品，申请延长修模调整时间71.3D图导出2D零件图后与成品图一一对应检查2.执行模具设计点检31.按规范设定沉槽的形状及定位尺寸公差31.按规范设计水口大小及位置2.规范导光板的水口凸出量31.按规范设计胶壳与铁框的配套间隙、凸包位置间隙、凸出高度、公差2.凸包外形倒角处理，铁框与塑胶结合面、卡扣处倒角设计41.按规范设计胶壳与铁框的配套间隙、凸包间隙、凸出量大小、公差2.计算凸包高度合适值，确保胶壳和铁框扣合量足够3.铁框做内撕扣设计51.厚度允许下搭采用厚的反光膜2.把排气槽设计在背面，排气槽的设计注意间隙，深度以及位置的选择。

4FAILUREMODEANDEFFECTSANALYSIS失效模式及后果分析1.设计防外扒结构（中胶壳长窄边增加一个避空槽，对应下铝框增加凸台插入中胶壳）2.设计避免在胶壳挡墙中间增加缺口3.挡墙根部缩水槽不可过深至胶为太薄4.薄弱结构侧壁贴胶固定71.外形及内槽规范拔模斜度2.做斜顶或者行位出模3.选用收缩率较小的材料，减小壁厚4.结构优化（在不影响装配的情况下转角位倒角、骨位倒角）5.塑胶螺牙孔拔模斜度按0.5设计61.按规范设计，灯槽与led间隙0.2mmmin.6零件图螺牙规格标识要清晰5监督供应商改善，规范来料检验61.在不影响装配的情况下，适当和客户沟通减小扭矩标准，规范扭矩标准2让供方提供韧性更好的材质螺母3.至少保证45圈牙30改进措施确认减少风险的必要措施现行探测控制探测度AP筛选符号预防措施探测措施依设计点检规范点检4M1.依设计点检规范点检2.尺寸公差配套计算2M依设计点检规范点检样件确认3M组装图模拟配套检查样件确认3M组装图模拟配套检查样件确认4L依设计点检规范点检样件确认3M依据设计规范点检间隙，装配铁框检查2M样件确认手触感应有无披锋2M风险评估识别针对失效原因和失效模式的控制方法1.依设计点检规范点检结构2.样件确认（尺寸测量目视观察配套检测）2M1.根据高度合理评估拔模斜度大小，测量头部，根部尺寸检测是否OK3M组装图模拟配套检查样件确认3M1.依设计点检表点检2.样件确认（尺寸测试，通止规检查）3M螺牙自动全检二次元或高清显微镜下观察4M样件扭力测试4M责任人计划完成时间状态：

开放状态完成状态取消状态改进措施描述实际完成时间严重度发生度探测度12345123改进措施确认减少风险的必要措施列复制：

AC列BI列FMEA分险评估评价评级评价评级对照评级APAPS+OS+OS+DS+OSO+SD1.2.3H.M.LL7-517-431-32M未评价完整8-718-231-32ML8-328-332-32M7-327-332-32M5-335-433-33L7-417-331-32M8-518-231-32M6-426-232-32M7-717-231-32M6-616-331-32M7-617-331-32M8-518-331-32M6-616-431-32M8-328-432-32M-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-0#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-#N/A-#N/A#N/A#N/A#N/A-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S+O评价评级评价评级对照评级AP严重探测对照评级S+OS+OS+DS+OSO+SD1.2.3H.M.LSOS+OSO1-231-333-33L111-134-524-#N/A#N/A#N/A#N/A121-231-231-333-33L131-33-#N/A-#N/A#N/A#N/A#N/A141-43-#N/A-#N/A#N/A#N/A#N/A151-53-#N/A-#N/A#N/A#N/A#N/A161-63-#N/A-#N/A#N/A#N/A#N/A171-73-#N/A-#N/A#N/A#N/A#N/A181-83-#N/A-#N/A#N/A#N/A#N/A191-93-#N/A-#N/A#N/A#N/A#N/A1101-103-#N/A-#N/A#N/A#N/A#N/A212-13-#N/A-#N/A#N/A#N/A#N/A222-23-#N/A-#N/A#N/A#N/A#N/A232-33-#N/A-#N/A#N/A#N/A#N/A242-43-#N/A-#N/A#N/A#N/A#N/A252-53-#N/A-#N/A#N/A#N/A#N/A262-62-#N/A-#N/A#N/A#N/A#N/A272-72-#N/A-#N/A#N/A#N/A#N/A282-82-#N/A-#N/A#N/A#N/A#N/A292-91-#N/A-#N/A#N/A#N/A#N/A2102