Final product damage. Damaged Packaging material 完成品受損 損壞的包裝材料 Customer dissatisfaction 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
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
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
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)
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
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
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
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
制程失效模式及效應分析(PFMEA)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
Sampling inspection by IPQA per control plan IPQA 抽樣檢查參照控制計划
4
56
3050
High Moisture content in raw Pre drying of material. 3001M 焗乾膠料 3001M 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
Current Process Control 2009/08/20
Draft
文嘉偉 Ray Man 陳穩華 Daniel Tan 版本﹕ Rev.: 版本﹕ Rev.: A
H 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.
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: 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):
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
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
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
Apperance reject 外觀退貨 Customer dissatisfaction 客戶不滿
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
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)
5
70
Burn 膠
Apperance reject 燒 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 mouldinA)表
Apperance reject 外觀退貨 Customer dissatisfaction 客戶不滿 Less cooling time 冷卻時間不足 Mould cooing lines are blocked. 運水不通 Injection pressure less 注塑壓力不足 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