资料丨实用的PFMEA现场问题确认表！
| 1.Attempt to build a bad part尝试各种方法制造不良品 | |
| 1-1 | Building a bad part has been attempted by the cross function team at the gemba. 跨功能小组已经在现场尝试了各种方法制造不良的产品。 |
| 1-2 | Part orientation of any feature of sub-component is controlled if required.(wrong orientation,upside down,backwards,indexed,inside out,radially,positional) 如需要，任何零件的方向都已经被有效的控制(错误的方向，上下放反，前后放反，顺序防错，内外放反，放射状的，位置放错)。 |
| 1-3 | Part is rejected if process is not fully performed. 如果整个生产过程没有完全执行，产品会被拒收。 |
| 1-4 | Proper shielding is in place to prevent foreign objects from entering assembly during process. 整个过程有合适的保护，以防止异物进入生产过程。 |
| 1-5 | Control are in place so that limits can not be set outside of specif cation. 工程中有控制可以防止错误的设置限度(与图纸、规格要求不符)。 |
| 1-6 | What happens if motion does not occur? 如果动作没有发生会有什么问题发生? |
| 1-7 | What happens if motion is incomplete or short/long? 如果动作没有完全，或者动作或长或短，会有什么问题发生? |
| 1-8 | What happens if motion exceeds normal travel? 如果动作超出了正常的形成，会有什么问题发生? |
| 1-9 | What happens if motion is too fast/slow? 如果动作太快或者太慢，会有什么问题发生? |
| 1-10 | What happens if force/torque is too low/high? 如果扭矩太高或者太低，会有什么问题发生? |
| 1-11 | What happens if part sticks to moving machine component? 如果产品粘在移动的设备上，会有什么问题发生? |
| 1-12 | What happens if too much/little lubricant is present at process? 如果过程现场有太多或者太少的润滑剂，会有什么问题发生? |
| 1-13 | What happens if fail to detect a bad part? 如果工站没有发现不良品，会有什么问题发生? |
| 1-14 | What happens if fails to accept a good part? 如果工站不能识别良品，会有什么问题发生? |
| 1-15 | What happens if equipment is not calibrated/verifed properly? 如果仪器没有校验或者适当的验证，会有什么问题发生? |
| 1-16 | What happens if part is dropped? 如果产品掉落，会有什么问题发生? |
| 1-17 | What happens if part skips operations? 如果一个生产过程遗漏，会有什么问题发生? |
| 1-18 | What happens if part is processed more than once? 如果相同的过程重复超过一次，会有什么问题发生? |
| 1-19 | What happens if nonconforming part is not contained? 如果不合格品没有被合适的围堵，会有什么问题发生? |
| 1-20 | What happens if part is not seated? 如果产品没有放置到位，会有什么问题发生? |
| 1-21 | What happens if part or componenet is missing? 如果过程缺一个零件，会有什么问题发生? |
| 1-22 | What happens if more than required quantity installed? 如果多安装了某个零件，会有什么问题发生? |
| 1-23 | What happens if a wrong/similar part is installed(e.g.similar fastner,nut etc) 如果安装了一个错误的或者类似的零件，会有什么问题发生(如： 类似的螺钉，螺母等)? |
| 1-24 | What happens if RPM is too high/low(inertia weld) ? 如果转速过快或者过慢(惯性焊)，会有什么问题发生? |
| 1-25 | What happens if pressure is too high/low(inertia weld) ? 如果压力过高或者过低(惯性焊)，会有什么问题发生? |
| 1-26 | What happens if shield gas flow is too high/low? 如果保护气体的流速过快或者过慢，会有什么问题发生? |
| 1-27 | What happens if weld is misaligned? 如果焊接未对齐，会有什么问题发生? |
| 1-28 | What happens if weld time is too long/short? 如果焊接时间过长或者过短，会有什么问题发生? |
| 1-29 | What happens if weld current is too high or low? 如果焊接电流过高或者过低，会有什么问题发生? |
| 1-30 | What happens if crimp/rivet is too deep/shallow? 如果铆接太深或者太浅，会有什么问题发生? |
| 1-31 | What happens if crimp/riviet is misaligned? 如果铆接没有对齐，会有什么问题发生? |
| 1-32 | What happens if a crimp/riviet segment breaks? 如果铆接片破损，会有什么问题发生? |
| 1-33 | What happens if process parameters are incorrect(jaws,pressure,voltage,current,etc) 如果过程参数不正确，会有什么问题发生(夹具，压力，电压，电流等)? |
| 1-34 | Any other method tried to attempt a bad part? 是否还尝试了用其他的方法试图制造不良品? |
| 2.Process Control过程控制 | |
| 2-1 | All CC/SC from PFMEA have a Poka-Yoke confirmed by sensor change of state or MVP.所有在PFMEA中列出的CC/SC 均有防错控制?该防错用感应器或者MVP确认过? |
| 2-2 | If the CC/SCs have no Poka-Yoke,SPC or 100% detection are used to control CC/SCs.All WI&implemented record is observed by the cross function team. 如果CC/SC没有用防错控制,是否使用SPC或者100%检测控制?审核小组确认所有的工作指导和相关记录均存在? |
| 2-3 | All product contamination is prevented(e.g.oil,grease,jewelry,foreign objects,fasteners). 所有的过程都能预防额外的产品污染(如： 油脂，首饰，异物，螺钉)? |
| 2-4 | What happens if chip/contamination is present at nest/part? 如果产品或者治具上有异物，会有什么问题发生? |
| 2-5 | Only authorized personnel can make machine programming change(all changes are locked out and functional). 只有被授权的人员才能够变更设备的程序/参数(所有的变更设备均有密码或者被锁住，并且确实有效)。 |
| 2-6 | Manual function of press machine is locked out from associates. 设备的手动功能是被禁止的。 |
| 2-7 | Limits on machines correspond to the limits on the drawing. 设备上设定的界限与图纸上设定的相一致。 |
| 2-8 | Critical adjustment are controlled. 关键参数的调整是受控的。 |
| 3.Sensor Verification感应器的验证 | |
| 3-1 | All sensors have change of state logic. 感应器的逻辑已被验证。 |
| 3-2 | All MVP parts are identfied to prevent mixing with production product. 所有的MVP均被清洗的表示， 以避免混入量产产品。 |
| 3-3 | All MVP parts are verified with the calibration or verification sticker. 所有的MVP产品均被校验过， 并且表面有校验标签。 |
| 3-4 | All MVP parts on the machine are listed in PFMEA&control plan. 所有生产线所使用的MVP产品均已列入PFMEA和控制计划中。 |
| 3-5 | Any MVP parts identifed in the PFMEA prevention or detection column are used on the machine. 所有PFMEA中预防或者探测措施中定义的MVP产品， 均被用于生产线。 |
| 3-6 | Variable output devices that are used to meet drawing dimensions are set up and verifed by a calibrated gage. 用于控制产品符合图纸尺寸的输出设备已经设置，并且用校验检具确认过。 |
| 3-7 | Calibration and verification sequence has been evaluated.The calibration pass and fail limits are set correctly. 校验和验证的顺序已经被评估了。 校验通过和失败的界限设置正确。 |
| 4.Change over/Handling 换线/搬运 | |
| 4-1 | Change out tooling can be detected by the tooling or machine(e.g.change over from left IC to right IC) . 模具的变更可以被设备和模具识别(如： 将左气帘换成右气帘)。 |
| 4-2 | P3 calls out to take verifcation samples for analysis to verify the process at shift start/adjustment on machines(e.g.weld samples,crimp diameters,LAT). P3文件在每班开机或者设备调试的时候规定了用样品来确认过程(如： 焊接样品，铆接直径， COP) |
| 4-3 | Man-it prevents processing product that is not on the bill of materials. 追溯性系统能够预防使用不在生产零件清单中的零件被使用。 |
| 4-4 | The bill of material matches the Man-it setup sheet. 生产零件清单和追溯性系统相一致。 |
| 4-5 | Mixed parts can be detected by tooling or machine. 混料的产品可以被设备和模具所探测出。 |
| 4-6 | Scrap containment process is followed. 报废品的围堵程序被遵守。 |
| 4-7 | Re-action plans are stated in the control plan. 控制计划中说明了反应计划。 |
| 4-8 | Re-action plans are stated in the WI. 工作指导书中说明了反应计划。 |
| 4-9 | There is no unapproved rework/repair. 过程中无不被认可的返工/返修。 |
| 5.Inspection检验 | |
| 5-1 | Parts wil not be damaged if checked multiple times(refer to control plan for number of cycles acceptable). 如果检查多次，产品不会被损坏(参考控制计划中规定的允许测试的次数)。 |
| 5-2 | Visual inspection is well defined in the WI with picture of acceptable conditions. 工作指导书中明确定义了如何进行外观检验，附图片说明可接受的状态。 |
| 5-3 | All controlled documents are released and followed. 所有受控文件都已经正式放行并被遵守。 |
| 6.Maintenance 维护 | |
| 6-1 | PM's are set up in the maintenance system. 维护系统中包含了预防性维护。 |
| 6-2 | All PM's listed in the prevention or detection column of the PFMEA are listed in the PM. 所有在PFMEA的探测和预防列中的预防性维护都已经被加入现场的维护系统。 |
| 6-3 | All PM has implementation record on gemba. 所有的预防性维护在现场都有相应的记录。 |
| 6-4 | What happens if contacting components are worn or damage? 如果接触面磨损或者损坏，会有什么问题发生？ |
| 6-5 | What happens if part or nest tooling is worn or broken? 如果产品或者nest tooling 磨损或者损坏，会有什么问题发生？ |
| 7.Traceability 追溯性 | |
| 7-1 | All component with go into the product have traceability. 所有使用在产品上的零件都可以被追溯。 |
| 8.Overview 总结 | |
| 8-1 | PEMEA is reviewed line by line by the cross function team at the gemba. 多功能小组在现场确认了PFMEA当中的每一条内容。 |
| 8-2 | All findings have been captured on the action register. 所有在现场发现的问题，都被列入了改善计划记录表中。 |
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