Process/Product Failure Modes and Effects Analysis (PFMEA)
Steven,Alin,Amao,Agen,Zhangshu
Process or Product Name: ,Panchangxing,Gongweixiong,Lou
3125 Prepared by:Steven Page 1 of 1
shubin,Wukecheng,Zhaotaoshun,
Responsible: Dongtao FMEA Date (Rev) ______20170817_______ (Rev) ___A/0_____
S O D R S O D R
Process Key Process Potential Failure
Potential Failure Mode E Potential Causes C Current Controls E P Actions Recommended Resp. Actions Taken E C E P
Step Input Effects
V C T N V C T N
Poor design 10 Too sharp at all joints of mold 9 Product anlysis at Check mold and stress analysis, Aling
CC/PHT defect loss court meeting 6 540 then redesign the case by NPD 10 5 5 250
Mold design
Poor design 10 Hollow casting to soft body 9 none Check mold, modify if need Aling
CC defect 6 540 10 5 5 250
MOLD Making
corner in this location is short design experience modify working mould Aling
mould sharp PHT 10 10 10 1000 10 2 2 40
NO
dirty short operating experience no use clean clay to repair mould Aling
mould B 8 10 10 800 gap 8 2 1 16
No good slip properties for 10 Uneven raw materal quality 6 Random sampling Enelarge sample size Dongtao
Slip properties casting CC defect 6 360 10 4 5 200
Ball mill time continuous 10 The residue on the sieve of 6 NO Control the residue on the Dongtao 10 2 3 60
rise. quartz sand and potassium sieve at incoming quality
Raw material GJ feldspar are big. 10 600 inspection.
The pre-milling method 10 No pre milling potassium 8 NO Add pre milling for potassium Dongtao 10 2 2 40
cannot reduce the time of feldspar. feldspar, quartz sand and other
Milling ball mill. GJ 10 800 hard materials.
Slip procedure
Screen residue control can 10 Screen residue control range is 8 SOP Reduce the ccreen residue Dongtao 10 2 2 40
not effectively control the too big. control range.
Residue(325#) ball milling time. GJ 6 480
Viscosity change is too big 10 The weight of adhesive dose not 6 SOP To control with accurate Dongtao 10 2 2 40
Viscosity GJ fixed 7 420 weighing binder viscosity
Screen residue is small Specification range is too N/A Update specification to 0.5~1 Dongtao
Glaze Glaze residue GJ 10 small, can not adapt to the 9 10 900 10 9 3 270
current production needs
Too wet 8 Not dewatering and remove water 5 Dewatering 1 minutes Prolong dewater gongweixong
Mold condition Warpage defect 3 120 8 3 3 72
Too dryer 7 Not apply water on mold 4 Make SOP to show Dig loss mold and revise SOP gongweixong
CC defect where to apply where 3 84 7 3 3 63
slip can't be drained 10 draining angle is too small 10 no increase draining angle gongweixong 10 2 1 20
mould clearly LCC 10 1000
small CC in 10 corner in 14 location is too 8 no modify mould in 14 location gongweixong 10 3 3 90
mould LCD sharp 10 800
mould gap 8 loose lump is too wet 10 no prepare two sets of loose lump gongweixong 8 2 3 48
loose lump B 10 800
Too low 10 kiln exhaust recycle is not 6 Open AHU if meed Sealing door and channel to gongweixong
Low firmness enough 3 180 outside 10 4 3 120
Casting Temp
Too high 8 Near dryer and kiln 6 Apply water on gound Add exhaust fan gongweixong
CC 3 144 8 6 2 96
harden time is too short harden time is not change with SOP According mold life,adjust gongweixong
harden time CC 8 mold life 8 8 512 harden time by master caster 8 3 2 48
casting time is too short casting time is not change with SOP According mold life,adjust gongweixong
casting time CC 8 mold life 8 8 512 casting time by master caster 8 2 2 32
no method to measurement haven't measure gage no learn from master caster ; new gongweixong
procedure mold moisture CC 8 9 10 720 operator must be trained at 8 2 1 16
least one month
CASTING
operator cann't repair off some operator havenot enough no train and help operator via gongweixong
operator clay crack hidden in the CC 8 more experience 9 10 720 caster performance by HR & team 8 2 2 32
piece leader,master casters monthly
during stick up,can't no guide no according shop humidity,delay gongweixong
stick up monitor piece moisture CC 8 8 10 640 to cast rim 8 3 2 48
de-molding air pressure is high short operating experience no use standard air pressure gongweixong
procedure RCC 8 10 10 800 8 2 3 48
Poor skill 10 Lacking training 6 Master training Caster incentive policy and gongweixong
Caster CC/B 5 300 Wave II training 10 4 3 120
CASTING low slip pressure 8 Casting time is concentrative 10 no use enough slip supply pressure gongweixong 8 2 2 32
slip pressure PH 10 800
fast short operating experience reduce fillind speed gongweixong
filling speed PH 8 10 10 800 8 2 3 48
no
mould is old target of mould life is too high no change mould life from 80 times gongweixong
mould life RCC 8 10 10 800 to 70 times 8 1 2 16
clay is fall into well cleaning method is not good supply suitable tool to plug up gongweixong
cleaning method BDO 8 enough 10 10 800 well 8 3 3 72
no
not easy to find defect cleaning method is not good improve cleaning method gongweixong
cleaning method PH 8 8 10 640 8 3 3 72
no
operate join location no standard method set up standard method gongweixong
LCC 10 10 10 1000 10 3 2 60
procedure NO
light is dark low voltage heighten voltage gongweixong
light PH 8 10 10 1000 8 3 3 72
no
operate CC in flush hole not finding small CC no use light to check flush holes gongweixong
procedure PHT 10 10 10 1000 one by one 10 2 2 40
operate 03 location touch batt short operating experience set up standard method gongweixong
LW 10 10 10 1000 10 2 1 20
procedure no
operate flush holes is too small manual punch set up standard method gongweixong
procedure PFL 10 10 10 1000 10 1 1 10
n0
operate CC while punching disobey operating procedure training caster gongweixong
LCC 10 10 10 1000 10 1 2 20
procedure n0
operate join location short operating experience add new item to operating gongweixong
procedure LCC 10 10 10 1000 procedure 10 2 3 60
N0
twice clay cleaning 10 short operating experience 10 NO modify clean procedure gongweixong 10 3 3 90
clean procedure LCC 10 1000
can't monitor clay moisture program SOP Drying room procedure Mao
dryer % CC 8 3 3 72 management 8 1 1 8
Body moisture Uneven body moisture Temperature record and
content content, dry wet, lead to CC 10 No control drying time 9 N/A 10 900 management Mao 10 9 2 180
uneven shrinkage
Can't cleam out all small have not suitable tool no design a new specil tool to Mao
operator piece inside bowl BDU 5 4 10 200 help clean 5 2 2 20
Can't cleam out all small have not suitable tool no design a new specil tool to Mao
operator piece inside bowl BDU 5 4 10 200 help clean 5 2 2 20
WIP&Spray
holding method 11B location on truck no loadng method set loading method Mao
on truck LCC 10 10 10 1000 10 2 2 40
no
High temperature in the Temperature rise of glaze in Put the glaze on the cold area Mao
Glaze glaze GJ 10 summer 8 N/A 5 400 in order to reduce the 10 6 2 120
temperature of the glaze
Thickness is not uniform 10 Glazing pressure is out of Yes Measure the thickness Mao 10 2 2 40
Operator WG control 10 10 1000
Crazing and GJ GJ and Crazing Use dry sponge to Add TQC inspeciton before kiln Yao Gui quan
Operator GJ 10 9 wipe smooth glaze 5 450 10 6 3 180
support is too high wrong design support size no Gauge check Yao Gui quan
support WH 6 6 10 360 6 1 1 6
Kiln
Small wheels of kiln car is
Position fall into the groove, pull LPHT 10 Improper process of 6 NO 8 480 Add automatic line to transpot. Yao，Guiquan 10 2 2 40
up the car, easily damaged transpotation.
products
dirty in batt' hole dirty is difficult to find clean batt Yao,guiquan
batt KD 8 10 10 1000 8 2 3 48
no
Kiln Batt is not flat lose checking 400% checking Yao,guiquan
batt W 10 10 10 1000 10 2 2 40
YES
Piece stuck to batt bowl is too heavy brush Al2O3 on bowl bottom Yao,guiquan(
loading method LCD 10 10 10 1000 10 4 3 120
no
loading under chimney 8 dirt dropping from chimney 10 no change loading position Yao,guiquan 8 2 2 32
position KD&IO 10 800
Kiln car speed is too fast. 10 The gases in the preheating 5 SOP Controls the temperature of Aling 10 3 2 60
Program LGP section of body not fully 6 300 pre-heating section
release
wrong scrape method no standard method Yao,guiquan
foot scrape LWH 10 10 10 1000 set up standard method 10 1 1 10
no
