Process FMEA在白车身制造工艺中的创新应用

Innovative Application of Process FMEA During Body in White Manufacturing

在汽车白车身制造过程中,焊接、涂胶、防错、包边都存在不同的失效模式,这就导致白车身制造过程中任何一项工艺都存在一定的质量风险。因此,白车身制造工程师应用PFMEA(Process Failure Mode and Effect Analysis)这一质量工具来识别工艺风险并采取有效措施降低风险。为了描述PFMEA在项目不同阶段和不同功能块之间的传递,将PFMEA文件进行分级:模板级、项目级和工厂级。PFMEA小组负责开发模板级,制造工程师基于模板开发项目级PFMEA,然后由车间工程师开发工厂级PFMEA,用于生产管控制造风险。工厂级PFMEA也随着生产制造不断演变更新,通过总结以往的经验教训,促进PFMEA模板更新,从而形成一个不断更新进步的闭环过程。此外,创新性地探索Design FMEA与Process FMEA的互联开发,从产品设计源头挖掘潜在质量缺陷,进一步地提高白车身制造过程中的质量风险管控能力。

During body in white manufacturing,there are different failure modes while welding,coating,errorproofing,hemming etc.All those processes have risks to threaten every step of body in white manufacturing.Therefore,manufacturing engineers have to apply one quality tool—PFMEA(Process Failure Mode and Effect Analysis)to identify process risk and take effective measures to reduce risk.To ensure that PFMEA documents are distributed at different timing of projects and different departments,PFMEA files are divided into 3 levels:template,project and factory level.The PFMEA team is responsible for developing template PFMEA,based on which manufacturing engineers develop project level PFMEA.After that,workshop engineers will finish factory level PFMEA for production control of manufacturing risks.Factory level PFMEA is also continuously updated during motor manufacturing,and feedback to update template PFMEA by summarizing past experience.Therefore this procedure is gradually formed as a closed-loop and continuous update development of PFMEA.In addition this paper innovatively explores the combination of Design FMEA and Process FMEA,which helps investigate potential failure modes from product design source,and further improves the quality risk control ability in the manufacturing of body in white.