中圖分類號(hào):U461 收稿日期:2025-03-04 DOI: 10.19999/j.cnki.1004-0226.2025.05.028
Quality Improvement of Workshop Commissioning Based on FMEA Failure Analysis Method and Its Case Study
Yang Qian Zhang ZhaohuiQin Zeyu China Automotive Industry Engineering Co.,Ltd.,Tianjin 3oo113,China
Abstract:ThispaperfocusesontheapplicationofFMEA(Failure ModeandEfects Analysis)intheequipmentcommissioningof acertainautomobileworkshop.Throughtheanalysisofthefailure modesandconsequencesofequipmentsuchasfans,burers,and conveyingmachinery,theimplementationstepsofFMEAareelaboratedinetail,includingteamformation,dentificatiooffailure modes,risk assessment,formulationof improvement measures,andcontiuous monitoring.Theapplicationefectisemonstrated throughpracticalcases,indicatingthatFMEAcaneectivelyreducequipmentfailurerates,improvethecommissoningqualityand productionefficiencyoftheautomobileworkshop,andprovideaneectivereferencefortheeficientimplementatioofprojectcommissioning work.
Key words:FMEA failure analysis method;Automobile workshop;Equipment commissoning;Quality improvement
1前言
汽車車間的設(shè)備穩(wěn)定運(yùn)行對(duì)產(chǎn)品質(zhì)量和生產(chǎn)效率至關(guān)重要。風(fēng)機(jī)、燃燒機(jī)、輸送機(jī)等設(shè)備在某汽車車間生產(chǎn)工藝中扮演關(guān)鍵角色,其故障可能引發(fā)一系列問題[1-2]。FMEA失效分析法作為一種有效的風(fēng)險(xiǎn)評(píng)估工具,能夠幫助識(shí)別潛在失效風(fēng)險(xiǎn),對(duì)提高車間調(diào)試質(zhì)量具有重要意義。
2FMEA失效分析法概述
FMEA即失效模式與影響分析,通過系統(tǒng)地識(shí)別潛在失效模式、評(píng)估其后果嚴(yán)重程度、分析失效原因并確定風(fēng)險(xiǎn)優(yōu)先級(jí)。它對(duì)系統(tǒng)、子系統(tǒng)或零部件功能進(jìn)行分析,找出可能的失效模式,依據(jù)預(yù)先設(shè)定的標(biāo)準(zhǔn)對(duì)失效模式的嚴(yán)重程度(S)發(fā)生頻率 (o) 和探測(cè)度 (D) 打分,計(jì)算風(fēng)險(xiǎn)系數(shù) RPN=S×O×D ,進(jìn)而根據(jù)RPN值對(duì)失效模式排序,優(yōu)先處理高風(fēng)險(xiǎn)項(xiàng)目,以提升產(chǎn)品或過程的可靠性[3]。
3汽車車間設(shè)備調(diào)試常見問題及影響
3.1風(fēng)機(jī)故障
風(fēng)機(jī)用于維持噴漆環(huán)境通風(fēng),常見故障如電機(jī)故障、葉片損壞、風(fēng)量不足等。電機(jī)故障可致風(fēng)機(jī)停轉(zhuǎn),溫濕度控制失衡,使漆霧積聚,影響漆面質(zhì)量,增加返修率;葉片損壞會(huì)引起振動(dòng)和噪音增大,影響風(fēng)量風(fēng)壓,導(dǎo)致漆層厚度不均;風(fēng)量不足則無法有效排出漆霧,危害人員健康,污染設(shè)備和工件。
3.2燃燒機(jī)故障
燃燒機(jī)在某汽車車間用于烘干和空調(diào)加熱等,通過烘爐升溫給工件提供熱量,以及冬季給空調(diào)升溫進(jìn)而控制空調(diào)送風(fēng)的溫濕度,其失效模式多樣。常見的有燃燒不充分、點(diǎn)火失敗、火焰不穩(wěn)定等。燃燒不充分會(huì)導(dǎo)致工件烘干不完全,漆面固化不良,影響涂層的附著力和耐久性,降低產(chǎn)品質(zhì)量,增加次品率。……