基于PFMEA分析法研究并解决了V80车型涂装过程中出现的B柱灰粒问题。首先,结合帕累托图分析了V80车型B柱涂装灰粒问题的影响范围与频次,确定国Ⅵ车型新增B柱尿素加注口小门涂装工艺是产生B柱灰粒异常问题的主要原因;其次,概述了新版FMEA的问题分析步骤与过程;然后,基于PFMEA七步法进行分析与研究,得到尿素口小门涂装中的一个工步为高优先行动级;接着,利用鱼骨图对高优先行动级项进行展开分析,选择最为有效的预防措施来应对风险项;最后,通过工装结构优化与工艺路径变更,将优先行动级从H降至L,基本解决了V80车型B柱灰粒问题,提升了产品的一次性涂装报交合格率,满足了公司精益生产的需要。

The problem of B-column ash particles problem in the painting process of V80 based on PFMEA analysis were studied and solved.Firstly,the influence range and frequency of ash particles in B-column painting of V80 model were analyzed with Pareto diagram,and it was determined that the main cause of abnormal B-column ash particles was the painting process of urea door of national VI model.Secondly,the analysis steps and process of the new version of FMEA were summarized.Thirdly,based on the seven-step method of PFMEA,it was concluded that one step in urea door painting was high priority action.Then,the fishbone diagram was used to analyze the high priority action level items,and the most effective preventive measures were selected to deal with the risk items.Finally,through the optimization of tooling structure and process path change,the priority action level was reduced from H to L,which basically solved the problem of the B-column ash particle of the V80-vehicle,and improved the qualified rate of the one-time coating,met the company's lean production needs.