摘要
化工产品的生产过程通常都经历复杂的反应机理,反应的进程受到多种因素的影
响,并且各种条件稍有偏差就有可能导致产品质量缺陷甚至工艺安全风险。因此对产
品生产条件和工艺过程的控制与管理是化工生产的核心课题之一。
本文的研究对象z公司,是世界领先的涂料树脂和交联剂制造商,所从事的辐射
固化树脂就是包含复杂化学反应的生产工艺。而在生产过程中,辐射固化产品本身有
容易意外聚合的特性,而这对安全稳定的生产带来极大挑战。历史上Z公司曾发生过
多起生产过程中的意外聚合事故,造成巨大的经济和商业信誉的损失。近几年的研究
发现,仅凭先进的技术条件还不能彻底消除缺陷,发生故障的原因涉及到质量管理的
方方面面。
因此2013年伊始,公司在全球范围内召集研发、生产、工艺和质量等各部门经验
丰富的技术人员组成课题组专门研究解决意外聚合,运用FMEA的方法找出问题发生的
主要原因并消除这些缺陷。在解决化工生产工艺过程中出现意外缺陷的问题时,通过
对人、机、料、法、环各质量因素的全面分析,找出Z公司现有系统下存在的人为失
误、设备故障、原料失效、抑制聚合方法失效和生产控制失效等几大突出问题。然后,
计对这些缺陷,本文从管理改善的角度总结出包括工艺变更管理、冗余设计、条码管
理、制成能力研宄和绩效考核等方法优化现有的体系,弥补工艺和技术的不足。通过
具体问题的研宄和解决,论证了 FMEA在企业分析和处理复杂管理问题时的重要作用。
关键词:辐射固化树脂;意外聚合;质量管理;过程FMEA;风险评估RPN

Abstract

The purpose of FMEA (Failure Mode and Effects Analysis) is to analyze the products

through their sub-system, spare parts or all of the detail process during the stage of product

design and process development, then to find the potential failure risk and the possible defects

so that we can improve the products quality and reliability with necessary corrective actions.

Our research will focus on company Z, who is a world leading manufacturer of Coating

Resins and Crosslink located in Belgium. Company Z established Radiation Curing (Radcure)

technology in 1990’s. Radcure Coatings is initiated by UV or Radiant point to efficiently cure

the mixture of Monomer and Oligomer. However, it's a big challenge to safely and stably

produce Radcure resins according to its easy gelation.

Due to the sophisticated mechanism of unexpected gelation during the production

process which is closely related with quality management, at the beginning of 2013,the

company launched a special project using FMEA methodology to investigate the root causes

and try to eliminate the defects of gelation with all kinds of experienced technical resources

including engineers from R&D, Process, manufacturing and Quality.

We are going to describe the general concept of FMEA, including the definition,

category, failure mode and detail implementation plan. Using FMEA methodology, we could

successfully solve the unexpected gelation during the Radcure resin production through

optimizing the process and quality management system. The application of this

process prevents the occurrence of the common and typical problems effectively. The success

application of the process has certain value of reference toward the other manufacturing

company.

Key words: Radcure Resins; Unexpected Gelation; Quality Management; p-FMEA; Risk

Analysis (RPN);