Incoming inspection procedures
- Purpose
Verify whether the quality of outsourcing materials and customer-supplied raw and auxiliary materials can meet the specified requirements to prevent the use and delivery of substandard products.
- Scope of application
Applicable to the inspection operations of the company's incoming raw and auxiliary materials, outsourcing parts, and outsourcing parts.
- Responsibilities
- Quality Department: Inspect all incoming materials, outsourced parts, and outsourced outsourced parts, notify relevant departments in time when defective products are found, and follow up the disposal methods and results;
- Warehouse Section: Responsible for the acceptance, temporary acceptance and storage of the raw materials and auxiliary materials provided by the customers, and notify the quality control department for timely inspection, so as to confirm and deal with the abnormal situation in time;
- Procurement Section: Dispose of unqualified incoming materials found and contact the supplier to take corrective measures.
- Engineering Development Section: Provide complete drawings for the quality of incoming materials.
- Relevant departments: review unqualified materials.
- definition
- Fatal Defect (CR): Defects that may cause life-threatening or unsafe conditions;
- Serious defects (MAJOR-major defects): defects that may cause malfunctions or reduce the original use functions;
- Minor defects (MINOR-Minor defects): defects that have no or only slight impact on the performance of the product;
- Sampling plan and AQL value:
Sampling standard: GB2828 general inspection level II
AQL acceptance level: CR severely bad=0, MA main bad=1.5, MI slightly bad=2.5.
Inspection conditions
The inspection is generally carried out under natural light on a sunny day or under the light intensity of 45W fluorescent lamp and lamp tube 1m away from the inspection table. Place the swatches or color samples or standard parts together with the object to be inspected, about 30cm-35cm away from the eyes, and the appearance inspection time is less than 3-5s is appropriate. If there is a dispute, the color light box can be judged by the standard light source (choose D65 light source). In addition, the inspector must have good eyesight and color recognition ability.
- Inspection method and judgment
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Internal calibration procedures
- Steel rule
- tape measure
- Electronic scale
- bench scale
- Vernier caliper
- micrometer
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Process inspection procedures
- Purpose: To inspect the entire production process, so as to detect and deal with unqualified products in time during product processing, and prevent the unqualified products from shifting order.
- Scope of application: It is suitable for the process inspection (first article inspection, patrol inspection) operation of each production link of the company.
- Term Definition
- First inspection: The inspection and confirmation process of the first few products produced before mass production (for starting, after repairing, changing colors, changing models, stopping for more than 24 hours, etc.).
- Inspection: In the manufacturing process, the process of inspection and confirmation of product quality in each production link.
- Sampling inspection: After the process product or finished product is completed, a certain number of samples are randomly selected from the product for inspection and confirmation.
- IPQC: Production process quality control.
- Responsibilities
- Engineering Development Section: Responsible for product research and development, design, and the issuance of corresponding drawings, BOM, production details, etc.
- PMC: Responsible for production planning and production material control.
- Production Department: According to PMC's production plan, it is responsible for the production of products and the handling of abnormalities in the manufacturing process.
- Quality Department: Responsible for the quality inspection and control process of all production links.
- Inspection sampling plan:
- Normal sampling standard: sampling every 4 hours, 20pcs fixed sampling every 4 hours in PU workshop, carpentry/backboard workshop, assembly line, nail cutting and corner cutting workshop, found that there are more than 2 general defects of MA or minor defects of MI When more than 3 or severe defects are found in CR, the 4-hour operation quantity must be fully inspected. When defects are found again during the full inspection, the production line needs to be stopped for rectification; PS workshop samples 3pcs per machine every 3 hours, and records 1pcs data;
- Job requirements
- Inspection basis: relevant drawings, samples, customer orders, appearance inspection standards, production schedules, process inspection standards, sampling plans, etc.
- Inspection method: visual inspection, measurement (caliper, tape measure, etc.), trial assembly, adhesion, etc.
- Inspection timing: color change, specification change, product change, shutdown for more than 24 hours, continuous production for 5 days
- First sample inspection
- Inspection content: material, model, specification, size, color, according to "Process Inspection Standards".
- Inspection basis: "Production Schedule", "Customer Order", samples, color swatches, "Process Flow Chart", "Inspection Standards", "Engineering Drawings", etc.
- Before mass production, each workshop of the production department will conduct an independent inspection of the first sample of the product. After the self-inspection is passed, the 3PCS product will be submitted to the IPQC for the first product confirmation.
- When IPQC confirms that the first sample is qualified according to the customer's sample or mass production sample, the production department can formally produce; if it is unqualified, IPQC will record all existing abnormal problems and fill in the "Product Confirmation Record Form" , IPQC informs the production department to re-produce the first piece, and then mass production can be performed after the IPQC confirms that it is qualified.
- The first piece must be signed on the product with the name of the person who made the first piece, the date of confirmation, and the status of the confirmation; and it must be placed in a place not far from the production place, and protected, as a sample for inspection.
- After completing the "Product First Piece Confirmation Record Form", it will be submitted to the quality team leader for review, and the quality manager will submit it to the clerk for filing after approval;
- The production department mass-produces based on the first sample.
- Process inspection
- Before mass production, IPQC needs to do a good job of re-inspection of the product quality of the upper process. If there are products with substandard quality, immediately notify the QC of the upper process and the workshop person in charge of the upper process to deal with it. If there are serious defects, improvement measures must be proposed. According to the "non-conforming product control procedures" implementation.
- IPQC must conduct inspections and random inspections of products based on inspection basis, inspect every process in the production workshop every 4 hours, and record the inspection results on the "First Inspection Day Report". When a non-conforming product is found, immediately notify the person in charge of the relevant responsible department to make improvement, and record the improvement result on the "First Inspection Day Report"; if it is serious, a "Corrective and Preventive Measures Processing Report" must be opened;
- In addition to the inspection of each process, IPQC also promptly conducts sampling inspections of each batch or pallet of products that have been completed to be transferred to the workshop, and confirm whether the product identification is correct, and fill in the "First Inspection Day Report" 》Feedback quality status.
- In the manufacturing process, when abnormal phenomena such as wrong materials, wrong knife type, wrong sample color plates, and serious unqualified are found, IPQC must immediately issue a "Corrective and Preventive Measures Processing Report" to deal with quality abnormalities that have occurred. The method is: IPQC fills in the "Corrective and Preventive Action Report", after the quality team leader review, execute the abnormal form to find the person in charge of the department/workshop to fill in the corresponding content, including cause analysis and corrective and preventive measures, and finally IPQC is responsible for follow-up The implementation effect of the corrective and preventive measures taken, and the case is closed.
- When an abnormality is found in each time period, it is necessary to track whether there is the same kind of problem in the previous time period, and if there is any, follow the "Non-conforming Product Control Procedure";
- If engineering drawing errors are found during the manufacturing process, material changes or structure needs to be modified, the "Corrective and Preventive Measures Processing Report" will be issued to the responsible department for correction in real time, and the "Corrective/Preventive Measures Control Procedures" will be implemented.
- Relevant documents are implemented in accordance with the "Records Control Procedures".
- Process inspection specifications and AQL judgment classification:
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Finished product inspection procedures
- Purpose: To control the quality of the finished products produced by the company before shipment, so as to achieve customer satisfaction.
- Scope: Suitable for the quality control of all products of our company before delivery.
- Rights and Responsibilities:
- QA: Responsible for the quality control and feedback of products when they are shipped;
- Warehouse Section: Responsible for product quality assurance during the handling and delivery process.
- Production Department: Responsible for the implementation of processing measures in the finished product inspection process.
- Sampling method
- Sampling standard: GB2828 general inspection level II.
- AQL acceptance level: CR severely bad = 0, MA main bad = 1.5, MI slightly bad = 2.5.
- Final product inspection
- After the product is packaged, it needs to be inspected by the quality department QA. The production department should place the products to be inspected in the area to be inspected, fill in the relevant information in the "Finished Product Storage Form", and notify the QA personnel to perform the inspection.
QA personnel should follow the product's "Shipment Inspection Standards", drawings, samples and other inspection specifications, in accordance with the GB/T2828.1-2003II AQL sampling level (refer to "Sampling Plan" for details), to determine the size and material of the product , Color specifications and quantity, etc., and record the inspection results in the "finished product inspection record sheet".
QA during the inspection process, if the inspection is qualified, it will notify the production department to enter the warehouse, and sign the "finished product warehousing list". If any unqualified phenomenon is found during the inspection process, a "Corrective and Preventive Measures Processing Report" must be issued to the responsible department to request improvement. Relevant personnel in the responsible department shall organize and analyze the causes of the defects, formulate corrective and preventive measures, and decide on their treatment methods. Fill out the measures and treatment methods in the "Corrective and Preventive Measures Processing Report" and reply to the Quality Department.
The abnormal tracking personnel of the quality department will track and verify the defects according to the content of the reply from the responsible department. Specific implementation of "corrective and preventive measures control procedures."
- When the finished product is put into the warehouse, the product is affected by various factors in the warehouse, and QA needs to re-inspect the outer packaging of the finished product according to the "Outgoing Inspection Standards" of the relevant product before shipment; It is found that the packaging does not meet the requirements and will affect the product and needs to be opened for inspection. The specific treatment shall be followed in accordance with 5.1.3 for the treatment found to be unqualified and 5.1.4. It can be shipped until there is no abnormality.
- The documents and records generated during the product inspection process are controlled in accordance with the "Document Control Procedures" and "Record Control Procedures". All inspection records must be submitted to the quality team leader and quality manager for approval.
- Finished product inspection specification
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