新产品试生产控制程序NewProductIntroductionTrialRunControlProcedurHiPWSHTIOPQ047V21讲解学习Word文件下载.docx

1、批准Approvals职位姓名签名PositionNameSignature1. 目标1. PURPOSE1.1 对新产品前期的注塑、喷涂、装配等的过程试验，调试及优化缩短新产品引进过程的周期，确保按时交货，并为新产品进入大批量生产制定优化工艺及程序。 1.1 Set up optimize process in Molding, Painting and Assembly to ensure delivery on time and shortest cycle time for new product introduction and ramp up.2. 范围2. SCOPE2.1 适用

2、于本公司所有试生产的通讯塑胶电子类产品2.1 Applicable to all wireless new plastic products.3. 职责3. RESPONSIBILITIES3.1 注塑负责公司制造或外来注塑模具的注塑过程3.1 Molding department is in charge of new product molding process.3.2 喷涂负责新产品喷涂移印过程3.2 Spray painting department is in charge of new product spray painting and pad printing process

3、.3.3 装配负责新产品装配过程3.3 Assembly department is in charge of new product assembling process.3.4 物流部负责提供试生产所需要的原辅材料 3.4 Logistic department is in charge of supplying all raw materials for trial run.3.5 物流部计划负责制定、下达试生产计划3.5 Logistic planning department is in charge of new product planning and issuing trial

4、 run plan.3.6 工艺工程师负责生产工艺的制定、调整3.6 Process engineer is in charge of setting and improving the process parameter and technology.3.7 注塑、喷涂、装配技术员负责按作业计划，根据工艺文件要求进行控制，并及时的掌握信息，反馈给制程工程师、质量部,并负责所使用的现场清洁,负责试生产产品的入库3.7 Molding/spray painting/assembly technician is in charge of operating according to trial r

5、un plan, controlling the process according to WI, providing the feedback/information to process engineer and QA in time, keeping the cleanliness of line and sending trial run products to store on time.3.8 质量部负责现场量具和检测设备的控制，检验并确认产品的质量 3.8 QA department is in charge of all measuring fixture, gages and

6、 testers and ensure product quality meet specification. 3.9工业工程设备人员负责提供适宜的设备，并对之进行保养、维护、检修。保障能源的供应，工业工程设计人员负责工装夹治具，包装材料方式等的设计及导入工作 3.9 IE department industrial engineer is in charge of providing and maintaining suitable equipment for produce and ensuring energy supply, design engineer in charge of j

7、ig/fixture/package designing and introducing.3.10 注塑、喷涂、装配部文员负责接物流部试生产计划，安排领料等试生产准备工作。3.10 Engineering clerk is in charge of receiving producing plan and preparing for trial run. 4. 定义4. DEFINITION4.1 PM：Project Management 4.2 ESI：Early Supplier Involvement 4.3 PE：Process Engineer for Molding/Spray

8、Painting/Assembly 4.4 IE：Industrial Engineering including Package Design/Equipment Plan 4.5 FOT：First of Trial Run 4.6 CPK Run：Index of Process Capability Run 4.7 EOL: End of Life 4.8 WI: Work Instruction4.9 特殊过程：Special Processa. 产品质量不能通过后续的监视或测量加以验证的工序；a. Product produced in the process cannot be

9、qualified by subsequent monitoring or testing method.b. 产品质量需要进行破坏性试验或采用复杂、昂贵的方法才能测量或只能进行间接监视的工作；b. Qualification of the product produced in the process be tested by destroying method or expensive test or indirect monitoring.c. 该工序产品仅在产品交付使用之后，不合格的质量特性才能暴露出来。c. Product produced in the process reveal

10、 the quality character only after be put in use.5. 作业标准5. STANDARD OPERATION PROCEDURE流程Flow程序 Procedure表单 Form相关部门 Related Dept.总则Principle根据客户要求，及时完成新产品的导入。According to customer requirement, complete new production on time供应商前期介入ESI PM提供新产品相关资料，包括产品图纸、材料表等。 PM provide related file about new produc

11、t including technical drawings, material form etc. PE、IE 进行过程成本及可行性分析，包括注塑、喷涂和装配过程。 PE/IE carry out the cost and feasibility analysis of molding/spray painting/assembly. PM组织新产品导入起动会议。 PM organize new product introduce kick off meeting.可行性评估表Feasibility report注塑生产估价表Molding CR喷涂生产估价表Spray painting C

12、R装配生产估价表Assembly CR项目部 PM dept. 工程部Engineering.新项目产品导入过程New Product introduction PM提供新产品的数据资料和新产品实施的计划表。 PM provide new product file and implement plan. PE、IE和PM进行新产品技术研究及计划实施讨论，包括相关工装治具、夹具、包装的设计、制程工艺技术检讨等。 PE/IE and PM discuss new product technology and implementing plan including jig/fixture/packa

13、ge design and process technology review. 对所做的设计方案进行内部检讨，审核及改进。 Engineering will review, check and improve the design. 提交设计方案给客户确认。 Submit the design to customer for confirmation. 如客户对提交的设计有更改要求时，则修改相应的设计方案，直至客户满意。 Revise the design until customer satisfied.Engineering dept.新产品首次运行测试FOT 物流部根据PM要求排定FO

14、T计划,确认相关机器、材料到位后，提前下达生产计划给工程部、质量部。 Logistic dept. arrange FOT plan according to PMs requirement, delivery the plan to engineering department and QA after confirmation of machine and material is ready. 注塑、喷涂、装配、质量部接到计划后，进行首次生产测试准备。领取首次生产测试资料，包括包材、原材料、客户图纸、原材料物性表、工装夹治具等。 After receiving FOT plan, Mold

15、ing/ spray painting/ assembly and QA prepare raw materials/ packages/ technical drawings/ BOM/ jig/ fixture etc for trial run. 首次生产测试进行，PE做出原始工艺参数、试模报告等。质量部根据客户要求做出品质控制计划、检验计划等。工程部生产出工程样品，客户样品（如有）及提样品给质量部进行首件检查。 Carry out the FOT, PE work out technical parameters/ mold test report etc. QA work out q

16、uality control plan and inspection plan according to customers requirement. Engineering department produce samples and submit to QA for inspection. QA inspect the set up samples and will refer to customer sample （if any）. 注塑，喷涂，装配部门生产中做好生产日报表。 Molding/ Spray painting/ Assembly departments take produ

17、ct record. 样品提交并记录、PE保留工程样品3模,其中1模提供给IE制定包装文件及相关资料。 Submit samples and record, PE keep 3 shots of samples, one of the shots is submitted to IE for setting up package document and related files. 质量部根据客户要求及检验计划做出首件检验报告、MFI报告及CAV报告等。 QA submit inspection report of first piece/ MFI report and CAV report

18、 etc according to customers requirement. . PE通过FOT做出WI、项目TRACKER，IE制定包装文件。 PE work out WI and project tracker according to FOT, IE work out packaging instruction document. 参照ECN/PCN或新产品再改进（如有）。 If there is ECN/PCN, follow according.（if any）加料记录注塑质量日报表装配生产跟踪记录表外观检测报告过程检验记录喷漆外观检验记录调漆记录喷漆记录喷枪设定记录包装文件Mo

19、lding Process Data SheetTrackerMaterial feeding recordMold test reportMolding quality daily reportAssembly track recordAppearance inspect reportProcess inspect recordSpray painting appearance inspect recordPaint mix recordPainting recordSpray gun set up recordpackaging instruction物流部项目部质量部Logistic D

20、ept.PMDEngineering DeptQA试生产Trial run 物流部根据PM要求排定试生产 计划,确认相关机器、材料到位后，提前下达生产计划给工程部、质量部。 Logistic dept. arrange trial run according to PMs requirement and deliver the plan to engineering department and QA after confirmation of machine and material is ready. 注塑、喷涂、装配、质量部接到计划后，进行试生产测试准备。领取试生产测试资料，包括包材、原

21、材料、原材料物性表、工装夹治具等。 After receiving Trial run plan, Molding/ spray painting/ assembly and QA get raw materials/ packaging material/Technical data sheet/ jig/ fixture etc for carrying out the trial run. 工程部技术员根据指导文件进行工艺设置及调整,生产出的首件样品送质量部确认OK后开始试生产，不合格及时反馈给工程部技术员. PE 和工程部技术员，进行重新调试。 Technicians set up a

22、nd adjust technical parameters according to WI. Start trial run after confirmation of set up samples by QA. If this set up sample fail, QA will review the process with PE and reproduce set up sample for confirmation. 将检查好的产品按照“塑件包装要求单”进行包装。 Qualified products pack according to Plastic Part Packaging

23、 instruction Sheet.特殊过程控制 Special process control 试生产过程中的注塑过程、喷漆过程、装配、焊接过程属于特殊过程。Including molding/ spray painting/ Assembly/Ultrasonic welding processes. 对特殊过程的控制参照相应的作业指导书。注塑过程参照“塑胶产品作业指导书”。喷漆过程参照“喷漆工程试样作业指导书”。装配过程参照“超声波焊接通用作业指导书”、“装配作业指导书”。For these special processes refer the corresponding WI. M

24、olding process refer to Plastic product WI; spay painting process refer to Spray painting trial run WI; assembly process refer to Ultrasonic welding general WI and Assembly WI. 试生产产品由质量部按照塑件类产品的监视和测量控制程序进行检验，检验合格后，注塑、喷涂、装配将试生产产品入库，所产生的不合格品按塑件类不合格品控制程序执行。产品的标识按照塑件类产品标识和可追溯性控制程序执行。 Trial run products

25、are inspected according to Plastic Product Monitor and Test Control Procedure and flow to warehouse if qualified. Unqualified products are dealt according to Unqualified Plastic Products Control Procedure. Product mark set up according to Plastic Product Mark and tracking Control Procedure. PE做出工艺参数

26、、试模报告，并保留工程样品3模、客户样品提交质量部。 PE work out technical parameters and mold test report and keep 3 shots of samples, samples for customer are submitted to QA. 试生产结束后，相关部门对试生产过程中发现的问题做出试生产反馈，项目部追踪问题的解决。 After trial run, related departments feedback problems found in trial run, PMD track until the problems a

27、re resolved. 试生产检验过程中发现的异常，按照纠正和预防措施控制程序执行。 If abnormal situations found during trial run, implement according to Rectify and Preventive Measures Control Procedure.装配产品试生产申请表塑件包装要求单喷漆工艺参数表 良率报告MOLDING TRIAL RUN REQUEST FORMSPRAY PAINTING TRIAL REQUEST FORMMolding Process Data Sheet Yield rate report

28、LogisticEngineeringCPK试生产CPK trial run 工程部在试生产过程中根据PM要求同时进行CPK测试。 Engineering carry out CPK trial run according to the requirement of PM during trial run. 注塑、喷涂、装配根据计划进行CPK测试，做出生产日报表，产品的标识按照塑件类产品标识和可追溯性控制程序执行。 Molding/ spray painting/ assembly department carry out CPK test, work out daily product re

29、port and set up product mark according to Plastic Product Mark and tracking Control Procedure. 质量部根据客户要求对生产产品CPK数据测试及收集，并做出CPK报告，FAI报告及MFI报告。 QA collect CPK test data and work out CPK report/ FAI report/ MFI report according to the requirements of customer. CPK测试产品经质量部确认OK后入库，所产生的不合格品按塑件类不合格品控制程序执行。 CPK trial run product is checked by QA, ok product is send to store , unqualified product is disposed according