PMP制程管理簡(jiǎn)介課件

Processmanagementplan

產(chǎn)品制程穩(wěn)定性品質(zhì)保證

Preparedby:QSMCSQERickMiaoNov242003revision01---ProductProcessStablizationQualityAssuranceProcessmanagementplan--NewprojecttransfercreatedbyPEteam.由PE小組制定的新項(xiàng)目移轉(zhuǎn)MassproductionPMPupdatebasedonissueandcustomerrequirement.量產(chǎn)機(jī)種因異常和客戶要求而進(jìn)行的PMP更新QA,JQEandauditteamtoauditprocessreferencePMP.QA.JQE與稽核人員稽核制程之依據(jù)PMPcoverfromIQCtoOQCoverallprocess.PMP涵蓋到從進(jìn)料檢驗(yàn)到出貨檢驗(yàn)的全部制程PMPgenerallytodriveprocessandQAsystemtocontrolcriticalstationwithkeyparameter.PMP通常用以推動(dòng)製程和品質(zhì)保證系統(tǒng)使用相關(guān)的關(guān)鍵參數(shù)管控重要站別

PMPupdateguideline.---PMP修改準(zhǔn)則

Preventiveactiontake.採(cǎi)取新的預(yù)防措施

Systemimprovement.系統(tǒng)得到改進(jìn)

Lessonlearnreview.所獲得經(jīng)驗(yàn)的回顧

QCandProcesscontrolenhancement.品管和製程控制得到加強(qiáng)

PMPfunctionandcontrolPMP功能與管制

NewprojecttransfercreatedbPPAPProductionPartApprovalProcess零/部件承認(rèn)程序PPAP零/部件承認(rèn)程序NewprojectPMPcreationAPQPteamPPAPteamPPAPleaderapproved

Defineprocessroadmap(PEhost)>QAqualityconcern.>CustomerRDdesignfunctionconcern>PEprocesscontrolconcernInputOutputQualitycontrolProcesscontrolfailPFMEAcreation(PEworkwithRD)

STandPTTrailrunreport-qualityyieldrate-issuehighlight

PMPcreation-PFMEAand-Roadmap-Customercontrolconcern.-Lessonlearn.(QTbuilding)

Self-review(JQEandPPAPteamapprrovedbyPPAPleader

SIPandSOP

creationCustomerSQEreview

UpdatecustomeroncernNewprojectPMPcreationAPQP>QA品質(zhì)相關(guān)>客戶RD設(shè)計(jì)功能相關(guān)>PE製程控制相關(guān)輸入定義製程路綫圖(PE主導(dǎo))輸出品質(zhì)管制製程管制PFMEA的建立(PE與RD負(fù)責(zé))在ST和PT階段完成試產(chǎn)報(bào)告-品質(zhì)量率統(tǒng)計(jì)-問(wèn)題點(diǎn)曝光PMP的建立-PFMEA和路綫圖-客戶管制相關(guān)內(nèi)容-經(jīng)驗(yàn)的獲得(QT階段)SIP和SOP的建立自審(JQE和由PPAP領(lǐng)導(dǎo)核準(zhǔn)的PPAP小組)更新客戶對(duì)相關(guān)內(nèi)容的要求客戶SQE審核未獲通過(guò)先期品質(zhì)規(guī)劃小組PPAP領(lǐng)導(dǎo)核準(zhǔn)PPAP小組新機(jī)種PMP的建立

>QA品質(zhì)相關(guān)輸入定義製程路綫圖輸出品質(zhì)管制PFMEA的建立MPPMPupdateandauditMPPMPupdateandaudit品質(zhì)異常PE所獲得的經(jīng)驗(yàn)更新PMP更新SOP和SIP內(nèi)部審核異常結(jié)案根據(jù)PMP進(jìn)行製程稽核未獲通過(guò)來(lái)自QA文管中心稽核組量產(chǎn)階段PMP修改與稽核

品質(zhì)異常PE所獲得的經(jīng)驗(yàn)更新PMP更新SOP和SIP內(nèi)部審核ProductProcessStabilizationQualityAssurance1.PSQAconception:Productprocessparameterstabilizationqualityassurance,meaningwithkeyprocessparameterconditioncontroltoensureproductqualitystably.

ProductsSpec.stabilizationlieonprocessparameterSpec.stabilization.Approvalforprocessesnotmeetingrequirement.2.ProcessQA:1)Partsassurance:afterproductionQCtocheckpartswithdimension,cosmeticandfunction.ifoutofSpec.totracktheprocessparameterandmakeadjustmentfollowexperience.incaseofprocessparameterbigdeviationwillbelotsoffailureparts.thereforewithhighrisk.2)Processassurance:InprocessmonitoredbyproductionlineandQApersonforpartsCharacteristicandprocessparameter.Anydeviationshouldfollowgoldprocessparametertosetup.Therebycancatchfailureinearlyperiodtomaketherealprevention.>Goldprocessparametercomefromtrialrunpartshaveapprovedbycustomers(itshouldfixedandcontrolledbyMEandQAteam)>Anyprocessparameterschangeoutofgoldprocessparametersshouldbeapprovedbycustomer.(Approvedbysuppliersthemselvesatfirst)-Doublecheckpartsdimension,functionandcosmeticmeetcustomerSpecornot.-ProcessparameterneedstudyreasonabletoleranceandconfirmedwithpartsSpec.andCustomers.ProductProcessStabilization產(chǎn)品製程穩(wěn)定性品質(zhì)保證1.PSQA的概念：產(chǎn)品製程參數(shù)穩(wěn)定性的品質(zhì)保證，意即採(cǎi)用關(guān)鍵製程參數(shù)設(shè)定的管控以保證產(chǎn)品質(zhì)量的穩(wěn)定性。產(chǎn)品規(guī)格穩(wěn)定性基於製程關(guān)鍵參數(shù)規(guī)格的穩(wěn)定性。對(duì)製程不能滿足需求的承認(rèn)。2.製程品質(zhì)保證：1)產(chǎn)品保證：品管對(duì)產(chǎn)品進(jìn)行尺寸、外觀和功能等方面的檢驗(yàn)，如果超出規(guī)格，須追蹤製程參數(shù)並依據(jù)經(jīng)驗(yàn)進(jìn)行調(diào)整。如果關(guān)鍵製程參數(shù)嚴(yán)重偏離，將會(huì)導(dǎo)致大量不良品產(chǎn)生，並造成嚴(yán)重的浪費(fèi)和損失。2)製程保證：在製程中，生産人員和品質(zhì)保證人員對(duì)產(chǎn)品的特性和製程參數(shù)進(jìn)行監(jiān)視。任何偏移應(yīng)遵照最佳製程參數(shù)進(jìn)行設(shè)置，從而能夠在早期即發(fā)現(xiàn)異常，並從真正意義上做到異常的預(yù)防。>最佳製程參數(shù)來(lái)源于被客戶承認(rèn)的試產(chǎn)產(chǎn)品(該參數(shù)應(yīng)被製程和品保小組修正和管控)>任何與最佳製程參數(shù)有偏移的製程參數(shù)均須被客戶承認(rèn)(在被客戶承認(rèn)之前應(yīng)首先被供應(yīng)商自己承認(rèn))-再一次對(duì)產(chǎn)品的尺寸、功能和外觀是否符合客戶的規(guī)格進(jìn)行確認(rèn)。-製程參數(shù)應(yīng)考慮到合適的公差，並與產(chǎn)品的規(guī)格和客戶進(jìn)行確認(rèn)。產(chǎn)品製程穩(wěn)定性品質(zhì)保證1.PSQA的概念：產(chǎn)品製程參數(shù)穩(wěn)定性PSQAparametercontrol

ProcessParametercontrolTrailrunProcessParameterPaintinga)pre-mixedb)Paintingparameterc)BakeconditionInjectiona)Injectionconditionb)Resinbaketemp.timeC)MFISpecSuppliersapprovedCustomerapprovedMPProcessParameterPE-functionandAssyQA-FAIandCosmeticPE-functionandAssyQA-FAIandCosmeticFailFailRe-trailagainUpdatetoPMPAndSop&SIPDCCissueofficallyProductionlineSetupIPQCFAIProductionQAauditWithPMPFailRe-adjusttoMPprocessparameterIPQCFAIFailProductionRecordadjustparameterRe-runtrailRunprocessFailPSQAparametercontrol

ProcesPSQA製程參數(shù)管控QA根據(jù)PMP稽核未通過(guò)製造巡檢首件記錄生産綫設(shè)定文管中心異常記錄更新至PMP及SOP和SIP再次試產(chǎn)以驗(yàn)證製程未通過(guò)重新調(diào)整里量產(chǎn)製程參數(shù)巡檢首件記錄未通過(guò)記錄生産參數(shù)的調(diào)整PE-功能組裝QA-FAI和外觀PE-功能組裝QA-FAI和外觀未通過(guò)未通過(guò)再次試產(chǎn)試產(chǎn)製程參數(shù)噴漆a)調(diào)漆b)噴漆參數(shù)c)烘烤條件成型a)成型條件b)塑膠粒烘烤溫度/時(shí)間c)熔融指數(shù)標(biāo)準(zhǔn)供應(yīng)商核準(zhǔn)客戶核準(zhǔn)量產(chǎn)製程參數(shù)PSQA製程參數(shù)管控QA根據(jù)PMP稽核未通過(guò)製造巡檢生産綫設(shè)SOPkeyparameters6majorportionsDocument/ProductInformation-Productpartnumber/revision,processstep/name,approvalstatus,revisionlevel,…DirectmaterialsP/N,description,usage,anddesignator.Workprocess/instructionforthestationIllustrationMachinename&stationnumber,machineprogramname/revistion,fixturesname/partnumber&revistion,tools/gagespartnumber/name,indirectmaterialswithdetaileddescrption,andtheirworkingconditions.Callouthighlights/specialnotesfortheoperationSOPkeyparameters6majorportSOP中的關(guān)鍵參數(shù)6個(gè)重要的部分：文件/產(chǎn)品的信息–產(chǎn)品的料號(hào)/版本，製程步驟/名稱，核準(zhǔn)狀態(tài)，版本級(jí)別，……原料料號(hào)，描述，用途和標(biāo)誌該站別的作業(yè)製程/指導(dǎo)圖示機(jī)器名稱和工站編號(hào)，機(jī)器程序名稱/版本，治具名稱/編號(hào)和版本，工具/量具編號(hào)/名稱，非直接物料的細(xì)節(jié)描述及其作業(yè)條件。著重強(qiáng)調(diào)並特別標(biāo)註作業(yè)的注意事項(xiàng)SOP中的關(guān)鍵參數(shù)6個(gè)重要的部分：SOPkeyparametersInformation-productpartnumber/revision,approvalstatus,revisionlevel,…Dimension---P-dimensionorengineeringteamconcerneddimension.(MeetcustomersofficialdrawingSPEC.atleast.)Cosmetic---Meetcustomersofficialcosmeticorgoldsamplecriteria.(specificSpec.tolerance)Function---reliabilityandfunctiontestingitems(suchasprogramtestingtorques,MFIandpullforcetesting)Systemmatching---forsomesinglepartswillbeassemblyatcustomersproductionline);(specialfordifficultassembly,gapandstep)Movablepartschecking---withsimulationtesting(asbutton,hook,sometinesneedbecheckedwithfixture)Illustration(describethekeycheckpointormotion)ECNchangerecord(latest3months)Customerqualityissuehistoryrecord(latest3months)SOPkeyparametersSIP中的關(guān)鍵參數(shù)信息----產(chǎn)品料號(hào)/版本，核準(zhǔn)狀態(tài)，版本級(jí)別，……尺寸----P尺寸或工程小組相關(guān)尺寸(至少須符合客供正式圖紙的規(guī)範(fàn))外觀----符合客供正式版本的外觀標(biāo)準(zhǔn)或樣品標(biāo)準(zhǔn)(明確的標(biāo)準(zhǔn)公差)功能----信賴性和功能測(cè)試項(xiàng)目(如程序測(cè)試，扭力測(cè)試，MFI測(cè)試和拉力測(cè)試)系統(tǒng)配合度----在客戶端生産綫組裝的單出料件(尤其指難以組裝，易產(chǎn)生間隙和斷差的料件)可動(dòng)部分的檢查----進(jìn)行模擬測(cè)試(如按鍵，轉(zhuǎn)軸，部分產(chǎn)品需要治具進(jìn)行檢驗(yàn))圖示(描述關(guān)鍵的檢驗(yàn)點(diǎn)和檢驗(yàn)動(dòng)作)工程變更記錄(至少3個(gè)月內(nèi)的變更項(xiàng)目)客戶端品質(zhì)異常履歷記錄(至少3個(gè)月內(nèi)的異常項(xiàng)目)SIP中的關(guān)鍵參數(shù)信息----產(chǎn)品料號(hào)/版本，核準(zhǔn)狀態(tài)，版SOPkeyparametersProcessflow---Processandpartscontrolstation.Processcontrol:forcriticalmanufacturedtestingmachinestation.(processwithclasswithS-safetycritical,M-majordefect,O-minordefectandKPC-keycont,charct)Partscontrol:forcriticalfinalinspectionandQCsamplesizestation.(ProcesswithclasswithS-safetycritical,M-majordefect,O-minordefectandKPC-keycont.charct)MachineandDevice,jigtoolsformanufactureCharacteristicsProcessparameter---keyoperationmanufactureparameterswillimpactproductsqualityorSpecifdeviationsofoutofspec.(keyoperationparametermonitoring.)Productcharacteristic---CustomerapprovedSpec,ofdimension,cosmetic,functionandreliabilitytesting,ORT(keycontrolcharacteristicsmonitoring)MethodCriticalproduct/processspecificationwithtolerance.Update.Measurementtechnique---withwhatkindsoftechniqueorinstrumenttomeasure(suchasAQL,visualorcolormeter)Samplesizeorfreq.---100%inspectionorsamlingsizewithfrequencydefinitions.Analysismethod---UsewhatkindofmethodtomarkFAiffailurecatchfrominspection.(Porto,CLCA,SCAR,SPCandCPK)Reactionplan---outofcontrolconditionareencounteredassameasCA.(suchasstopline,holdlots,re-studytheprocessparameterandscrap)SOPkeyparametersPMP中的關(guān)鍵參數(shù)製造流程----製程和料件的管控站別a)製程管控：指重點(diǎn)地生産用測(cè)試機(jī)器的站別(製程中以S-安全臨界級(jí)，M-主要不良，O-次要不良和KPC-關(guān)鍵控制特性)b)料件管控：指重點(diǎn)的最終檢驗(yàn)和品管樣本大小的站別(製程中以S-安全臨界級(jí)，M-主要不良，O-次要不良和KPC-關(guān)鍵控制特性)用於生産的機(jī)器、裝置、治具特性

a)製程參數(shù)----關(guān)鍵作業(yè)的工藝參數(shù)會(huì)對(duì)產(chǎn)品的質(zhì)量造成影響，若其偏移導(dǎo)致了超出規(guī)格，則對(duì)產(chǎn)品的規(guī)格亦會(huì)造成影響(關(guān)鍵作業(yè)參數(shù)的監(jiān)控)b)產(chǎn)品特性----客戶承認(rèn)的尺寸、外觀、功能和信賴性測(cè)試的規(guī)格方法

a)關(guān)鍵產(chǎn)品/製程(包括公差)的規(guī)範(fàn)及其更新b)量測(cè)技術(shù)----使用何種類型的技術(shù)或設(shè)備進(jìn)行量測(cè)(如允收級(jí)別，視覺(jué)或顔色計(jì)量)c)樣本大小或採(cǎi)樣頻率----全檢或定義其樣品大小和採(cǎi)樣頻率d)分析方法----當(dāng)在檢測(cè)中發(fā)現(xiàn)失效現(xiàn)象，使用何種方法進(jìn)行失效分析(Porto，CLCA，SCAR，SPC和CPK)應(yīng)激計(jì)劃----當(dāng)遭遇失效現(xiàn)象，改善措施能夠被立即實(shí)施(如停綫，hold庫(kù)存，重新研究製程參數(shù)及報(bào)廢)PMP中的關(guān)鍵參數(shù)對(duì)製造流程的審核戴爾品質(zhì)項(xiàng)目目的製造流程圖實(shí)用的文件，用以正式化生産/組裝流程；定義工序，綫外組裝步驟，檢驗(yàn)站別等。對(duì)其格式的任何更改必須預(yù)先得到核準(zhǔn)對(duì)製造流程的審核戴爾品質(zhì)項(xiàng)目目PMP制程管理簡(jiǎn)介課件PFMEAreview

對(duì)製程失效模式和效應(yīng)分析的審核DellQualElement戴爾品質(zhì)項(xiàng)目Purpose:目的ProcessFMEASummary製程失效模式和效應(yīng)分析大綱FailureModeandEffectsAnalysis;LivingDocumentidentifyingandassessingriskforpotentialmodesfoundinsupplier’smanufacturingprocess.失效模式和效應(yīng)分析：實(shí)用的文件，用以識(shí)別和評(píng)估供應(yīng)商生産製程中潛在的失效模式造成的風(fēng)險(xiǎn)。AlternateFormatsMUSTBeApprovedinAdvance對(duì)其格式的任何更改必須預(yù)先得到核準(zhǔn)PFMEAreviewPFMEA制程名稱/目的預(yù)估失效模式預(yù)估失效影響嚴(yán)重度S預(yù)估失效原因發(fā)生率O現(xiàn)行控制措施難檢度DRPN建議控制措施責(zé)任人完成日期狀態(tài)已採(cǎi)取之措施SODRPN裝上蓋卡鉤卡不到位影響外觀和功能6人工操作3無(wú)6108使用夾具----OK使用夾具和增加檢驗(yàn)工站62224裝FDDFDD錯(cuò)位FDD磁片彈不出8人工操作3無(wú)8192使用夾具----OK使用夾具和增加檢驗(yàn)工站82116PFMEA制程名稱/目的預(yù)估失效模式預(yù)估失效影響嚴(yán)重度S預(yù)估對(duì)製程管制計(jì)劃的審核戴爾品質(zhì)項(xiàng)目目的製程管制計(jì)劃實(shí)用的文件，用以定義品質(zhì)檢驗(yàn)時(shí)機(jī)、方法、製程參數(shù)及對(duì)失效的應(yīng)對(duì)措施。對(duì)其格式的任何更改必須預(yù)先得到核準(zhǔn)對(duì)製程管制計(jì)劃的審核戴爾品質(zhì)項(xiàng)目PMP制程管理簡(jiǎn)介課件Processmanagementplan

產(chǎn)品制程穩(wěn)定性品質(zhì)保證

Preparedby:QSMCSQERickMiaoNov242003revision01---ProductProcessStablizationQualityAssuranceProcessmanagementplan--NewprojecttransfercreatedbyPEteam.由PE小組制定的新項(xiàng)目移轉(zhuǎn)MassproductionPMPupdatebasedonissueandcustomerrequirement.量產(chǎn)機(jī)種因異常和客戶要求而進(jìn)行的PMP更新QA,JQEandauditteamtoauditprocessreferencePMP.QA.JQE與稽核人員稽核制程之依據(jù)PMPcoverfromIQCtoOQCoverallprocess.PMP涵蓋到從進(jìn)料檢驗(yàn)到出貨檢驗(yàn)的全部制程PMPgenerallytodriveprocessandQAsystemtocontrolcriticalstationwithkeyparameter.PMP通常用以推動(dòng)製程和品質(zhì)保證系統(tǒng)使用相關(guān)的關(guān)鍵參數(shù)管控重要站別

PMPupdateguideline.---PMP修改準(zhǔn)則

Preventiveactiontake.採(cǎi)取新的預(yù)防措施

Systemimprovement.系統(tǒng)得到改進(jìn)

Lessonlearnreview.所獲得經(jīng)驗(yàn)的回顧

QCandProcesscontrolenhancement.品管和製程控制得到加強(qiáng)

PMPfunctionandcontrolPMP功能與管制

NewprojecttransfercreatedbPPAPProductionPartApprovalProcess零/部件承認(rèn)程序PPAP零/部件承認(rèn)程序NewprojectPMPcreationAPQPteamPPAPteamPPAPleaderapproved

Defineprocessroadmap(PEhost)>QAqualityconcern.>CustomerRDdesignfunctionconcern>PEprocesscontrolconcernInputOutputQualitycontrolProcesscontrolfailPFMEAcreation(PEworkwithRD)

STandPTTrailrunreport-qualityyieldrate-issuehighlight

PMPcreation-PFMEAand-Roadmap-Customercontrolconcern.-Lessonlearn.(QTbuilding)

Self-review(JQEandPPAPteamapprrovedbyPPAPleader

SIPandSOP

creationCustomerSQEreview

UpdatecustomeroncernNewprojectPMPcreationAPQP>QA品質(zhì)相關(guān)>客戶RD設(shè)計(jì)功能相關(guān)>PE製程控制相關(guān)輸入定義製程路綫圖(PE主導(dǎo))輸出品質(zhì)管制製程管制PFMEA的建立(PE與RD負(fù)責(zé))在ST和PT階段完成試產(chǎn)報(bào)告-品質(zhì)量率統(tǒng)計(jì)-問(wèn)題點(diǎn)曝光PMP的建立-PFMEA和路綫圖-客戶管制相關(guān)內(nèi)容-經(jīng)驗(yàn)的獲得(QT階段)SIP和SOP的建立自審(JQE和由PPAP領(lǐng)導(dǎo)核準(zhǔn)的PPAP小組)更新客戶對(duì)相關(guān)內(nèi)容的要求客戶SQE審核未獲通過(guò)先期品質(zhì)規(guī)劃小組PPAP領(lǐng)導(dǎo)核準(zhǔn)PPAP小組新機(jī)種PMP的建立

>QA品質(zhì)相關(guān)輸入定義製程路綫圖輸出品質(zhì)管制PFMEA的建立MPPMPupdateandauditMPPMPupdateandaudit品質(zhì)異常PE所獲得的經(jīng)驗(yàn)更新PMP更新SOP和SIP內(nèi)部審核異常結(jié)案根據(jù)PMP進(jìn)行製程稽核未獲通過(guò)來(lái)自QA文管中心稽核組量產(chǎn)階段PMP修改與稽核

品質(zhì)異常PE所獲得的經(jīng)驗(yàn)更新PMP更新SOP和SIP內(nèi)部審核ProductProcessStabilizationQualityAssurance1.PSQAconception:Productprocessparameterstabilizationqualityassurance,meaningwithkeyprocessparameterconditioncontroltoensureproductqualitystably.

ProductsSpec.stabilizationlieonprocessparameterSpec.stabilization.Approvalforprocessesnotmeetingrequirement.2.ProcessQA:1)Partsassurance:afterproductionQCtocheckpartswithdimension,cosmeticandfunction.ifoutofSpec.totracktheprocessparameterandmakeadjustmentfollowexperience.incaseofprocessparameterbigdeviationwillbelotsoffailureparts.thereforewithhighrisk.2)Processassurance:InprocessmonitoredbyproductionlineandQApersonforpartsCharacteristicandprocessparameter.Anydeviationshouldfollowgoldprocessparametertosetup.Therebycancatchfailureinearlyperiodtomaketherealprevention.>Goldprocessparametercomefromtrialrunpartshaveapprovedbycustomers(itshouldfixedandcontrolledbyMEandQAteam)>Anyprocessparameterschangeoutofgoldprocessparametersshouldbeapprovedbycustomer.(Approvedbysuppliersthemselvesatfirst)-Doublecheckpartsdimension,functionandcosmeticmeetcustomerSpecornot.-ProcessparameterneedstudyreasonabletoleranceandconfirmedwithpartsSpec.andCustomers.ProductProcessStabilization產(chǎn)品製程穩(wěn)定性品質(zhì)保證1.PSQA的概念：產(chǎn)品製程參數(shù)穩(wěn)定性的品質(zhì)保證，意即採(cǎi)用關(guān)鍵製程參數(shù)設(shè)定的管控以保證產(chǎn)品質(zhì)量的穩(wěn)定性。產(chǎn)品規(guī)格穩(wěn)定性基於製程關(guān)鍵參數(shù)規(guī)格的穩(wěn)定性。對(duì)製程不能滿足需求的承認(rèn)。2.製程品質(zhì)保證：1)產(chǎn)品保證：品管對(duì)產(chǎn)品進(jìn)行尺寸、外觀和功能等方面的檢驗(yàn)，如果超出規(guī)格，須追蹤製程參數(shù)並依據(jù)經(jīng)驗(yàn)進(jìn)行調(diào)整。如果關(guān)鍵製程參數(shù)嚴(yán)重偏離，將會(huì)導(dǎo)致大量不良品產(chǎn)生，並造成嚴(yán)重的浪費(fèi)和損失。2)製程保證：在製程中，生産人員和品質(zhì)保證人員對(duì)產(chǎn)品的特性和製程參數(shù)進(jìn)行監(jiān)視。任何偏移應(yīng)遵照最佳製程參數(shù)進(jìn)行設(shè)置，從而能夠在早期即發(fā)現(xiàn)異常，並從真正意義上做到異常的預(yù)防。>最佳製程參數(shù)來(lái)源于被客戶承認(rèn)的試產(chǎn)產(chǎn)品(該參數(shù)應(yīng)被製程和品保小組修正和管控)>任何與最佳製程參數(shù)有偏移的製程參數(shù)均須被客戶承認(rèn)(在被客戶承認(rèn)之前應(yīng)首先被供應(yīng)商自己承認(rèn))-再一次對(duì)產(chǎn)品的尺寸、功能和外觀是否符合客戶的規(guī)格進(jìn)行確認(rèn)。-製程參數(shù)應(yīng)考慮到合適的公差，並與產(chǎn)品的規(guī)格和客戶進(jìn)行確認(rèn)。產(chǎn)品製程穩(wěn)定性品質(zhì)保證1.PSQA的概念：產(chǎn)品製程參數(shù)穩(wěn)定性PSQAparametercontrol

ProcessParametercontrolTrailrunProcessParameterPaintinga)pre-mixedb)Paintingparameterc)BakeconditionInjectiona)Injectionconditionb)Resinbaketemp.timeC)MFISpecSuppliersapprovedCustomerapprovedMPProcessParameterPE-functionandAssyQA-FAIandCosmeticPE-functionandAssyQA-FAIandCosmeticFailFailRe-trailagainUpdatetoPMPAndSop&SIPDCCissueofficallyProductionlineSetupIPQCFAIProductionQAauditWithPMPFailRe-adjusttoMPprocessparameterIPQCFAIFailProductionRecordadjustparameterRe-runtrailRunprocessFailPSQAparametercontrol

ProcesPSQA製程參數(shù)管控QA根據(jù)PMP稽核未通過(guò)製造巡檢首件記錄生産綫設(shè)定文管中心異常記錄更新至PMP及SOP和SIP再次試產(chǎn)以驗(yàn)證製程未通過(guò)重新調(diào)整里量產(chǎn)製程參數(shù)巡檢首件記錄未通過(guò)記錄生産參數(shù)的調(diào)整PE-功能組裝QA-FAI和外觀PE-功能組裝QA-FAI和外觀未通過(guò)未通過(guò)再次試產(chǎn)試產(chǎn)製程參數(shù)噴漆a)調(diào)漆b)噴漆參數(shù)c)烘烤條件成型a)成型條件b)塑膠粒烘烤溫度/時(shí)間c)熔融指數(shù)標(biāo)準(zhǔn)供應(yīng)商核準(zhǔn)客戶核準(zhǔn)量產(chǎn)製程參數(shù)PSQA製程參數(shù)管控QA根據(jù)PMP稽核未通過(guò)製造巡檢生産綫設(shè)SOPkeyparameters6majorportionsDocument/ProductInformation-Productpartnumber/revision,processstep/name,approvalstatus,revisionlevel,…DirectmaterialsP/N,description,usage,anddesignator.Workprocess/instructionforthestationIllustrationMachinename&stationnumber,machineprogramname/revistion,fixturesname/partnumber&revistion,tools/gagespartnumber/name,indirectmaterialswithdetaileddescrption,andtheirworkingconditions.Callouthighlights/specialnotesfortheoperationSOPkeyparameters6majorportSOP中的關(guān)鍵參數(shù)6個(gè)重要的部分：文件/產(chǎn)品的信息–產(chǎn)品的料號(hào)/版本，製程步驟/名稱，核準(zhǔn)狀態(tài)，版本級(jí)別，……原料料號(hào)，描述，用途和標(biāo)誌該站別的作業(yè)製程/指導(dǎo)圖示機(jī)器名稱和工站編號(hào)，機(jī)器程序名稱/版本，治具名稱/編號(hào)和版本，工具/量具編號(hào)/名稱，非直接物料的細(xì)節(jié)描述及其作業(yè)條件。著重強(qiáng)調(diào)並特別標(biāo)註作業(yè)的注意事項(xiàng)SOP中的關(guān)鍵參數(shù)6個(gè)重要的部分：SOPkeyparametersInformation-productpartnumber/revision,approvalstatus,revisionlevel,…Dimension---P-dimensionorengineeringteamconcerneddimension.(MeetcustomersofficialdrawingSPEC.atleast.)Cosmetic---Meetcustomersofficialcosmeticorgoldsamplecriteria.(specificSpec.tolerance)Function---reliabilityandfunctiontestingitems(suchasprogramtestingtorques,MFIandpullforcetesting)Systemmatching---forsomesinglepartswillbeassemblyatcustomersproductionline);(specialfordifficultassembly,gapandstep)Movablepartschecking---withsimulationtesting(asbutton,hook,sometinesneedbecheckedwithfixture)Illustration(describethekeycheckpointormotion)ECNchangerecord(latest3months)Customerqualityissuehistoryrecord(latest3months)SOPkeyparametersSIP中的關(guān)鍵參數(shù)信息----產(chǎn)品料號(hào)/版本，核準(zhǔn)狀態(tài)，版本級(jí)別，……尺寸----P尺寸或工程小組相關(guān)尺寸(至少須符合客供正式圖紙的規(guī)範(fàn))外觀----符合客供正式版本的外觀標(biāo)準(zhǔn)或樣品標(biāo)準(zhǔn)(明確的標(biāo)準(zhǔn)公差)功能----信賴性和功能測(cè)試項(xiàng)目(如程序測(cè)試，扭力測(cè)試，MFI測(cè)試和拉力測(cè)試)系統(tǒng)配合度----在客戶端生産綫組裝的單出料件(尤其指難以組裝，易產(chǎn)生間隙和斷差的料件)可動(dòng)部分的檢查----進(jìn)行模擬測(cè)試(如按鍵，轉(zhuǎn)軸，部分產(chǎn)品需要治具進(jìn)行檢驗(yàn))圖示(描述關(guān)鍵的檢驗(yàn)點(diǎn)和檢驗(yàn)動(dòng)作)工程變更記錄(至少3個(gè)月內(nèi)的變更項(xiàng)目)客戶端品質(zhì)異常履歷記錄(至少3個(gè)月內(nèi)的異常項(xiàng)目)SIP中的關(guān)鍵參數(shù)信息----產(chǎn)品料號(hào)/版本，核準(zhǔn)狀態(tài)，版SOPkeyparametersProcessflow---Processandpartscontrolstation.Processcontrol:forcriticalmanufacturedtestingmachinestation.(processwithclasswithS-safetycritical,M-majordefect,O-minordefectandKPC-keycont,charct)Partscontrol:forcriticalfinalinspectionandQCsamplesizestation.(ProcesswithclasswithS-safetycritical,M-majordefect,O-minordefectandKPC-keycont.charct)MachineandDevice,jigtoolsformanufactureCharacteristicsProcessparameter---keyoperationmanufactureparameterswillimpactproductsqualityorSpecifdeviationsofoutofspec.(keyoperationparametermonitoring.)Productcharacteristic---CustomerapprovedSpec,ofdimension,cosmetic,functionandreliabilitytesting,ORT(keycontrolcharacteristicsmonitoring)MethodCriticalproduct/processspecificationwithtolerance.Update.Measurementtechnique---withwhatkindsoftechniqueorinstrumenttomeasure(suchasAQL,visualorcolormeter)Samplesizeorfreq.---100%inspectionorsamlingsizewit