0902生產(chǎn)過程控制程序

1目的Objective對本公司所生產(chǎn)的產(chǎn)品在生產(chǎn)過程中各個影響質(zhì)量的因素實施控制，確保全過程處于受控狀態(tài)，所有出廠產(chǎn)品的各項指標均能滿足用戶要求，特制定本程序。TheobjectiveofthisprocedureistocontrolthefactorsinfluencingproductqualityinAICQproductionprocess,andtoensurethewholeprocessisundercontrolandalltheindicesoftheex-factoryproductsmeetthecustomerrequirements.2適用范圍ApplicableScope適用于公司生產(chǎn)過程及職能部門的管理。Thisisapplicabletothemanagementofproductionprocessandfunctionaldepartment.3職責Responsibility3.1技術(shù)工程部負責技術(shù)準備工作及現(xiàn)場技術(shù)服務(wù)工作。TheEngineeringDepartmentisresponsibleforthetechnicalpreparationandon-sitetechnicalservices.3.2制造部負責按月計劃組織生產(chǎn)，搞好均衡調(diào)度，解決生產(chǎn)中存在的實際問題，做好設(shè)備維護、保養(yǎng)和文明生產(chǎn)檢查工作，確保生產(chǎn)正常秩序。TheManufacturingDepartmentisresponsibletoorganizetheproductionperthemonthlyplan,tobalancetheassignment,tosolverealissuesduringproduction,toconductmaintenanceandrepairoftheequipment,andtocheckthecivilizationproduction,soastoensurethenormalproductionorder.3.3采購物流部負責按月生產(chǎn)計劃編制物質(zhì)采購計劃，組織原材料、協(xié)配件和設(shè)備配件的采購。ThePurchaseandLogisticsDepartmentisresponsibletoformulatethematerialpurchaseplanperthemonthlyproductionplanandtoorganizethepurchaseofrawmaterials,componentsandequipmentfittings.3.4人力資源部負責協(xié)調(diào)生產(chǎn)人員的上崗培訓(xùn)、教育與考核。TheHumanResourcesDepartmentisresponsibletoorganizethequalificationtraining,educationandappraisaloftheproductionstaff.3.5質(zhì)量部負責原材料、協(xié)配件，半成品和成品的檢驗和驗證。TheQualityDepartmentisresponsibleforthetestandinspectionoftherawmaterial,components,semi-finishedproductsandfinishedproducts.4工作程序WorkProcedures4.1過程策劃ProcessPlanning由橫向協(xié)調(diào)項目組按《產(chǎn)品質(zhì)量先期策劃控制程序》進行工藝、設(shè)備、工裝、生產(chǎn)、檢驗等的策劃，并制訂過程流程圖和控制計劃。根據(jù)過程流程圖和控制計劃編制相應(yīng)的各類工藝卡、操作規(guī)程、檢驗作業(yè)指導(dǎo)書和其他作業(yè)指導(dǎo)書，現(xiàn)場使用的各類作業(yè)指導(dǎo)書和用于指導(dǎo)生產(chǎn)的各種樣品/樣件、缺陷照片等須放置在相應(yīng)工位處，使操作人員易于得到。TheCrossFunctionTeamwillplanfortheprocess,equipment,tooling,productionandinspection,andformulatetheprocessflowchartandcontrolplanpertheAdvancedProductQualityPlanningControlProcedure.Theprocesscards,operationspecification,inspectioninstructionandotheroperationguidewillbecompiledpertheprocessflowchartandthecontrolplan.Theoperationinstructionsforsiteuse,sampleproduct/partforproductionguidanceandthedefectiveproductpicturesshouldbeplacedinproperworksiteeasyfortheoperatortoreach.4.2過程控制ProcessControl4.2.1操作人員應(yīng)通過培訓(xùn)，考核合格后，發(fā)放<上崗證>方可上崗，具體按《培訓(xùn)控制程序》執(zhí)行。Theoperatorcanonlyworkonhispostafterqualifiedtraining.ThedetailsareshownontheTrainingControlProcedure.4.2.2操作員應(yīng)正確使用、維護和保養(yǎng)設(shè)備，制造部設(shè)備科實行定期檢修和及時搶修，做到備品備件齊全，執(zhí)行《設(shè)備管理控制程序》。Theoperatorshouldoperate,maintainandrepairtheequipmentproperly.TheEquipmentSectionofManufacturingDepartmentwillperformregularinspectionandon-timerepair,andensurethesparepartsarefullyavailable.TheEquipmentManagementControlProcedurewillbeapplied.4.2.3生產(chǎn)用的原材料、協(xié)配件，要有檢驗合格單或合格的質(zhì)量證明，不同類別應(yīng)明確標識，按《采購控制程序》執(zhí)行。如因市場原因需變更原材料的，由采購物流部填寫<材料代用申報單>向技術(shù)工程部申報辦理，經(jīng)認可后實施采購。Therawmaterialsandcomponentsforproductionmusthaveinspectionqualificationorqualityverification,withdefinitelabelsattachedtodifferentgoods.ThePurchaseControlProcedurewillbeapplied.Whentherawmaterialsneedtobechangedduetomarketreasons,thePurchase&LogisticsDepartmentshallfillinMaterialReplacementRequestFormandsubmitittoEngineeringDepartment.Thepurchasecanonlybeactualizedafterapproval.4.2.4現(xiàn)場使用的技術(shù)文件必須是現(xiàn)行有效版本，按《技術(shù)文件管理制度》執(zhí)行。Thetechnicaldocumentusedonsitemustbethecurrentvalidversionbasedon“technicaldocumentmanagementsystem.4.2.5操作工在生產(chǎn)中必須嚴格執(zhí)行工藝紀律。Theoperatormustperformstrictlytheprocessdisciplineduringproduction4.2.6生產(chǎn)過程中防止不同規(guī)格、型號的產(chǎn)品混淆，嚴格按《產(chǎn)品標識和可追溯性控制程序》執(zhí)行。Inproductionprocess,besuretoavoidmixingdifferentproducttypesandmodelsinstrictaccordancewiththeProductIdentificationandTraceabilityControlProcedure.4.2.7生產(chǎn)現(xiàn)場的原材料、在制半成品、成品及不合格品的存放、搬運、防護按《搬運、貯存、包裝、防護和交付控制程序》執(zhí)行。Atproductionsite,therawmaterials,semi-finishedproductsunderproduction,finishedproductsandnonconforminggoodsmustbestored,handledandprotectedinaccordancewiththe“Handling,Storage,Packaging,Preservation&DeliveryControlProcedure”.4.3關(guān)鍵、特殊工序控制CriticalandSpecialProcessControl4.3.1關(guān)鍵工序、特殊工序操作人員要經(jīng)過專門、專業(yè)培訓(xùn)后，持證上崗。Theoperatorsforcriticalandspecialprocessmustbeprovidedwithspecialandprofessionaltraining,andcanonlybeallowedtoworkwithqualificationcertification.4.3.2電工，電、氧焊工，叉車司機，要定崗、定員，不能隨意更換、變動。Theelectrician,electricity&chlorinewelder,andforkliftdriverhavetobefixedpositionforfixedpersonnel.Norandomshiftorchangeofthepersonnelisallowed.4.3.3關(guān)鍵設(shè)備（含高、精、稀設(shè)備）必須定人、定機，按《設(shè)備管理制度》執(zhí)行。Thecriticalequipment(includingtheadvanced,precisionandrareequipment)hastobeappointedtocertainpersonsforcertainequipment.TheEquipmentManagementSystemisapplied.4.3.4關(guān)鍵（特殊）工序控制卡，由制造部門負責編制，并負責工序控制和工序質(zhì)量分析。TheManufacturingDepartmentisresponsibletoformulatethecritical(special)processcontrolcard,tocontroltheprocess,andtoanalyzetheprocessquality.4.4質(zhì)量控制QualityControl4.4.1操作工每班或轉(zhuǎn)換產(chǎn)品時必須首檢，首檢合格后才能正常生產(chǎn)。Theoperatorhastoconducttheinitialinspectionforeveryshiftoreverychangeofproduct.Thenormalproductioncanbelaunchedafterqualifiedinitialinspection.4.4.2在生產(chǎn)中操作工和檢驗員應(yīng)嚴格執(zhí)行“三檢”制，自制件作好《作業(yè)流程卡》記錄，裝配總成作好《裝配檢查記錄》。Inproduction,theoperatorandtheinspectorshallimplementstrictlythe“3-check”systemandestablisharecordof“workingflowcard”forlocalpartsandan“assemblycheckrecord”forassemblingassy.4.4.3在生產(chǎn)過程中，如因設(shè)備、工裝等過程能力的影響使產(chǎn)品暫時達不到規(guī)定要求且在一定范圍之內(nèi)時，應(yīng)由制造部向技術(shù)工程部門提出書面申請，辦理偏差手續(xù)（重大偏離許可需經(jīng)總經(jīng)理批準）后方可生產(chǎn)。生產(chǎn)的產(chǎn)品僅用于規(guī)定期限和數(shù)量。Inproductionprocess,iftheproductcan'tmeetthespecificationstemporarilywithinacertainrangeduetorestrictionofequipmentandtoolingprocesscapabilities,theManufacturingDepartmentshouldsubmitinwrittenapplicationtotheEngineeringDepartmentforhandlingthevariationprocedures(greatvariationhastobeapprovedbytheGeneralManager)priortoproduction.Theproductsmadearerestrictedfortheprescribedperiodlimitationandvolume.4.4.4生產(chǎn)中發(fā)生不合格品，應(yīng)隔離存放，其處理按《不合格品控制程序》執(zhí)行。Thenonconformingproductsintheproductionprocessshouldbestoredinisolation,andbedisposedaccordingtoNonconformingProductControlProcedure.4.4.5生產(chǎn)過程中，發(fā)現(xiàn)質(zhì)量異?，F(xiàn)象，出現(xiàn)批量的不合格或嚴重質(zhì)量問題，制造部按《糾正和預(yù)防措施控制程序》報質(zhì)量部處理。Inproductionprocess,ifitisfoundofanyqualityabnormity,batchquantitydefectsorseriousqualityproblems,theManufacturingDepartmentshallreportthecasetotheQualityDepartmentperthe“CorrectiveandPreventativeActionControlProcedure”.4.4.6嚴格按《檢驗、測量和試驗設(shè)備控制程序》對檢驗設(shè)備、量檢具、儀器、儀表，進行維護、保養(yǎng)、檢定或校準，確保設(shè)備完好，測量準確。Maintainandrepairthetestequipment,inspectiontools&gages,instrumentsandmetersinstrictaccordancewiththe“Inspection,MeasuringandTestEquipmentControlProcedure”,soastoensurecompletenessandprecision.工藝員進行工藝紀律和工藝文件的宣貫、培訓(xùn)、檢查和考核。Theprocessoperatorisresponsibletopublicize,implement,inspectandappraisetheprocessdiscipline.4.6生產(chǎn)環(huán)境ProductionEnvironment4.6.1生產(chǎn)各班組按制造部制定的定置管理圖存放工位器具。TheproductionteamsarerequiredtoputthetoolsandinstrumentsattheplacesdesignatedonthemanagementdrawingbytheManufacturingDepartment.4.6.2各班組生產(chǎn)的產(chǎn)品應(yīng)擺放整齊，分類、分區(qū)存放，有明顯的標識。Theproductsproducedbytheteamsshouldbeplacedneatlybycategoryandlocationwithobviousidentification.4.6.3現(xiàn)場環(huán)境必須保證符合文明生產(chǎn)安全要求，確保道路暢通、門窗明亮。由質(zhì)量部及制造部組織檢查和考核，執(zhí)行5S標準。Thesiteenvironmentmustconformtothesafetyproductionrequirementsforthecivilizationproduction.Thepassagemustbecleared,doorsandwindowclean.TheQualityDepartmentandtheManufacturingDepartmentwillorganizechecksandassessment.TheSSstandardisapplied.4.7管理說明NotestoManagement4.7.1為保障對顧客及時供應(yīng)，防止因意外情況影響供貨及時，由制造部組織各相關(guān)部門針對可能出現(xiàn)的停電、停水、原材料/外購件短缺、勞動力短缺、關(guān)鍵設(shè)備故障、裝運提前通知系統(tǒng)故障等非自然災(zāi)害造成的偶發(fā)性事故制訂應(yīng)急計劃。應(yīng)急計劃須注明計劃的具體實施部門/人、具體應(yīng)急措施及相應(yīng)控制要求，確保計劃的可行性，并經(jīng)主管領(lǐng)導(dǎo)批準。Towardoffdelayofproductsupplytocustomerduetoaccidentalevents,theManufacturingDepartmentshallorganizerelevantdepartmentstoformulateemergencyplansregardingthepossiblenonactofgodincidents,suchaspowerorwatershutoff,rawmaterial/outsourcingpartsshortage,laborshortage,criticalequipmentfailure,shipmentadvancenoticesystemfailure,etc.Theemergencyplanshouldincludethespecificactiondepartment/personoftheplan,detailedemergencymeasurementandcontrolrequirementstomakesurethefeasibilityoftheplanandgetapprovedbythesupervisor.4.7.2對于涉及產(chǎn)品安全性的過程按《產(chǎn)品安全性管理辦法》規(guī)定執(zhí)行。TheProductSafetyControlProcedureappliestotheprocessinvolvingtheproductsafety.4.7.3制造部應(yīng)嚴格按照控制計劃中規(guī)定的方法進行過程控制，當過程出現(xiàn)更改時，制造部保存相應(yīng)的更改后的生效記錄。TheManufacturingDepartmentshouldcontroltheprocessperthedescribedapproachinthecontrolplan.Iftheprocessischanged,theManufacturingDepartmentshallretainthecorrespondingeffectiverecordsforthemodifiedprocess.4.7.4對于顧客要求的特殊特性，應(yīng)在控制計劃及作業(yè)指導(dǎo)書上進行特殊標識，當顧客要求時，應(yīng)向顧客提供表明符合這些要求的文件。Asforthecustomerspecialcharacteristics,speciallabelsmustbeindicatedinthecontrolplanandtheoperationinstruction.Thedocumentssatisfyingtheneedsofthecustomershouldbeofferedtothecustomeruponrequest.4.7.5現(xiàn)場操作人員所涉及的操作規(guī)程、工藝卡片、工藝文件等指導(dǎo)性文件，應(yīng)置于現(xiàn)場，便于人員操作。Tofacilitateoperation,theguidancedocuments,suchasoperationrules,processcardsandprocessfilesrelatedtothesiteoperators,shouldbeplacedonthesite.4.7.6為保持/超出執(zhí)行PPAP批準時的過程能力，質(zhì)量部必須監(jiān)督控制計劃和過程流程圖執(zhí)行的有效性。Tomeet/surpasstheprocesscapabilityasstatedinPPAPApproval,theQualityDepartmentmustmonitortheimplementationeffectivenessofthecontrolplanandprocessflowdiagram.由操作人員按控制計劃要求對重要特性采用控制圖進行控制，對于設(shè)備故障、工裝更換、材料變更、測量器具變更、工藝變更等均須在控制圖上標明，發(fā)現(xiàn)控制圖出現(xiàn)異常波動或能力不足時，須執(zhí)行控制計劃中規(guī)定的反應(yīng)計劃，必要時進行100%檢驗。Theoperatorshallusecontroldiagramtocontroltheimportantcharacteristicspertherequirementofthecontrolplan.Theequipmentfailureandthechangeoftooling,materials,measurementgagesandprocessshallbeindicatedinthecontroldiagram.Thereactionplansetupinthecontrolplanshouldbeinitiatediftheabnormalfluctuationandinabilityisspottedonthecontroldiagram,andifnecessary,100%inspectionneedstobedone.在過程控制圖顯示過程異常時，及時進行分析處理。制造部負責組織對涉及特殊特性的項目持續(xù)進行過程能力測定，確保過程能力充足。如果過程能力低于額定值須進行產(chǎn)品100%檢驗，以便剔除不合格產(chǎn)品，并由質(zhì)量部負責分析，制訂明確進度和責任及具體要求的糾正措施計劃。顧客要求時此計劃須經(jīng)顧客評審和批準。Makepromptanalysisandfindsolutionswhentheprocesscontroldiagramdisplaysthattheprocessisabnormal.TheManufacturingDepartmentisresponsibletoorganizetheverificationofcontinuousimplementationprocesscapabilityrelatedtotheprojectwithspecialcharacteristicsinordertoensureadequateprocesscapability.100%inspectionshouldbecarriedoutwhentheprocesscapabilityisbelowratedvalue,soastoeliminatedefectiveproducts.TheQualityDepartmentisresponsibletoconductanalysis,andtoformulatedefiniteschedules,dutiesanddetailcorrectiveactionplan.Thisplanhastobereviewedandapprovedbythecustomeruponrequest.4.7.7當發(fā)生作業(yè)的初步運行、材料的改變、作業(yè)更改、運行時間過長的停頓，由制造部組織質(zhì)量部、工程技術(shù)部門進行作業(yè)準備驗證，推薦采用末件比較的方法或采用如下具體項目檢查：Incaseofinitialoperation,materialchange,operationalmodificationandovertimepauses,theManufacturingDepartmentshallorganizetheQualityDepartmentandEngineeringDepartmenttoverifytheoperationalpreparation.Itisrecommendedtoadoptthelastpartcomparisonmethodorthefollowingitemstocheck作業(yè)指導(dǎo)書是否在工作現(xiàn)場；Iftheoperationinstructionisavailableattheworksite;操作人員是否具有規(guī)定的資格；Iftheoperatorpossessestherequiredqualification;設(shè)備的狀況；Statusofequipment產(chǎn)品的質(zhì)量狀況；Thequalitystatusoftheproduct環(huán)境的適宜性等。Thefitnessofenvironment.4.7.8外觀項目控制（對于顧客指定的或本公司規(guī)定的外觀項目須按以下要求進行控制）：AppearanceProjectControl(thefollowingcontrolappliestotheappearanceprojectdesignatedbythecustomerorspecifiedbythecompany):在有外觀要求的作業(yè)區(qū)域，必須配備必要的照明設(shè)施，對于有嚴格的顏色要求的產(chǎn)品工位必須使用自然光或白色光源，防止燈光反射造成顏色失真。Fortheoperationareawithappearancerequirement,necessarylightingfacilitiesshouldbeequipped.Fortheproductionsitewithstrictcolorrequirement,naturalorwhitelightsourcemustbesuppliedtoavoidlightreflectionandcolordistortion.在加工和檢驗處，須放置標樣，并使操作人員易于看到。Thesamplesshouldbeplacedonthemachiningandinspectionsiteseasyfortheoperatortosee.對標樣以及檢測設(shè)備須按《檢驗、測量和試驗設(shè)備控制程序》規(guī)定進行周期檢驗和控制。Thesamplesandtestequipmentmustbeinspectedonaregul