Hardware Manufacturing Quality Performance Management & Operation Methods

No.1  Purpose:

In order to improve quality, reduce defective rate, control defective products, and ensure product quality.

No.2  Scope:

All product quality related to the manufacturing department is applicable.

No.3  Responsibilities:

1. Factory director: approve the quality performance assessment methods, approve the quality performance assessment results, and supervise the implementation of the quality system
2. Supervisor and section chief: strengthen the management of the section group, ensure that tools, molds, fixtures and equipment are in good working condition, guide employees to operate in accordance with SOP, be responsible for the quality of the undergraduate group, lead the quality performance assessment of the employees of the undergraduate group, and ensure the normal operation of the management of this system.
3. Master and shifter: responsible for the guidance of the operation skills and product inspection of the employees of the group, the preliminary analysis and solution of the causes of the defects, and the record of the quality status of the team materials, and the right to reward and punish the quality control of the materials of the employees.
4. Operator: Strictly follow the SOP or sample operation, earnestly implement the first article inspection and independent inspection work, do not produce defective products, do not accept defective products, do not let go of defective products, and do a good job in the differentiation and isolation of defective products.
5. Quality controller: Carefully do the first article inspection and process inspection in accordance with the inspection standards. Ensure stable production of the process under quality control, timely do a good job in the identification and identification of defective products, notify relevant personnel in time and assist in improvement when abnormal situations are found, and be responsible for the classification and statistics of defective products.

No.4  Contents:

4.1 Quality management operation method

4.1.1 Prenatal raw material inspection

1. Inspection of raw materials that do not enter production is classified as pre-production raw material inspection
2. Before the raw materials enter the warehouse, IQC will inspect them, and if they do not meet the product requirements, they will be judged to be returned to the supplier, and if they meet the requirements, they will be deemed qualified and labeled as qualified, and the warehouse or workshop material personnel can be stored only then.
3. During the storage of raw materials in the warehouse or workshop raw material area, the warehouse or workshop material clerk must be maintained in accordance with the general principles of warehouse management. Such as: three modernization, five defense, first in, first out, etc.
4. When the material clerk or operator picks up the materials in the warehouse, he must see the material qualification label, and then preliminarily determine whether there is any abnormality before he can receive the materials; If there is an abnormality in raw materials, it is necessary to report the situation to the superior or the issuing unit in time.
5. If the operator finds that the quality of the material is abnormal before production and can no longer be used, he should report to the material staff in time in order to replace the qualified material.

4.1.2 First Article Confirmation:

1. After receiving each “dispatch work order”, the operator must first make the following preparations: determine the station and equipment, receive materials, receive molds, fixtures and auxiliary tools, etc.
2. Before the production, the master will debug the machine, first the master will make the first product, explain the product requirements and precautions with the operator, and after the operator understands, he can make the first product that meets the requirements according to the drawing or template, which is called its first piece.
3. After the master verbally confirms that the first article meets the requirements, the operator himself takes the first product to the on-site quality controller to confirm, and the quality controller will determine whether the first piece meets the quality requirements according to the product standards.
4. Meet the quality requirements is regarded as qualified, the quality controller will affix the “first sample qualification label” and sign, unqualified, the quality controller explains the reason, the operator will make the production, until the quality controller determines that it is qualified before mass production, the production model is not made and the private producer gives a warning in advance, resulting in a malignant quality accident fine.
5. The operator will place the qualified first sample in the visible place of the station, and often check whether the first sample is different during the production process, until the first batch of tasks is completed, and the first sample is shipped with the bulk goods.

4.1.3 In-production Inspection:

1. After the operator completes the first sample, the first 10 products produced must be self-inspected one by one, which can be compared with samples, drawings or SOP tables, etc., in order to test the stability of mold, fixture and equipment performance, and under the premise of quality assurance, you can also find more convenient and faster operation methods.
2. In the mass production process, operators are required to do their own inspections in order to detect and solve problems early, thereby reducing material waste and saving repair time, and improving individual and overall efficiency.
3. In the production process, the operator must know the requirements and characteristics of this process or product (accessories), and do a good inspection or mutual inspection of raw materials or semi-finished products in the upper process, so as to pick out the defective materials and no longer use them to ensure product quality.
4. At the production site, masters, shifters, etc. should constantly inspect the product quality of each station, and require each station to be carefully inspected at least once an hour. Explain the problems that have occurred or are prone to occur to the operators in detail, and repeatedly promote and strengthen the awareness of operators, especially the on-line production of new products.
5. All managers of the workshop must use measuring tools such as tape measure, vernier caliper, angle ruler, height gauge, etc., and must have the knowledge of basic drawing recognition, so as to better use it in the work and reduce production errors.
6. In production, when the operator has doubts or does not understand the product, he must ask the master or the shift clearly, and then carry out production after the problem is solved.

4.1.4 Delivery  Inspection:

1.  In the production process, the operator should uniformly and neatly discharge the qualified products on the left hand side of the station, and the small products can be placed in containers without damaging the product quality.
2. For the defective products that appear in the production, they should be selected during the process and placed uniformly or repaired in time, and the defective products that cannot be repaired should be reported to the master for handling.
3. When the operator completes the dispatch task of the batch, he should first rectify the station, count the number of outputs, and find the quality controller for shipment inspection.
4. If the quality controller points out the product defect, the operator must immediately rework, wait for the quality controller to check again, after the product is confirmed to be qualified, the operator can receive the operator’s product after receiving the “process card” from the material clerk, count the quantity in person, and make a receipt record.
5. After the material clerk receives the “Process Card” signed and confirmed by the quality controller, he can receive the operator’s products, count the quantity in person, and make a receipt record.
6. After the operator completes the delivery, he can receive the next batch of production task “Dispatch Work Order”

4.2 Management of defective products

4.2.1 Disposal of defective raw materials:

1. Every on-site production personnel must know the requirements and characteristics of the product, and be able to distinguish the quality of the material of each part.
2. When picking materials, material clerks and operators must see the raw material or accessories conformity label.
3. When using materials, the materials or accessories that are judged to be bad should be picked out and stored separately, and the bad materials can be used again after meeting the quality requirements after being repaired, and the materials that cannot be repaired should be returned to the material for replacement.

4.2.2 Handling of defective products:

1. First of all, in the production of products, it is necessary to work in strict accordance with samples, drawings or SOPs (work instructions), and the judgment of poor production is also based on samples, drawings or SOPs.
2. During the production process, for defective products, they should be maintained in time when they are minor, and if they are more serious, they should be picked out and put away, and pre-repaired before the batch is completed or left for work; It is strictly forbidden to mix the defective product into the qualified product and flow into the next process.
3. For defective products that can no longer be repaired, they can only be scrapped after the master and quality control are judged, and the material clerk can give replacement materials. If the scrap value is more than 20 yuan, fill in the “Scrapping Application Form”, which needs to be approved by the plant director and manager.
4. At the time of delivery, the quality control or master determines that the product is unqualified, and the operator is good to repair it in time, and the working hours are not recorded and punished.

4.2.3 Poor treatment of semi-finished products:

1. Defective semi-finished products or accessories made by the previous process or department shall be returned to the previous process or department for maintenance in a timely manner.
2.  If there is a defective product in the department and the department cannot repair it, it needs to be repaired by other departments, and apply to the PMC department at the level of section chief.
3. Packaging or outgoing defective products need to be returned to the manufacturing department for repair, you must apply to the PMC department, and the manufacturing department will arrange for repair.

4.3   Quality Management Reward and Punishment Regulations: For details, please refer to the Regulations on Rewards and Penalties of the Manufacturing Department and the Management System for the Use of Workshop Materials.

4.3.1  Incentives

1. All production personnel in the workshop discovered and negotiated to solve major quality problems by themselves, and gave the discoverers two commendations.
2. Give more than 2 commendations to the proponents for the production process, production process and operation methods that can put forward reasonable and reliable suggestions and can indeed improve quality and efficiency.
3.  If it is found that there is intentional destruction of product quality, it can stand up to stop it and timely reflect or report to the management or quality control personnel, and give the parties commendation.

4.3.2  Penalties

1. The material receiver shall carefully check the relevant information according to the “Dispatch Work Order” when sending materials, and impose a fine on the batch rework caused by the wrong issuance, depending on the seriousness of the case.
2. The operator shall operate according to the positioning of the mold during the production process, and those who change the mold without the unity of the workshop master shall be punished according to the circumstances.
3. Those who cause deformation or abnormality due to improper operation methods and unreasonable stacking methods shall be punished, and those who repeatedly make mistakes will be punished more severely.
4. After rework, the product is re-inspected for quality inspection and re-examination for reward and punishment.
5. The operator does not pay attention to the defective product, and continues to produce malignantly, so that the poor quality increases, and the penalty shall be imposed.
6. Operators or direct personnel shall be punished for batch rework or losses caused by opportunistic or cutting corners in the production process.
7. Each process must be produced according to the product’s process and quality standards, and if it refuses to perform, the defective product will be deliberately flowed to the next process and punished.

5  Summary:

Quality is the quality of the production product, is the top priority of the production process, and is related to the interests of customers, companies and workshops. For production line personnel, it is necessary to implement the quality concept of “product quality is made, not tested”.