Raw-material

Raw-material

The forging materials are mainly carbon steel and alloy steel of various compositions, followed by aluminum, magnesium, copper, titanium and the like and alloys thereof. The raw state of the material is bar, ingot, metal powder and liquid metal. The ratio of the cross-sectional area of ​​the metal before deformation to the cross-sectional area after deformation is called the forging ratio. Correct selection of forging ratio, reasonable heating temperature and holding time, reasonable initial forging temperature and final forging temperature, reasonable deformation and deformation speed have a great relationship to improve product quality and reduce cost.

Conventional small and medium forged materials use round or square bars as blanks. The grain structure and mechanical properties of the bar are uniform and good, the shape and size are accurate, and the surface quality is good, which is convenient for mass production. As long as the heating temperature and deformation conditions are properly controlled, high-quality forgings can be forged without requiring large forging deformation.

Ingots are only used for large forgings. The ingot is an as-cast structure with large columnar crystals and a loose center. Therefore, it is necessary to break the columnar crystal into fine crystal grains by large plastic deformation, and loosely compact, in order to obtain excellent metal structure and mechanical properties.

The powder metallurgy preform which is pressed and sintered can be made into a powder forging by hot forging without flashing. Forging powder is close to the density of general die forgings, has good mechanical properties, and has high precision, which can reduce subsequent cutting. The powder forgings have a uniform internal structure and are not segregated and can be used to manufacture workpieces such as small gears. However, the price of powder is much higher than the price of ordinary bars, and its application in production is limited.

By applying static pressure to the liquid metal poured in the mold to solidify, crystallize, flow, plastically deform and form under pressure, a die forging of desired shape and performance can be obtained. Liquid metal die forging is a forming method between die casting and die forging, and is particularly suitable for complex thin-walled parts which are difficult to form by general die forging.

Forging materials in addition to the usual materials, such as various components of carbon steel and alloy steel, followed by aluminum, magnesium, copper, titanium and other alloys, iron-based superalloys, nickel-based superalloys, cobalt-based superalloys The deformed alloys are also finished by forging or rolling, except that the alloys are relatively narrow in plasticity, so the forging difficulty is relatively large, and the heating temperature, opening and forging temperature and final forging temperature of different materials have strict requirements.

  1. purpose

Effectively handle customer-related processes to ensure customer satisfaction.

  1. Scope of application

This procedure is applicable to the determination, review and change control of requirements related to auto parts business.

  1. Duties and responsibilities

3.1 the sales department and customer representatives are responsible for the centralized management of customer-related processes;

3.2 relevant departments shall cooperate with the implementation.

  1. Work procedures

4.0 process input: customer requirements; Market information; Sales plan; Laws and regulations.

4.1 determination of requirements related to products

The sales department and the customer representative are responsible for identifying customer requirements related to the product, for oral or telephone orders, fill in the oral/telephone order record form, sign a written contract or record the product requirements, including:

  1. A) customer’s express requirements, including product quality requirements, delivery, support services (such as transportation, etc.), price, etc.;
  2. B) service requirements that are not specified by the customer but are necessary for the intended or specified use;
  3. C) statutory and regulatory requirements relating to the product and applicable government, safety and environmental regulations, including the acquisition, storage, handling, recycling, destruction or eventual abandonment of materials;
  4. D) other commitments made by the company, etc.;
  5. E) special features specified by customers. The company shall pay special attention to the special performance specified by the customer. The company meets the requirements of customers in terms of special features, documentation and control. If customers provide symbols for special features, the company shall adopt and identify them in the following documents:

— product and process FMEA;

— control plan;

— inspection instructions and on-site operation instructions;

— process flow chart.

  1. F) feasibility of manufacturing

This requirement is similar to the review of product requirements, but the connotation is quality planning activities. Before a company signs a contract for a product (generally a new product), it must review the manufacturing feasibility of the product, including:

Is the product fully defined?

— does the engineering performance specification meet the written requirements?

Can the product be manufactured to the tolerance specified in the drawing?

— can the product be manufactured with the required CPK value?

Is there sufficient capacity to produce the product?

Is the quality and cost reasonable?

The project team is responsible for filling the evaluation results into the feasibility commitment form.

4.2 contract and order review the sales department shall organize the review of the contract and order draft according to the identified/confirmed requirements before accepting the contract.

4.2.1 scope of contract review

The company reviews the following contracts:

  1. A) draft contract;
  2. B) other requirements within the framework of the signed contract;
  3. C) external publicity materials or written commitments related to auto parts business formulated by the company.

4.2.2 all contracts within the scope of the review shall be reviewed to ensure that:

  1. A) requirements are clearly defined and documented;
  2. B) any contract or order requirements inconsistent with the tender have been resolved;
  3. C) the company has the ability to meet the requirements of the contract or order;
  4. D) the content of the contract must be accurate and legal.

4.2.3 content and method of review

  1. A) contract/order review: the sales manager shall review the draft contract item by item and other departments shall cooperate.
  2. B) review of external publicity materials or written commitments: original texts/printed samples shall be submitted to the management representative for review and approval by the general manager.

4.2.4 review records

After the completion of all kinds of review activities, personnel at all levels shall issue review opinions in the contract review record form, which shall be kept by the sales department. For telephone or verbal orders, the recorder confirms the order content with the customer.

4.3 contract execution

4.3.1 the sales department shall deliver the contract requirements in the following ways

  1. A) the auto parts business with special requirements shall be delivered to the technical department, which shall be responsible for translating the requirements related to the products into product specifications and service requirements, compiling the project quality plan or carrying out process development.
  2. B) regular and mature contracts/orders without special requirements shall be copied and directly sent to the production department.

4.3.2 personnel at all levels shall organize the implementation of the contract/order as required.

4.4 change of requirements related to products

4.4.1 the sales department shall organize the review of the above changes related to product requirements in accordance with the provisions of this procedure.

4.4.2 the sales department shall submit the revised information to the technical department and the production department in the form of the contract change notice to ensure that the revised information can be correctly delivered to the relevant personnel and be implemented.

4.5 customer communication

4.5.1 responsibilities and scope of customer communication

4.5.1.1 when organizing the contract review, the sales department shall timely communicate with customers on the performance and quality requirements of the products, as well as the contract implementation and changes.

4.5.1.2 the sales department shall introduce product information to customers, answer customers’ inquiries, including contract changes and record them.

4.5.1.3 technical department supervisors shall communicate with customers about the technology, quality and other information of auto parts.

4.5.2 communication with customers involves the following contents:

  1. A) product information, such as technical quality requirements, delivery requirements, etc.;
  2. B) inquiries (such as inquiries, quotations), the handling of contracts or agreements and their modifications;
  3. C) customer feedback, including customer complaints.

4.5.3 communication and implementation

  1. A) in the language or manner specified by the customer, such as cad data, edi, 8D reporting.
  2. B) each customer representative shall effectively implement all communication arrangements with customers.
  3. C) in the process of communication, changes and communication information related to contract/order and other requirements shall be recorded.
  4. D) the sales department shall investigate and deal with the customer complaints it has accepted, and effectively solve them, and make records in the on-site service work records.

5 relevant forms/records

  1. Contract review record form
  2. Site service record sheet

C order receiving registration form

  1. Contract registration form
  2. Contract change notice
  3. project quality plan

G. Group feasibility commitment table

2500T forging production line

1.Purpose
Manage product delivery process to ensure on-time delivery.
2.Scope
Applicable to product delivery management.
3. Responsibility and authority
The sales department is responsible for the management of product delivery.
4.0 working procedure
4.0 process input: delivery plan.
4.1 the sales department shall determine the mode and time of product delivery according to the requirements of the order for product delivery, prepare the “shipping plan”, issue the “shipping notice”, and inform the product name (drawing number, quantity and receiving unit) of the product.
4.2 the salesman shall take delivery of the goods at the warehouse with the shipment notice, and the warehouse administrator shall record the flow direction of the batch number products.
4.3 the warehouse distributes products according to the shipment notice, and records the batch number of products;
4.4 the quality control department shall be responsible for providing the corresponding inspection and test records according to the product batch number. If electronic records are required, the quality control department shall send an email to the receiving unit on the same day.
4.5 after checking the goods, the salesman shall go to the quality control department to get the material sheet and test report of the batch products after checking the name and quantity. Material list and test report should go together with the product.
4.6 for nearby places, the salesman will deliver the goods by car and handle the goods acceptance procedures at the customer’s office.
4.7 for the long journey, the salesman shall handle the consignment/mail, and the salesman shall maintain the delivery certificate procedures, timely track the acceptance of the customer and accept the receipt in the normal response time of the customer.
4.8 after receiving the customer receipt, the salesman shall go through relevant procedures in the financial department in time.
4.9 the salesman shall track the acceptance and use of the customer, solve the problems raised by the customer in a timely manner, including the possible reasonable requirements of the customer.
4.10 in case of customer service requirements, the salesman shall provide relevant services. In case of need, the salesman shall contact relevant production or technical personnel, go to the customer for service, record the service contents and results, and fill in the on-site service record form, including the customer’s evaluation of the service.
4.11 salesman/resident representative shall track and record the delivery and acceptance of products and the use of customers in assembly. Report major nonconformities and customer complaints by phone in a timely manner.
5. Relevant documents/records
a. Shipping order
b. Certificate of delivery procedure/customer receipt
c. The delivery plan

1.Purpose
Measure customer satisfaction to find improvement direction.

2.Applicable to the measurement of customer satisfaction.

3. Responsibility and authority
The sales department is responsible for the management of customer satisfaction.

4. Workflow
4.0 process input: customer communication and information feedback, product quality and delivery certificate/record.
4.1 measurement and analysis of customer satisfaction
4.1.1 planning of satisfaction monitoring and measurement
Conduct regular customer satisfaction surveys.
A. survey cycle: quarterly.
B. Survey objects: covering 90% of the customers, responsible personnel of relevant units of customers under investigation.
C. Survey items: quality of the company’s products; Delivery status; Service status; Production interruption of customers caused by our products; Significant customer feedback on product quality or delivery issues, additional shipping costs, customer perception, etc.
D. Investigation department: sales department.
E. Survey methods: statistical survey methods were adopted.
F. The customer satisfaction survey shall take into account both the last customer satisfaction and dissatisfaction, as well as the actual production and operation status.
4.1.2 carry out investigation
4.1.2.1 the sales department shall organize a customer satisfaction survey every quarter.Survey customers who have contracts and/or business dealings with the company in the form of a customer satisfaction questionnaire. The main means of transmission are: fax, visit, mail, E-mail and please carry.
4.1.2.2 after the “customer satisfaction survey form” is issued, the sales department shall timely track, feedback and contact customers to fill in and reply to the status.
4.1.2.3 relevant units of the company shall organize and carry out an investigation on the actual operation status of the company:
A. The sales department shall make monthly statistics and analysis of delivery, service quality level, customer notification, and customer production interruption (including sales returns).
B. Monthly statistics and analysis of product quality level by quality control department.
C. The production department organizes each workshop to calculate the process capability and process capability index of the company’s important processes every month.
D. The financial department calculates the actual operating cost, excess freight and profit of the company every month.
E. Submit the above analysis results to the sales department.
4.1.3 summarize and analyze the satisfaction
The sales department shall organize relevant departments to analyze according to the results of customer satisfaction survey and the actual operation status of the company, and form a “customer satisfaction statistical analysis report”, which shall include the trend of customer satisfaction and the main aspects of customer dissatisfaction as well as the performance indicators and improvement measures.
4.2 collect customer feedback and provide after-sales service
4.2.1 collection and feedback of feedback information
A. After receiving customer feedback, the sales department shall timely provide feedback to the quality control department and other relevant departments with the “customer feedback information processing report”.
B. The sales department keeps a record of the accounts.
4.2.2 processing of feedback information

Deliver customer feedback from sales to quality control.

The quality control department shall organize relevant departments to study and formulate corrective measures, and propose service methods, which shall be implemented by relevant departments.

C. After the completion of the service, the service implementation unit shall feed back the service results to the sales department and quality control department.
4.2.3 realization of after-sales service
4.2.3.1 telephone service method: put the summary record of the result of telephone service on the “field service record”. If necessary, if the telephone cannot be said clearly or words need to be confirmed, the report shall be sent to the customer in the form of fax. The original copy of the fax shall be attached to the field service record.
4.2.3.2 on-site service method: after the end of on-site service, the entrusted on-site service personnel shall keep the service content in the form of “on-site service record”. If it needs to be confirmed by the customer, it must be signed by the customer representative. After returning to the company, the service personnel shall submit the “on-site service record” to the sales department for preservation and feedback to the quality control department.
4.2.4 provide guaranteed return and replacement services, and relevant expenses shall be included in the quality cost.
4.3 plan improvement measures
In view of the problems in the analysis results, the sales manager shall organize the relevant departments to make improvements, and supervise and promote the improvement process. Related corrective and verification work according to “improve control procedures”.
4.4 implementation of improvement measures
4.4.1 the sales department is responsible for improving service quality and delivery quality.
4.4.2 the technical department is responsible for the improvement of application development problems and product performance problems.
4.4.3 the quality control department is responsible for the improvement of product quality problems.
4.4.4 the workshop is responsible for the improvement of the process capability of the unit.
4.4.5 the financial department is responsible for the improvement of price issues.
4.5 submit for management review
All related units shall submit investigation report, investigation analysis report and implementation of improvement measures during the management review of the company.

5. Relevant documents/records:

a.Customer satisfaction questionnaire

b.Customer satisfaction statistics

c.Customer feedback information processing report

Tensile-test-equipment
  1. purpose

This procedure identifies and establishes the steps required to ensure customer satisfaction with the product, promotes contact with everyone involved to ensure that the required steps are completed on time, and guides resources to prevent defects, reduce costs, continuously improve, and provide quality products at the lowest cost in a timely manner to satisfy customers.

  1. Scope of application

This procedure applies to the process development of all products required for the production and/or service of the company.

  1. Duties and responsibilities

3.1 technology department is the centralized management unit of this procedure, responsible for the establishment of project team and the completion of task allocation.

3.2 all departments shall cooperate with the implementation.

  1. Work procedures

4.0 process input: customer product requirements, contract/development agreement;Similar product development information

4.1 development preparation

4.1 the general

APQP process is generally divided into: planning and determining the project; Sample development; Process design and development (including review and validation); Product and process validation; Feedback, evaluation and corrective action. The company has no product design and development activities.

  • The basic principles of APQP
  1. A) the purpose is to fully meet customer requirements and expectations.
  • Optimize resource allocation to produce quality products that satisfy customers at the lowest cost.
  • Promote early identification and prevention to reduce deterioration and avoid late or late changes.
    • The basic method of APQP
  1. A) logical thinking: an analytical method that emphasizes the input and output of the process.
  • Synchronization technology: shorten the implementation cycle, close interface relationship, and emphasize efficiency.
  • Multi-participation: including internal functional representatives and external customer and supplier representatives planning together.
  • Application of error – proofing technology, FMEA, SPC, etc.

4.4 project approval

The sales department, by collecting market information, customer requirements or market survey, on the basis of analysis of sufficient data, based on the company’s business plan and business objectives, puts forward the “project development application form”, which will be reviewed by technical, production, quality control and other departments and reported to the general manager for approval.

4.5 basic process of APQP

4.5.1 plan and determine the project stage:

4.5.1.1 constitute a project team: after the approval of the project development application form, the general manager shall determine the project team leader, organize and set up a project team with representatives of technology, sales, quality control, finance and production (including customers and qualified suppliers when feasible), define their respective responsibilities and urge the project team to carry out work regularly.

4.5.1.2 input data collected by project team members: input data may include customer calls, such as “market research report”, service information and invalidation of main engine plant, return report, company business plan and business objectives, product/process benchmark, previous experience, customer contract or order.

4.5.1.3 project team members shall, on the basis of understanding customers’ needs, expectations and requirements, compile (initial) product process flow chart, product initial material list, (initial) product/process special features list, etc., conduct feasibility analysis and form the feasibility analysis report.

Feasibility analysis: when the project is feasible, it can be carried on to the next stage. If it is not feasible, the technical department can change the relevant scheme or cooperate with the sales department to negotiate with customers.

4.5.1.4 preparation, review and assignment of design tasks: the project team leader shall prepare the design specification and submit an application for review, and the technical supervisor shall organize relevant personnel to conduct review to ensure sufficient and appropriate design input; The content should be complete, clear and not contradictory. After the review, the general manager approves the design specification.

4.5.1.5 plan making: the project team leader shall, according to the requirements of the project, organize the members of the project team to discuss and form the APQP work plan, which shall specify the task requirements, group indirect communication and schedule of each stage and fully consider the current work requirements. See appendix 1 for the work schedule of APQP.

4.5.1.6 members of the project team shall be responsible for organizing and carrying out skills training: the analysis techniques involved in the planning activities, such as FMEA, PPAP, SPC, MSA and development skills training, shall be carried out for the members participating in APQP.

4.5.1.7 manager support: after the project is determined, the project team leader shall fill in the written document of manager support and submit it to the manager for further support, and the design and development shall enter the next stage.

4.5.1 sample development

4.5.2.1 preparation of sample trial production plan: the technical department shall prepare the “notice of new product trial production plan” to ensure the trial production of samples as planned.

4.5.2.2 preparation of sample control plan: process design members of the project team are responsible for preparing the sample control plan. For similar products, the same control plan can be applied to the implementation process of similar products if the universality of the products has been reviewed.

4.5.2.3 the technical department is responsible for preparing the sample process procedures. The sample process specification can be made use of similar product process documents that have been reviewed.

4.5.2.4 preparation list: the technical department shall be responsible for the preparation of the order form/new product equipment/tooling/mold/fixture list, the design of new tooling according to the order form, and the preparation of the test equipment list. Technical documents shall be examined and approved according to the requirements of the administrative measures for technical documents.

4.5.2.5 material procurement: the procurement department is responsible for selecting suppliers from the prescribed suppliers and purchasing materials according to the material list and procurement control procedures.

4.5.2.6 sample trial-manufacture: the production department is responsible for organizing and the production workshop is responsible for trial-manufacture according to the requirements of “notice of trial-manufacture plan for new products”, “control plan” and “process specification”; The quality control department is responsible for testing and testing the samples according to the provisions of the control plan and the process specification, and checking and accepting the new tooling; The quality control department is responsible for process verification.

4.5.2.7 sample confirmation

  1. A) sample validation may be performed in one or more of the following ways:

— the company tests and tests the samples;

— samples can be submitted to customers for bench or performance testing.

  1. B) the technology department and the sales department are responsible for collecting customer product design confirmation (installation test) information and keeping it by the technology department.

4.5.2.8 sample technical document changes

In the sample development stage, the technical department shall change the technical documents according to the technical document management measures.

4.5.2.9 management support: after the sample trial production is completed, the project team shall submit an application, and the general manager shall organize members of relevant departments to review the work in the sample development stage. After the review is passed, the project team leader shall fill in the written documents of “group feasibility commitment” and “management support” and submit them to the manager for further support, and the design and development shall enter the next stage. If the original plan cannot be carried out, the work plan should be adjusted according to the situation.

4.5.3 process design and development:

4.5.3.1 process design input and review

The technical department is responsible for collecting the input data of this process and organizing relevant personnel to review and keep records of the input according to the requirements of the product/process quality checklist.

4.5.3.2 process design output and review

  1. A) preparation of process flow chart: process designers in the technical department shall prepare process flow chart and characteristic matrix table according to product drawing and product special characteristic list. The technical department is responsible for the review according to the process flow chart checklist.
  2. B) drawing the layout of workshop: the technical department shall draw the layout of workshop according to the principles of process flow chart framework, detection point setting requirements, optimized utilization of site space, reasonable logistics and man-machine engineering. The technical department organizes relevant departments to review the floor plan according to the workshop floor plan checklist.
  3. C) determination and review of process FMEA analysis and process special characteristics: members of the project team, technical department and quality control department shall prepare product and process special characteristics and process FMEA analysis table according to process flow chart and characteristic matrix table. The project team leader shall organize relevant department members to review the process FMEA and process special features according to the process FMEA checklist.
  4. D) preparation of pilot production control plan: project team members shall prepare the pilot production control plan. For similar products, the same control plan can be applied to similar product realization process if the commonality of products has been reviewed.
  5. E) preparation and review of process procedures: the technical department shall prepare the process procedures (including inspection work instruction) according to the requirements of the pilot production control plan, and propose new tooling design tasks. After the completion of the design, the approval shall be conducted in accordance with the provisions of the technical document management measures.
  6. F) new tooling design: the technical department is responsible for new tooling design. After the completion of the design, the approval shall be conducted in accordance with the provisions of the technical document management measures.
  7. G) preparation of measurement system analysis plan: members of the project team shall prepare the measurement system analysis plan in accordance with the manual of measurement system analysis. Measurement system analysis is mainly aimed at the measurement system involved in the control plan.
  8. H) preparation of the initial process capability study plan: the project team members shall be responsible for the preparation of the initial process capability study plan. Initial process capability studies are conducted for all production process projects of developed products.
  9. I) preparation of product packaging specifications: the technical department is responsible for the preparation of product packaging specifications.

4.5.3.3 process design changes

The technical department shall change the design documents according to the “technical document management measures”.

4.5.3.4 management support: after the goal of the process design and development stage is completed, the project team shall submit an application, and the general manager shall organize members of relevant departments to review the process design and development stage. After the review is passed, the project team leader shall fill in the written documents of “group feasibility commitment” and “management support” and submit them to the manager for further support, and the design and development shall enter the next stage. If the original plan cannot be carried out, the work plan should be adjusted according to the situation.

4.5.4 process validation and verification

4.5.4.1 prepare and issue pilot production plan: the production department is responsible for preparing production plan.

4.5.4.2 job preparation verification: the production workshop shall conduct job preparation verification according to the product production control procedure.

4.5.4.3 pilot production: the production workshop shall organize production according to the pilot production plan. The technical department shall cooperate with the workshop to confirm the process according to the product production control procedure; The quality controller monitors and measures the products according to the control plan. The production department shall provide corresponding records to the technical department; Technical department, production workshop to verify the process.

4.5.4.4 measurement system analysis: the quality control department carries out dual analysis of measuring tools according to the measurement system analysis plan, evaluates, records and forms “measurement system analysis report”.

4.5.4.5 initial process capability study: the workshop shall carry out the initial process capability study according to the initial process capability study plan, and prepare the “initial capacity analysis report”. In case of insufficient capacity, corrective measures shall be proposed.

4.5.4.6 package evaluation: the technical department shall evaluate the package specification and package, and provide the results to the project team.

4.5.4.7 supplier PPAP:

  1. A) the technical department puts forward the requirement for suppliers to submit PPAP;
  2. B) technical department and purchasing department shall collect supplier PPAP documents as required;
  3. C) the technical department shall organize relevant departments to review the supplier PPAP, and approve the batch supply of the supplier after the review is passed.

4.5.4.8 process confirmation

  1. A) when the customer has no PPAP requirement, the project team shall confirm the company according to the procedure after 4.5.4.11.
  2. B) when customers have PPAP requirements, implement customer requirements, and the purchasing department is responsible for collecting customer PPAP approval documents. The customer confirms the following method:

— customer PPAP approval;

— customer confirmation of product drawing (countersign or sign similar confirmation opinions);

— customer replacement production drawing;

— other written documents of the customer;

— the customer orders again according to the original drawing (the order contract shall prevail).

4.5.4.9 mass production control plan: after PPAP is passed, project team members shall improve on the basis of pilot production control plan and prepare mass production control plan to meet the control requirements of mass production. The project team leader organizes members of relevant departments to review.

4.5.4.10 preparation list: the technical department is responsible for the preparation of material purchase list and tooling summary table; For similar products, if the commonality of the products has been reviewed, the same list can be applied to the implementation process of similar products.

4.5.4.11 after the trial production, the project team shall submit the application for development review, and the technical department shall organize members of relevant departments to review the design and development process and fill in the record form of design and development review.

4.5.4.12 quality planning, confirmation and summary: APQP shall be confirmed and summarized before the delivery of the first batch of mass production products. Including review:

— whether the control plan is timely updated and fully configured;

— whether the process instructions are advanced, detailed, operable and immediately available;

— whether the measuring tools and test equipment are analyzed for duality, accurate and reliable;

— whether all control plans and process flow charts are followed;

— whether APQP has always received the attention and support of the company’s management and conducted a management review.

4.6 engineering change

4.6.1 internal changes

4.6.1.1 in case of parts stopping production, delivery time, price or other factors requiring replacement materials, the purchasing department shall apply to the technical department for change.

4.6.1.2 if the quality control department finds any quality variation during the inspection, and the process capability analysis confirms that the production conditions must be changed, the change application shall be submitted.

4.6.1.3 when the manufacturing conditions must be changed by introducing new equipment or new processing technology, the production department or relevant departments shall apply for the change.

4.6.1.4 in the process of production, the production department shall apply for change if there are operational improvement Suggestions.

4.6.1.5 in the process of production, inspection and sales of products by other departments, if unreasonable or improvable product design is found, each unit can fill in the “engineering change application form” to apply for change to the engineering department.

4.6.2 customer changes

When the customer requests to change, the sales department shall provide the customer change data and engineering change application form to the technical department to evaluate the feasibility of the change, and the production department shall count the inventory quantity. If the client has a specified format, use a standard format file.

4.6.3 engineering change review

4.6.3.1 external engineering change application, the technical department shall organize relevant departments or multi-functional groups to discuss the feasibility of the change. If it is not feasible, the reasons for the infeasibility shall be recorded and faxed to the customer by the sales department for reassessment.

The technical department shall work with the customer to review patented designs that affect changes in form, fit and function (including performance, and/or durability) to properly evaluate all impacts.

4.6.3.2 internal engineering change application form, after receiving the engineering change application form, the technical department supervisor shall review the product quality, environmental protection, cost, production efficiency and other factors according to the change content. If it is confirmed that it is not feasible, it shall explain the specific reasons for returning it to the application unit for processing. If no consensus is reached, the management shall rule.

The sales department is responsible for notifying and obtaining the consent of customers of any changes affecting the implementation of the products required by customers.

For proprietary designs, impacts on form, fit, function (including performance and/or durability) shall be reviewed with the customer so that all impacts are properly assessed.

4.6.3.3 the engineering change review shall be completed within 2 working weeks, if required by the customer, within the time specified by the customer.

4.6.4 formulate the change plan

After the above change requirements are verified to be feasible, the technical department supervisor shall appoint engineers to organize a multi-functional team to take comprehensive consideration of product quality, environmental protection, cost, efficiency and other factors, and formulate a change plan, which shall be consistent with customer requirements. And record in engineering change request form.

4.6.5 engineering change approval

The engineer will complete the engineering change application form for the change scheme and submit it to the head of the technical department for approval. The technical department will submit the approved engineering change application form and the change data to the business department for the customer’s approval of the change scheme.

4.6.6 implementation of engineering change

After the approval of the engineering change application form, the engineer shall fill in the engineering change notice, distribute it to the production department, technical department and other relevant units, and urge all units to implement the change according to the content requirements of the engineering change notice. The technical department is responsible for tracking the implementation of engineering changes.

4.6.7 engineering change validation

4.6.7.1 the engineer shall arrange the sample production and trial production according to the sample production requirements of this procedure, and submit the qualified samples and relevant materials to the sales department for the customer’s confirmation after the qualified samples are tested.

4.6.7.2 the product size and safety performance test after the change shall be conducted by the laboratory of the quality control department of the company or by an external laboratory entrusted by the company.

4.6.7.3 for material/component changes, the supplier or the company’s outsourced laboratory shall test and provide the corresponding test report. The test report shall be approved by the head of technical department.

4.6.7.4 the technical department is responsible for ensuring that additional verification/identification requirements, such as those for npi, are met when requested by customers.

4.6.8 summary of engineering change

After the completion of engineering changes, if the customer drawings, product specifications and functionality are affected, the technical department shall modify the corresponding control plan, FMEA, inspection specifications and other documents, and the sales department or technical department shall submit them to the customer for approval according to the PPAP procedures, and track the approval results.

4.6.9 file preservation

Change documents related to automobile products shall be retained until the product is discontinued and the after-sales service period is 1 year.

Impact-test-machine

Product production control procedure

1.Purpose

Control the manufacturing process to ensure process capability and manufacturing quality.

2.Scope

Applicable to the company’s auto parts production process control.

  1. Responsibility and authority

The production department is responsible for this process management.

  1. Workflow

4.0 process input: order/delivery plan; Inventory; Product specification/work instruction.

4.1 production plan

4.1.1 receive orders

After signing the contract, the sales department issues the production order to the production department, and the production department signs it.

4.1.2 status survey (inventory, order demand, production capacity, wip)

Production department according to the production orders issued by the sales department, inventory statistics, production capacity analysis.

4.1.3 decompose the production plan

Production department according to master the relevant information (safety inventory, production capacity, order demand, wip) according to the relevant requirements of order demand, and consider the priority of each order, do the monthly order decomposition, using the production schedule, regular weekly or daily production plan to the relevant workshop.

4.1.4 production realization

4.1.4.1 under normal circumstances:

Workshop production plans issued from the production department, in order to further review, have the ability to produce according to the sales department and production department of production plan and instructions, decomposition to the team and individuals, and completes the process of design, material of the declaration, tooling equipment, acquisition and related preparatory work, at the same time to organize the process production scheduling work.

If the workshop is unable to produce or the production plan has relevant problems, the head of the workshop shall report to the production department and sales department, and the production department shall make a clear reply and adjustment within one day.

4.1.4.2 in case of abnormality:

  1. A) in case of emergency orders from customers, the production department shall give instructions according to the demand of emergency orders and issue relevant workshops as required. The workshops shall organize production scheduling in the form of fast lanes.
  2. B) inspection and coordination

In the process of production operation or the current month, the production department shall check and track the production schedule of the production plan, communicate and coordinate the problems encountered, and make mandatory requirements when necessary.

  1. C) program evaluation

During the production operation or at the end of each month, the production department will make summary analysis and report according to the completion of the production plan of each workshop, that is, the completion rate of the plan and the failure rate of the working procedure, and make rewards and penalties evaluation through the production management system.

  1. D) demand analysis of equipment and personnel

The workshop shall make a comprehensive analysis of the monthly production plan, make a rectification plan if it is unable to complete the task according to the relevant plan indicators, and report to the production department in time.

  1. E) management review

After receiving the workshop’s rectification plan, the production department shall review the rectification plan according to the relevant requirements, and feed back the implementation of the relevant instructions to the workshop.

4.2 production process management

4.2.1 production preparation

4.2.1.1 the production department shall implement cleaning site and stationary site.The regulations on the cleaning of the factory and the location of tools and articles on site shall be implemented in accordance with the 5S related specifications.

4.2.1.2 the production department shall prepare materials, and external procurement or outsourcing shall be carried out according to relevant procedures.

4.2.1.3 the production operation plan shall be arranged according to the requirements of customers, according to the principle of priority and priority, which is conducive to quality control, and conducive to logistics.

4.2.1.4 the production department shall be responsible for the training of operators, and the training of operators in key processes shall be strengthened according to the human resource control procedures.

4.2.1.5 the equipment management personnel of the production department shall be responsible for checking the production equipment and molds, carrying out regular maintenance, and carrying out pre-maintenance, which shall be carried out in accordance with the equipment and tooling control procedures.

4.2.2 job preparation verification

4.2.2.1 timing of verification: during the initial production, material replacement and operation change.

4.2.2.2 the production department is responsible for the verification of facilities and environmental preparation conditions, including equipment, tooling, measurement system, operation documents, material preparation, etc.

4.2.2.3 the production department is responsible for verifying process status to ensure process capability. Generally, the first piece inspection is adopted.

4.2.2.4 if the quality is not stable, the production department shall continue to adjust the machine tools and tooling.

4.2.2.5 normal production can only be started after the first piece of inspection is qualified.When the material is changed, the operation is changed, and the production is resumed after a long period of discontinued production, it should be verified in time.

4.2.3 normal production

Under normal circumstances:

  1. A) the production unit shall, according to the production plan issued by the production department, organize production according to the product operation instruction and process specification.
  2. B) the control of process documents shall meet the requirements of technical document management measures.
  3. C) the process documents must specify the product processing process, process parameters, material requirements, tooling requirements and related inspection requirements, etc. as the basis for process control.
  4. D) product storage and handling in the production process shall be carried out according to the product protection and control procedures.
  5. E) each inspection shall be carried out according to the requirements of process control in the production process, and the specific implementation shall be in accordance with the product monitoring and control procedures.

4.2.4 in case of abnormality:

  1. A) suspicious or unqualified products found in the production process shall be subject to the control procedures for nonconforming products.
  2. B) after any abnormality occurs in the production process, corrective measures shall be put forward according to the improvement control procedures for continuous improvement.
  3. C) relevant leaders (scheduling) of the production department, who are directly responsible for coordinating quality-related activities and problems.

4.2.5 inspection and coordination

In the process of production operation or the current month, the production department shall check and track the production schedule of the production plan, communicate and coordinate the problems encountered, and make mandatory requirements when necessary.

4.2.6 production inspection

Product in the production process, on-site quality control personnel to carry out inspection, in accordance with the “product monitoring and control procedures” implementation.

4.2.7 identification management and protection

According to the labeling management “product packaging, labeling provisions” control implementation.

4.2.8 production records

4.2.8.1 control the production process and fill in corresponding records according to the product control plan.

4.2.8.2 after the end of the production on the day, the team leaders shall fill in various production statistical statements, submit them to the production supervisor of the unit for summary, and make a daily report to the production supervisor of the workshop of the production department

4.2.9 final inspection

In the process of production or after the completion of product processing, the inspection shall be carried out according to the requirements of drawings and process control, and the specific implementation shall be in accordance with the product monitoring and control procedures.

4.2.10 handling warehousing

4.2.10.1 after the product is processed, relevant warehousing procedures, such as warehousing receipt and inspection report form, shall be handled after passing the inspection.

4.2.10.2 product storage and handling in the production process shall be carried out in accordance with the product protection control procedures.

4.2.11 delivery

The sales department will implement the delivery according to the arrangement of customers, and follow up the situation of the product delivery. Implement delivery control procedures.

4.2.11 statistics

4.2.11.1 the production department shall make statistics on the planned completion status (completion rate) of the corresponding production units.

4.2.11.2 the quality control department shall make statistics on the defective rate of process.

4.2.12 production evaluation and improvement

During the production operation or at the end of each month, the production department will make a summary analysis and report according to the completion of the production plan of each workshop, that is, the completion rate of the plan and the defective rate of the process, and the responsible unit will analyze the causes, compile and implement the rectification plan, and implement the improvement control procedure.

5.Relevant documents/records

  • 5S management specification
  • Product inspection specification
  • Provisions on product packaging and marking
  • Product protection control procedures
  • Work instruction/process card for each process
  • The production plan
  • Three control record
  • Product inspection record
  • Process SPC records
  • Batch number management ledger
product-testing

1.0 purpose

Inspect and test raw materials, purchased parts, semi-finished products and finished products to prevent unqualified raw materials, purchased parts from unexpected use, unqualified semi-finished products from being transferred and unqualified finished products from leaving the factory.

2.0 scope of application

Applicable to the company’s raw materials, purchased parts, semi-finished products, finished products inspection and test control.

3.0 responsibilities

3.1 the quality control department is responsible for the inspection and test of raw materials, purchased parts, semi-finished products and finished products.

3.2 the production workshop is responsible for the implementation of process inspection.

3.3 the laboratory of quality control department is responsible for testing the specified project.

3.4 the technical department is responsible for formulating and issuing inspection procedures and relevant standards for raw materials, purchased parts, semi-finished products and finished products.

4.0 working procedure

4.1 preparation before inspection and test

4.4.1 by qc department according to the control plan, process documents, inspection instruction, before starting the inspection, review is a crucial test of each way and the method to make provisions of the project, its contents include: inspection method, inspection tools and precision, sampling method, assessment method, recording method, indicate that may need to provide the quality records, test and verification records.

4.1.2 when preparing sampling plan for data reception of counting characteristics, the acceptance criterion must be C=0 sampling plan.

4.1.3 inspection method

Sampling inspection: inspectors shall conduct sampling inspection of raw and auxiliary materials, purchased parts, semi-finished products and finished products.

Full inspection: the inspection of semi-finished products in the process by workshops and inspectors.

Self inspection: inspection performed by the operator himself.

“Three inspection system” : first inspection, patrol inspection, final inspection.

  1. First inspection: operators and inspectors inspect the first three products processed or assembled in each process. Batch production is not allowed if the first inspection is unqualified.
  2. Inspection: the inspector shall make sampling inspection in the process of product processing or assembly. If the inspection fails, the inspector shall timely adjust the process for correction, conduct the first inspection again, and conduct 100% inspection on the processed products.
  3. Final parts inspection: workshop inspectors shall inspect 1-3 pieces of products finally completed by operators.

4.2 incoming inspection and test

4.2.1 after the arrival of raw materials and purchased parts, the warehouse keeper shall fill in the “material entry and delivery inspection form” and send it together with the quality certificate documents to the external inspection room under the quality control department.

4.2.2 after receiving the “inspection sheet for materials entering the warehouse”, the external inspection room shall carry out inspection, test or verification in accordance with the “verification and inspection rules for purchased (co-purchased) parts”/drawings;If the warehouse keeper cannot provide the supplier’s “quality certificate” at the same time, the external inspection room has the right to reject the inspection.

4.2.3 the inspector of the external inspection room shall fill in the inspection and test results on the “materials warehousing delivery and inspection sheet” respectively, one copy shall be fed back to the purchasing department, and the other copy shall be kept by himself. If qualified, the materials shall be warehoused, and if unqualified, relevant provisions of the control procedures for nonconforming products shall be followed.

4.2.4 inspectors shall record the inspection results and transfer them to the quality control department for approval. In addition to timely monitoring the quality of incoming goods, it can also be used as the data of supplier evaluation.

4.3 process inspection and test

4.3.1 the technical department shall make control plans, inspection procedures and inspection process CARDS according to product drawings and other requirements.

4.3.2 process inspection and test shall be carried out by relevant personnel organized by the workshop according to the requirements of process documents, and the quality control department shall be responsible for verifying and monitoring the effectiveness of process inspection and test. Evaluate the process capability of important or special processes as needed.

4.3.3 operator self-inspection

Operators shall conduct self-inspection in accordance with the requirements of the control plan/process document and mutual inspection if necessary, or the team leader and full-time inspectors shall assist in inspection and approve the self-inspection results.

4.3.4 full-time inspectors in the workshop shall inspect and test process characteristic items according to the inspection procedures/control plan, and fill in the results in the “quality inspection record form”.

4.3.5 monitoring the effectiveness of process inspection

  1. The quality control department shall check the completion inspection records of full-time inspectors in the workshop to verify whether the inspection items and frequency meet the requirements of process documents;
  2. The quality control department shall reinspect and record the completed products.

4.3.6 if unqualified products are found during the process inspection and test, the control procedures for unqualified products shall be followed.

4.4 final inspection and test

4.4.1 the final product inspection can only be carried out after all the specified assembly procedures, inspection or test procedures have been completed and the specified requirements have been met; Inspectors perform inspections in accordance with inspection procedures/control plans and fill in final product inspection records.

4.4.2 for qualified products, only after the inspector issues the “product qualification certificate” can they be put into storage.

4.5 delivery inspection

4.5.1 before shipment, the quality control department’s delivery inspector shall unpack and inspect each batch of products according to the inspection items in the “product delivery inspection report”, and sign/seal the invoice after passing the inspection. And fill in the “product delivery inspection report form”.

4.5.2 the delivery inspector shall deliver all quality certificates to the warehouse keeper, who shall deliver them to the owner of the carrier to deliver to the customer.

4.5.3 upon customer’s request, chemical analysis supporting data of materials and test report of products shall be provided.

4.6 full size inspection and functional test

Annual full-size inspection and functional test shall be carried out by the quality control department in accordance with the specified requirements and according to the frequency specified by the customer (if the customer has no requirements, the annual production of 40,000 sets of products shall be conducted once a year), and the test report shall be reviewed when the customer requires.

4.7 all inspection and testing and reporting shall be completed within the specified time.

4.8 all inspectors must hold certificates.

4.9 emergency release

4.9.1 for the production raw materials and purchased parts that are in urgent need of production but have no time for inspection and test, the purchasing department shall fill in the “emergency release application form” and report to the technical deputy general manager/chief engineer for approval; Pass the approved emergency release form to production department and quality control department. Related warehouse to release the specified products, quality control department/production department to supervise the production process; Production workshop must hang “emergency release” and other forms of signs production, and maintain the sign; If the inspection and test results are qualified, the quality control department/production department shall delist and release the products and notify relevant units. In case of non-conformance, it shall be recovered and replaced immediately.

4.9.2 for homemade products production needs, in the process of inspection and testing completed or necessary reports received and verified, can’t transfer product order or release, need emergency release, by the production department to fill in the emergency release apps, approved by the deputy general manager/chief engineer, workshop or warehouse do identification and record, in order to recover when the result is unqualified.

5.0 related documents/records

5.1 sampling inspection scheme and acceptance criteria

5.2 product quality inspection records

5.3 materials entering the warehouse and sending inspection sheet

5.4 inspection records of purchased parts