1、,Process management plan,產品制程穩定性品質保證Prepared by: QSMC SQE Rick MiaoNov 24 2003 revision 01,-Product Process Stablization Quality Assurance,New project transfer created by PE team. 由PE小組制定的新項目移轉 Mass production PMP update based on issue and customer requirement. 量產機種因異常和客戶要求而進行的PMP更新 QA ,JQE and audi
2、t team to audit process reference PMP. QA.JQE與稽核人員稽核制程之依據 PMP cover from IQC to OQC overall process. PMP涵蓋到從進料檢驗到出貨檢驗的全部制程 PMP generally to drive process and QA system to control critical station with key parameter. PMP通常用以推動製程和品質保證系統使用相關的關鍵參數管控重要站別PMP update guideline.-PMP修改准則Preventive action take
3、 .採取新的預防措施System improvement .系統得到改進Lesson learn review.所獲得經驗的回顧 QC and Process control enhancement.品管和製程控制得到加強,PMP function and control PMP功能與管制,PPAP Production Part Approval Process,零/部件承認程序,New project PMP creation,新機種PMP的建立,MP PMP update and audit,量產階段PMP修改與稽核,Product Process Stabilization Quali
4、ty Assurance,1.PSQA conception: Product process parameter stabilization quality assurance,meaning with key process parameter condition control to ensure product quality stably.Products Spec. stabilization lie on process parameter Spec. stabilization. Approval for processes not meeting requirement. 2
5、.Process QA :1) Parts assurance: after production QC to check parts with dimension, cosmetic and function.if out of Spec. to track the process parameter and make adjustment follow experience.in case of process parameter big deviation will be lots of failure parts.therefore with high risk .2) Process
6、 assurance: In process monitored by production line and QA person for parts Characteristic and process parameter. Any deviation should follow gold process parameter to set up. Thereby can catch failure in early period to make the real prevention. Gold process parameter come from trial run parts have
7、 approved by customers( it should fixed and controlled by ME and QA team) Any process parameters change out of gold process parameters should be approved by customer.( Approved by suppliers themselves at first)-Double check parts dimension, function and cosmetic meet customer Spec or not.-Process pa
8、rameter need study reasonable tolerance and confirmed with parts Spec. and Customers.,產品製程穩定性品質保證,1.PSQA的概念：產品製程參數穩定性的品質保證，意即採用關鍵製程參數設定的管控以保證產品質量的穩定性。 產品規格穩定性基於製程關鍵參數規格的穩定性。 對製程不能滿足需求的承認。 2.製程品質保證：1)產品保證：品管對產品進行尺寸、外觀和功能等方面的檢驗，如果超出規格，須追蹤製程參數並依據經驗進行調整。如果關鍵製程參數嚴重偏離，將會導致大量不良品產生，並造成嚴重的浪費和損失。2)製程保證：在製程中，生
9、産人員和品質保證人員對產品的特性和製程參數進行監視。任何偏移應遵照最佳製程參數進行設置，從而能夠在早期即發現異常，並從真正意義上做到異常的預防。最佳製程參數來源于被客戶承認的試產產品(該參數應被製程和品保小組修正和管控)任何與最佳製程參數有偏移的製程參數均須被客戶承認(在被客戶承認之前應首先被供應商自己承認)-再一次對產品的尺寸、功能和外觀是否符合客戶的規格進行確認。-製程參數應考慮到合適的公差，並與產品的規格和客戶進行確認。,PSQA parameter control Process Parameter control,Trail run Process Parameter,Paintin
10、g a)pre-mixed b)Painting parameter c)Bake condition,Injection a)Injection condition b)Resin bake temp.time C)MFI Spec,Suppliers approved,Customer approved,MP ProcessParameter,PE-function and Assy QA-FAI and Cosmetic,PE-function and Assy QA-FAI and Cosmetic,Fail,Fail,Re-trail again,Update to PMP And
11、Sop&SIP,DCC issue offically,Production line Set up,IPQC FAI,Production,QA audit With PMP,Fail,Re-adjust toMP process parameter,IPQC FAI,Fail,Production Record adjust parameter,Re-run trail Run process,Fail,PSQA製程參數管控,SOP key parameters,6 major portions Document/Product Information-Product part numbe
12、r/revision,process step/name,approval status,revision level, Direct materials P/N,description,usage,and designator. Work process/instruction for the station Illustration Machine name&station number,machine program name/revistion,fixtures name/part number&revistion,tools/gages part number/name,indire
13、ct materials with detailed descrption,and their working conditions. Call out highlights/special notes for the operation,SOP中的關鍵參數,6個重要的部分： 文件/產品的信息 產品的料號/版本，製程步驟/名稱，核准狀態，版本級別， 原料料號，描述，用途和標誌 該站別的作業製程/指導 圖示 機器名稱和工站編號，機器程序名稱/版本，治具名稱/編號和版本，工具/量具編號/名稱，非直接物料的細節描述及其作業條件。 著重強調並特別標註作業的注意事項,SOP key parameters
14、,Information-product part number/revision,approval status,revision level, Dimension-P-dimension or engineering team concerned dimension.(Meet customers official drawing SPEC.at least.) Cosmetic-Meet customers official cosmetic or gold sample criteria.(specific Spec.tolerance) Function-reliability an
15、d function testing items(such as program testing torques,MFI and pull force testing) System matching-for some single parts will be assembly at customers production line);(special for difficult assembly,gap and step) Movable parts checking-with simulation testing (as button,hook,sometines need be che
16、cked with fixture) Illustration(describe the key checkpoint or motion) ECN change record(latest 3 months) Customer quality issue history record(latest 3 months),SIP中的關鍵參數,信息- 產品料號/版本，核准狀態，版本級別， 尺寸- P尺寸或工程小組相關尺寸(至少須符合客供正式圖紙的規範) 外觀- 符合客供正式版本的外觀標準或樣品標準(明確的標準公差) 功能- 信賴性和功能測試項目(如程序測試，扭力測試，MFI測試和拉力測試) 系統配
17、合度- 在客戶端生産綫組裝的單出料件(尤其指難以組裝，易產生間隙和斷差的料件) 可動部分的檢查- 進行模擬測試(如按鍵，轉軸，部分產品需要治具進行檢驗) 圖示(描述關鍵的檢驗點和檢驗動作) 工程變更記錄(至少3個月内的變更項目) 客戶端品質異常履歷記錄(至少3個月内的異常項目),SOP key parameters,Process flow-Process and parts control station. Process control:for critical manufactured testing machine station.(process with class with S-
18、safety critical,M-major defect,O-minor defect and KPC-key cont,charct) Parts control:for critical final inspection and QC sample size station.(Process with class with S-safety critical,M-major defect,O-minor defect and KPC-key cont.charct) Machine and Device,jig tools for manufacture Characteristics
19、 Process parameter-key operation manufacture parameters will impact products quality or Spec if deviations of out of spec.(key operation parameter monitoring.) Product characteristic-Customer approved Spec,of dimension,cosmetic,function and reliability testing,ORT(key control characteristics monitor
20、ing) Method Critical product/process specification with tolerance.Update. Measurement technique-with what kinds of technique or instrument to measure(such as AQL,visual or color meter) Sample size or freq.-100%inspection or samling size with frequency definitions. Analysis method-Use what kind of me
21、thod to mark FA if failure catch from inspection.(Porto,CLCA,SCAR,SPC and CPK) Reaction plan-out of control condition are encountered as same as CA.(such as stop line,hold lots,re-study the process parameter and scrap),PMP中的關鍵參數,製造流程- 製程和料件的管控站別a)製程管控：指重點地生産用測試機器的站別(製程中以S-安全臨界級，M-主要不良，O-次要不良和KPC-關鍵控
22、制特性)b)料件管控：指重點的最終檢驗和品管樣本大小的站別(製程中以S-安全臨界級，M-主要不良，O-次要不良和KPC-關鍵控制特性) 用於生産的機器、裝置、治具 特性a)製程參數- 關鍵作業的工藝參數會對產品的質量造成影響，若其偏移導致了超出規格，則對產品的規格亦會造成影響(關鍵作業參數的監控)b)產品特性- 客戶承認的尺寸、外觀、功能和信賴性測試的規格 方法a)關鍵產品/製程(包括公差)的規範及其更新b)量測技術- 使用何種類型的技術或設備進行量測(如允收級別，視覺或顔色計量)c)樣本大小或採樣頻率- 全檢或定義其樣品大小和採樣頻率d)分析方法- 當在檢測中發現失效現象，使用何種方法進行失效分析(Porto，CLCA，SCAR，SPC和CPK) 應激計劃- 當遭遇失效現象，改善措施能夠被立即實施(如停綫，hold庫存，重新研究製程參數及報廢),對製造流程的審核,對其格式的任何更改必須預先得到核准,PFMEA review 對製程失效模式和效應分析的審核,Alternate Formats MUST Be Approved in Advance 對其格式的任何更改必須預先得到核准,PFMEA,對製程管制計劃的審核,對其格式的任何更改必須預先得到核准,
