注塑零件关键项目检查清单.xls

plastic injection key items - checklist 注注塑塑零零件件关关键键项项目目检检查查清清单单 supplier result valeo sqa54% not acceptable date item #mandatory items to be checked at supplierok / nokrecommendation raw material原原材材料料 1 are the material properties conform? (viscosity, color)原材料性能是否符合？（熔体流动速率，颜色 .） ok each batch should be delivered with the material certificate and should be within agreed tolerances每批须随附原材料出厂检查报告，各项指标必须符合要求。 -check the material conformity index (viscosity)检查材料各项指标的符合性（ 熔体流动速率.） for example for pc must comply with sae j576-1991 reference astm d128 requirement 14.5 -21.9 g/10 min. 比如，pc,必须符合sae j576-1991 astm d128 熔体流动速率14.5 -21.9 g/10 min。 2 is the raw material humidity under control ?原材料的含 水率是否受控？ ok dryer is mandatory on sensitive material (all material expect pp device measurement to be relevant , the temperature of the water is a first information but not enough , the tooling t to be measured t to be recorded before start up 作业指导书中标示出测量的正确位置，明确测 量设备，只测量水温是不足够的，模具的温度需测量并记录在启动检查单上。 11 if handling system (as robot) in use: is tooling designed to prevent any short molding?如果机械手取 件，模具设计上是否考虑有防止缺料现象发生？ nok the design of the tool has to include in an appropriate location a cavity or a pocket instrumented with sensor to allow material to flow in and this in order to control the right quantity of plastic material filling in the mold. this mean will allow to prevent short shot 模具设计必须包含在型腔内适当的位置袖珍传感器存在检测 材料流入与否，来保证流入模腔的料量合适足够。总之可以避免缺料现象发生。 12 is plastic injection press plc locked to prevent operator to adjust process parameters on his / her own and a log book is existing for following every process changes?塑料注塑工位的参数调整面板是否 被锁，防止随意调整，并在工作台放置记录本来记录 参数的任何变动。 ok the setter records his changes in the logbook. after several recurrence the process sheet has to be updated.工艺员记录每次调整，在发生几次后需更新工 艺卡。 13 does the supplier operator check the “start up check sheet“ prior mass production starts ?供应商处的工人 是否依据启动检查清单在批产前进行了检查？ ok the operator respects the “start up check sheet“ including: - the preparation of the material (qty/ time/ temperature of the dryer), - first in the meantime supplier can produce parts if there is a clear information on the packaging“ wiating for decision“ - raw material in use to be clearly displayed on the materials tank 工人遵守“启动检查”，包含以下几项： -原材料的准备（数量/烘干时间和温度） -首末件的确认：功能要求，装配点，飞边，重量，外观的符合性 -调试产品的报废，与控制计划的要求保持一致 -尺寸/装配/外观.功能试验等 -测量之前产品的冷却时间必须定义，此期间生产的产品必须有“待确认”的标 示在外包装上 -在使用的原材料料筒上必须有明确的材料标示 14 are the first 5 set up parts automatically disposed (trashed) ?是否调试的前5模产品自动报废？ nok “5 parts“ has to be considered as an example - certain geometry or process complication could require more set up parts. anyhow all the set up parts would need to be disposed（5件产品）是参考数量，工艺出现异常时肯定调试产品数 量会增加，无论如何，所有调试产品都必须报废。 15 are first and last parts of the shift compared to a master sample for validating the “start up check sheet“?首末件是否与用于启动检查的标准样件做了比 较？ ok the 1st set and the last set are compared to a master sample for checking the conformity of 100% on functional requirement, interfaces, flash, 射出速度，开模速度，模具运行速度，模具顶杆速度 - injection pressure, pack pressure, back pressure, clamped tonnage; 注塑压力 ，锁模压力，背压，保压压力 - mold temperature: cooling + hot runner temperature, screw temperature 模具温度，冷却+热流道温度，料筒温度 all input parameters are monitored by sensors.所有参数都能通过传感器被监控 到 no heating zone working in % 18 does supplier know cpk for the 3 main critical parameters: - dosing time - injection time - weight of the part供应商是否知道3个主要参数需计 算cpk -定量给料时间 -注塑时间 -零件重量 ok these parameters to be followed in order to track any deviation, for example: if wrong cpk for dosing time, it means a worn out of the screw which is a classical sympthom and need pm为防止偏差这些参数必须跟踪，比如，如果定量给料时 间cpk偏差，意味着螺杆可能磨损，这是个典型的先兆，需要维护。 19 is the injection machine capable of making spc?注塑 机的能力是否有spc控制？ ok does the press is able to display output parameters on the last 100 shots: cushin, max pressure, total cycle time, injection time注塑机能够显示最近100模 所采用的参数吗？进料位置，最大压力，总周期，注射时间等。 unloading取取件件20 does the unloading process prevent parts from damage? are parts dropped “gently“ on the conveyor belt preventing from create cracks or fractures ? 取件过程能否预防损坏零件？ 零件是否轻柔的被放置在传送带上防止造成裂纹和破 碎？ okrobot unloading, belt drop机械手，传送带的跌落等 21 if any of the injection press sequence has to be interrupted - are the parts in “process“ automatically disposed ?是否任何与注塑压力相关的因素中断，所 有在此过程中生产的零件自动报废？ nok check when safety barrier is opened - if parts are disposed when machine is stopped check if the press is operated in manual sequences / steps that all the parts made along the debugging steps are disposed 22 does the handling devices follow a maintenance plan including greasing, 0 axis check (cf recommendations)?取件装置的维护是否按照计划执 行了？润滑，取件基准确认？ ok robot needed to be grease, robot 0 axis, end of arm cleanliness, conveyor sensor and cleanliness 23 does the injection machine follow a maintenance plan including sensor verification & calibration (cf recommendations)? 注塑机是否按照维护计划进行了 维护保养？比如传感器的确认有效和校准？ nok sensor verification and calibration, oil analysis, grease checks, 传感器的确认和 校准，油路分析，润滑系统的检查 start up生生产产启启动动 24 is the tool maintenance plan fully respected especially with regards vents / slide / ejector and cam pins ? does the mold is send to the tool shop repair with the last shot included?模具是否完全依照维护计划进行了 维护，尤其是排气孔，滑块，浇口和侧抽芯？模具送 往维修车间时是否随带有末件产品？ nok comprehensive tool maintenance plan and evidence that the plan is being followed is important to the life of the mold and the on going quality of the part specific items such as clean water lines (proper cooling) , complete clean and grease of all moving components to minimize wear ( guide pins and bushings, ejector system, cam pins, slides and vents) in case of repair, the last produced part helps the tool maker to understand the failure. any change ,repair to be recorded make the difference between preventive and curative maintenance so that to improve permanently the preventive number of shot to be recorded in the life cycle sheet so that to define a frequency for some changes inspection for appearance / aspect parts 外外观观件件的的注注塑塑 25 for appearance / aspect parts - is the operator trained to follow an a eye path to check the control points on the part in a defined sequential manner ? 对于外观件 ：工人是否被培训按照定义了的检验路线进行所有控 制点的目视检查？ nok hand position, eye path, time for controlling every are, item to check on each area to be precised in an inspection sheet and respected by the operator for example: white mark means water leakage or sharp burnt angle means some gas not released, some clear picture to be displayed for the non conformity well known finish goods成成品品 26 is the material batch number recorded and linked to the batch of finish goods?从成品的批次是否可追溯到 原材料的批次号？ ok the material batch number can be track back with the finish good batch number? 从成品的批次是否可追溯到原材料的批次号？ 27 does the packaging prevent the part to get damaged by: - humidity/ moisture/ cold conditions ? - packaging weight? - vibration, transportations, shocks? 包装是否可防止以下原因造成的损坏 -湿度/水汽/低温 -包装承重？ -振动，运输，撞击 ok for ex. for pa66, high sensitivity to humidity during storage for ex. deformation