品质工作手册英文版.doc

Mega Bloks Inc. 品质工作手册MEGA BLOKS QUALITY MANUAL &STANDARD OPERATING PROCEDURESPrepared by: Quality Department, Mega Bloks Inc. SZRevised Date: Feberay 05, 2004Version: 06Approved by:Nick Reonegro, Mega Bloks Inc. HKTable Of Contents 1 QUALITY ASSURANCE REQUIREMENTS1.1 Factory General Requirements - P4A. I.C.T.I. Compliance - P4B. Personnel Requirements - P4C. Equipment Requirements - P41.2 Safety and Reliability Tests - P7A. Safety Tests - P7 (revised)B. Reliability Tests - P9 (revised)C. Electronic Toys Additional Tests - P12 (revised)1.3 Factory Quality System - P17 A. Factory Incoming QC Requirements -P17 (revised)B. Factory WIP QC Requirements - P18 (revised)1.4 New Color Development Procedure - P21 (revised)1.5 EPS Testing Procedure - P23 (revised)1.6 Risk Assessment Procedure - P241.7 Quality Plan Development Requirement - P25 (revised)1.8 Date Coding and Lot Tracking Requirement - P27 (revised)1.9 Packaging Validation Requirement - P291.10 Labeling Requirements - P30 A. Regular Products Labeling - P30 (revised)B. Direct Ship Labeling - P34C. Special Order Labeling - P341.11Pilot Run Requirements - P35 (revised)1.12Lab Testing Procedure - P382 QUALITY CONTROL REQUIREMENTS2.1 Overall Mega Bloks Quality Vision - P39 2.2 Incoming Quality Control Requirements- P402.3 Molding Quality Control Requirements - P412.4 Spray Paint & Other Surface Finish Quality Requirements - P43 (revised)2.5 Other Operations Quality Requirements - P442.6 Final Assembly Quality Control Requirements - P45 (revised)2.7 AQL Criteria Acceptable Quality Level - P46 (revised)2.8 Defect Classification - P482.9 Pull Force Standards for Blocks - P521.1Factory General RequirementsIt is understood that all suppliers with whom Mega Bloks Inc. enters into contracts with to produce toys for us, with our Mega Bloks logo on said packages would adhere to all of the following conditions.A - I.C.T.I. ComplianceThe International Council of Toy Industries standard is the standard that Mega Bloks has adopted to use as its base to evaluate our vendors in China. We expect that all of our vendors comply with these regulations. It is also essential that any party with whom we enter into contract with is operating in accordance with the local laws of the country or territory in which they are situated, as stated in our manufacturing agreement and procurement policy. Should any of our vendors be found to be in violation of either of the above conditions, we expect corrective action to be taken immediately. The abuse or violation of these conditions will result in the termination of our business relationship. See the Annex of this report for the latest ICTI audit report.B-Personnel RequirementsAs stated in our procurement policy and manufacturing agreement, we expect all of our factories in China to have English speaking contacts in the following areas: planning, engineering, quality control, and production. It goes without saying that sales and marketing staff of the company also need to be able to communicate in English. Please refer to the supplier contact sheet in the Annex of this report; this is to be returned to Mega Bloks China duly completed.C-Equipment RequirementsIn order for our factories in China to be able to control the quality of their manufactured products, and also to ensure that we comply with safety and performance standards for these items, we at Mega Bloks have compiled a list of equipment that should be on hand at every factory (Table 1). Also note that Table 2 is a list of equipment that we strongly recommend every factory to have on hand. In the Annex of this report is a supplier equipment checklist that we require all factories to fill in and return to Mega Bloks China.In order to emphasize strongly the safety requirements of our products, we also require that all of our suppliers, in any factory that produces any items for Mega Bloks DO NOT MAKE USE OF KNIVES OR ANY OTHER CUTTING INSTRUMENTS WITH BREAK OFF BLADES. This is also included in our manufacturing agreement, and Mega Bloks China staff will be auditing our vendors factories regularly to ensure compliance with this point. Please refer to the photos on the following page to clarify this point.TABLE 1: CRITICAL EQUIPMENTEquipmentParameters & requirementTransit testing machine220-250 rpm, 1 inch oscillation, size to accommodate full range of master carton sizesOvenCan provide stable temperature at 55-57 degree, 48 hrs above, size must be able to accommodate full master cartons.Ice BoxSize must be able to accommodate full master cartons of all items produced and can provide stable temperature of -17CHumidity containerCan provide 20-40 degree stable temperature, 48hrs or more, in adjustable relative humidity from 20-95%Pull & push scaleRange: 0-60 lbs, must meet minimum range, some tests require very small forces (0.5 kgs)Torque screw driverTorque range: 0-6 kgf.cmSmall part gageRefer to ASTM and EN-71 standardsSharp edge testerRefer to ASTM and EN-71 standardsSharp point testerRefer to ASTM and EN-71 standardsSound level meterMechanical tape recommendedUPC Bar Code TesterMust check quality and readability of bar codesTABLE 2: RECOMMENDED EQUIPMENTEquipmentParameters & requirementTorque tester0-10 kgf.cmDrop Test TableRefer to ASTM and EN-71 standardsPreschool play figurine test gaugeRefer to ASTM and EN-71 standardsSupplemental gauge for bulbous endsRefer to ASTM and EN-71 standardsAccessibility probeRefer to ASTM and EN-71 standardsZebra Bar Code Label Printer and SoftwareMust be capable of printing bar code labels conforming to standards enclosed in this report1.2Safety & Reliability TestsIt is crucial that all of our vendors products comply with all published and accepted safety standards. In most cases Mega Bloks standards are more demanding than the accepted norm. This is due to the fact that we pride ourselves on the quality of our products, and we are constantly forcing ourselves to higher performance levels, and higher levels of product quality. Listed below are Mega Bloks standards of testing for reliability and safety. In most cases, some or all of these criteria will be restated in the EPS of the project. Mega Bloks China QA requires that the Safety and Reliability Testing Follow-up Sheet (included in the Annex of this report) be filled in and returned to them by the factory immediately upon receipt of the EPS for the awarded project.A. SAFETY TESTSTest DescriptionPerformance & RequirementS/S & CyclePRODUCT DROP (IMPACT) TESTComply with EN-71, ASTM, CANADAIAN, AUSTRALIAN standards.Every lot shipped, every time when start the production, change the supplier, or a new order.2 units per lotSMALL PARTS CHECKUse the small part checking cylinder (inside diameter31.7mm), as per ASTM and EN-71Every lot shipped, every time when start the production. 2 units per lot.SHARP POINT CHECK Use the sharp point tester, as per ASTM and EN-71. A metal wire with diameter less than 2mm will be considered a sharp point.Every lot shipped, every time when start the production. 2 units per lot.SHARP EDGE CHECKUse the sharp edge tester, as per ASTM and EN-71.Every lot shipped, every time when start the production. 2 units per lotTENSION TESTComply with EN-71, ASTM, CANADAIAN, AUSTRALIAN standards.Every lot shipped, every time when start the production, change the supplier, or a new order. 2 units per lotTORQUE TESTComply with EN-71, ASTM, CANADAIAN, AUSTRALIAN standards.Every lot shipped, every time when start the production, change the supplier, or a new order. 2 units per lotPOLYBAG STANDARD1 - All polybags, regardless of size, will have a material thickness of 0.0197” or 0.050mm.2 - If finished bag size is less than 2.75” (70mm) X 1.5” (38mm), there is no need for ventilation holes3 All sizes above this will have ventilation holes (2-4 holes), the holes diameter should be 3-5mm4 If bags contain small parts, which can escape from the vent holes, then small parts must be packed inside a smaller bag or packed by some other method.NOTE: these standards are more stringent than ASTM and EN-71 standards.Every lot shipped, every time when start the production, change the supplier, or a new order. 2 units per lotPVC CONTENT STANDARDDEHP content less than 0.05%EEC less than 0.01%PVC heavy metal soluble content (ASTM)Overall Phthalates less than 0.1%; CARTON WEIGHT LIMITMaximum weight of any carton shipped to Mega Bloks is 40lbs (18kgs)Determined at time of product designB. RELIABILITY TESTSTest DescriptionPerformance & RequirementS/S & CycleAGING TESTParts are to be removed from packaging for this test, and in a state as used by the end consumer(some assembled, some not)Oven 55C, 48hrs. Then check：1) Product must pass the drop, pressure, torque test etc all normal and abuse tests, no crack, no broken pieces allowed.2) Injected parts, spray paint, pad print, and label no color fading.3) Spray paints, pad print, label: must pass the tape adhesion test.4) Label: no detach, no peeling up, no air bubble (for slight air bubble under the label, if there is no air bubble after re-stick by hand, should be acceptable).6 pcs, as per EPS requirementRELIABILITY DROPToy is to be removed from final packaging and in assembled state, as if in use by the end consumer.Drop 4 times, from 30” height, in 4 different orientations. Must be dropped onto the most sensitive area on first drop, and then random for the other 3.Repeat this procedure 2 times each sample1) If any safety issue (refer to International safety norms in section A above): critical defect.2) If any function issue on electronics: Major defect.3) If any function requirements not met as per EPS requirements, Major defect6 pcs, as per EPS requirementENVIROMENT SIMULATED TEST (or PRE-CONDITION TEST)Parts must be in final packaging for this test, and any change in packaging method must be validated by re-performing this test4) Oven test 55C, 4hrs then air cool for 4 hrs, then cooling test: -17C, 4hrs, then air cool 4 hrs. That is one cycle, perform 2 cycles total.5) Check same points as the requirements on Aging test.6 pcs, as per EPS requirementHUMUIDITY TEST1） 21-24.5C, 20-70% relative humidity for 4 hrs.2） 35-40C, 90-95% relative humidity for 48 hrs.3） Check same points as the requirements on Aging Test6 pcs, as per EPS requirementTAPE ADHESION TEST (Chrome parts)1) Apply test tape (3M #898, ” width) on the chromed surface, pressing down with fingertip to assure adherence, and leaving a loose tab at one end for grasping.2) Within 90 seconds of application, grasp the loose end of tape and pull off quickly at 90o to the chromed surface.3) Some chrome parts come off Major BERASER ABRASION TEST (Chrome parts)1) Use an eraser Staedler Mars Plastic #52650 and apply a normal hand pressure on the decorated surface of the parts and rub 10 times lengthwise. Next, at this same rubbing location, scratch the paint or chrome with fingernails 10 times lengthwise.2) Chrome must not come off, plastic below coating should not be visible Major BCROSSHATCH TEST (Spray Painted and Pad Printed parts)1) With an exacto blade scribe 6 parallel lines, completely through the coating film 1/16” apart. Then scribe another set of 6 parallel lines through the coating film 1/16” apart, intersecting the first set at an angle of 45o.2) Apply test tape (3M #898 ” width) to the scribed area, pressing down with fingertip to assure adherence, and leaving a loose tab at one end for grasping.3) Within 90 seconds of application, grasp the loose end of tape and pull off quickly at 90o to the paint surface.4) 1 or 2 diamonds removed - Minor5) 3 or more diamonds removed Major BLABEL ADHESION TESTUsing 3M #898 tape, adhere to label leaving a tab to be able to pull. After 90 seconds, pull tab. If area of label removed is greater than 5%, label is rejected. If less than 5%, minor6 pcs, as per EPS requirementLIFE TESTMust comply with EPS6 unitsTRANSIT TESTTransit test: 220RPM for 1hr, then turn the carton 90 and test 1 hr.Full master cartonSTATIC LOAD TEST1) Weigh box and measure box height.2) Divide 144” by the box height (in inches), to obtain multiple of how many boxes needed to reach height of 144”3) Multiply weight of box by the number obtained in step 2)4) Apply weight obtained in 3) uniformly over box, for a duration of 24 hrs5) Check same items as carton dropFull master cartonCARTON DROPASTM standard:Carton weight: 1-20.99 lbs, height: 30 inch;Carton weight: 21-40.99 lbs, height:24 inch;Carton weight: 41-60.99lbs, height: 18 inch;Carton weight: 61-100lbs, height: 12 inch;1) No deformation, no crack.2) No wire ties loose, broken.3) No part came apart. No scratch mark.4) No function problem, no small parts, crack piece were found.5) Check for off set of the part in blister, check for scratch mark on the blister.Full master cartonPVC COLD CRACK TESTASTM standard drop test, but for items with PVC content (suit for soft PVC material) and PEVA material in packaging must perform as follows:1) Packages must be kept in ice box at a temp of -15oC for 24 hrs2) Immediately upon removing from ice box, make first drop on most sensitive corner, check for damage3) Then make 3 drops on edges, check again for any damage4) Put back into icebox for 2 hrs, -15oC, and make subsequent 5 drops5) Requirements same as carton drop, but pay special attention to cracks in PVC at each phase.C. ELECTRONIC TOYS ADDITOINAL TESTSTest DescriptionPerformance & RequirementS/S & CyclePARAMETERS OF ELECTRONIC COMPONENTSTest the correlative value of DIP, SMD resistance, inductance, coil, and speaker with correlative electronic equipment to verify whether meet the certification submitted by the supplier.Test withstands volt and capacitance and tolerance for SMD and DIP by electronic instrument, test feature and life of motor, type of wires, test AMP of transistor also test feature of IC.Other components need to be tested in accordance with certification attached samplesTest when the design is finished or changed the supplier. Test 50 unitsBATTERY LIFE TESTComply with the EPS6 pcsRUST TESTPut the metal parts in container, with 10% salt liquid for 48 hrs at 56C, then check. If rust area less 5%, Major B, if rust area over 5%, rejected.6pcsHUMUIDITY TESTBefore the test, check the resistance and working current wherever accessible.Perform same test as for non-electronic toys, except must be 72 hrs in the humidity.Must meet regular requirements, plus there should be no damage, any corrosion on the accessible position of product, which will affect the function, the resistance should not increase exceeds 10%. 6 pcs, as per EPS requirementTest electronic parameter for COB1） Stand by current2） Operate current 3） COB function4） IC current5） Test the frequency and cycle6） Test the frequency and waveform of TX PCBA7） Test the frequency and the waveform of the RX PCBA8） Other electronic parameterRefer to EPSTest the electronic parameter of PCBA 1. Stand by current2. Operate current 3. COB function4. IC current5. Test the frequency and cycle6. Test the frequency and waveform of TX PCBA7. Test the frequency and the waveform of the RX PCBA8. Other electronic parameterRefer to EPSTest the parameter of battery and speaker100 percentCheck the load voltage of batteries and the sound quality of speaker 100% using test jigTest conditionEvery time when start the production or change the supplier.Test the ratio of tin and fluxCheck the scale of the tin and colophony or sent the sample to China office for testSTD: tin 60% colophony (flux) 2.2% If the samples can not suiting for certification, we have right to feedback it to supplier.Testing Bonding IC Defected IC should be less than 2%If defected IC rate is over 2%, except Bonding reason, we have right to pay from IC supplier.Test the ratio of COB rejected in productionThe COB defect must be less than 2%Samples and result must be approved by MEGABLOKS Electronic Engineer Test the ratio of COB rejected in productionThe PCBA defect must be less than 2%Samples and result must be