工厂评估及评分指引1(1).doc

Manufacturer Approval Procedure 供稱商認可程序(For SQE application ; 供應商品質工程師適用)Emerson Radio CorporationDoc No.: QD10CORPORATE OPERATION PROCEDURERev.: ASubject: Manufacturer Approval ProcedurePage 1 of 25Revision Change RecordRevisionPara.Description of changeWritten byReviewed byEndorsed byValid dateAEdison Yip2002/10/09Part I: Factory Management Audit and Rating List 工廠評估及評分指引Scope: Applicable for Guang Dong Province Factories Only. 只適用於廣東省製造廠.Section A: Material Management A部分: 物料管理A1 Part Material/Finished Goods Warehouse 原料/成品 倉庫A1.1Zone segregation 區域隔离0 No segregation management. 沒有分區管理.1 Clear zone includes Receiving, IQC Passed, Waiting for Disposition (MRB), RTV, Special Material Scrap清楚隔離區域,包括收貨區, IQC已檢合格區,待處理區(MRB),待退供應商區,特殊物料存放區.2 (1) + Material properly located within the area, not putting outside the border, good management. (1) + 物料正確放置, 沒有超區, 管理完善3 (2) + Fail safe operation. For example, there is only 1 part on the same pallet. (2) + 運作接近不可能出錯. 例: 同卡板上只可能有一種物料A1.2Material identification 物料鑒別0 Poor ID and labeling. 標識方法及使用標簽執行差.1 Material ID label (name, P/N, manufacturer, lot, qty) and IQC passed label (name, P/N, inspector name (chop) and date) well used.有效使用: 物料ID標簽(名稱,零件號碼,供應商,批數,數量) 及IQC檢驗合格的標籤(名稱, 零件號碼, 檢驗員姓名, 日期). 2 (1) + Proper implementation and protection of labels.(1) + 標簽正確使用和保護.3 (2) + every external carton is labeled correctly.(2) + 每一外包裝均正確標示.A1.3Disposition of MRB materials 待檢討物料的處理0 Direct return to vendors or scrap. 直接退料給廠商或作廢料處理.1 MRB or similar meeting in place for material review and disposition decision.适當召開物料檢討會議,檢討物料狀況及作處理決策.2 (1) + MRB or similar procedure properly implemented with every disposition clearly recorded.(1) + 物料檢討程序正確執行,并清楚記錄每份MRB的處理細則. 3 (2) + MRB procedures well defined and documented.(2) + 物料檢討程序定義清析并有文件証明.A1.4Material protection 物料的保護0 No special requirement or intention for material package protection.對物料包裝保護方面沒有特別要求或意識.1 Proper sealing and protection of material carton after usage or opening by IQC or warehouse operator. IQC或倉管員開箱或取用物料后正確封箱和保護.2 (1) + Requirements well documented., no violation of material storage advise such as height, direction, static sensitive, flammable, dangerous chemicals.(1) + 作業要求有文件証明, 沒有圍反物料標示如高度, 方向, 靜電, 易燃物, 危險化學品. 3 (2) + Proper warehouse operation monitoring or regular audit by third party (e.g. IPQC).(2) + 有第三個体(如:IPQC)監督或定期審核(評估)倉庫運作是否正確.A1.5Storage environment/shelf life monitoring and control儲存環境的監測及控制.0 No storage condition/shelf life requirement set up.沒有制定對儲存環境的要求.1 Special materials identified for particular storage condition/shelf life requirements.特殊物料有特殊的儲存環境.2 (1) + Daily monitoring of conditions and proper records maintained, Control actions taking place of specification conditions.(1) + 每天監測(環境)條件并維持紀錄,發現超出規限條件有採取控制行動.3 (2) + All special materials are well managed including those in production area. (2) + 所有特殊物料均有管理, 包括生產場地.A1.6 Material lot records 物料批數紀錄.0 Received/ Issued material records written on stock record book.收/發物料情況寫在倉庫紀錄帳簿上.1 Color coding system or other effective system is well implemented for different materials to ensure First-In-First-Out (FIFO) on monthly basis.顏色卡或其他有效制度充份利用于確認不同物料的月份先入先出(FIFO).2 Bin card system or other effective system is well implemented for different materials to ensure First-In-First-Out (FIFO) up to every lot.物料倉存紀錄卡充份利用于確認每批物料的先入先出(FIFO).3 (2) + Requirements documented(2) + 作業要求有文件証明.A1.7Material storage control 物料儲存控制.0 No special requirement or intention to control. 沒有特別的控制要求或意識.1 Material storage in good order with some over loading.物料儲存有序, 但仍然有超載.2 (1) + With effective over loading management + Requirements documented.(1) + 有效超載管理 + 作業要求有文件証明.3 (2) + Regular audit for proper storage and handling by third party (e.g. IPQC).(2) + 有第三個体(如:IPQC)定期審核及評估倉庫儲存處理是否正確.A1.8 Material Positioning 物料的擺位追溯性0 Mainly depends on operators experience and skill, informal storage location assignment.主要依靠倉管員的經驗和技巧,沒有正式指定儲存位置.1 Some kind of material stores within dedicated area/zone for easy positioning.為便于追溯部份物料存放在指定儲存區域內.2 Makes use of clearly marked storage location in warehouse areas and record.在倉庫內清楚標明各物料存放區域并紀錄在案.3 (1) / (2) + material storage position can be well traced in defined numbering area.(1) / (2) + 能清楚追蹤各物料的準確存放指定數位化位置,以便查找.A2 Production line/ Inspection area 生產線 / 檢查區域A2.1Parts & WIP status identification 部件及半成品(WIP)狀態的識別0 No special requirements for clear separation and identification of OK/NG units and waiting for inspection / checked passed units easily leading to material mix up.沒有特別要求要清楚區分和識別OK/NG部件,待檢/已檢通過的部件,容易引致物料混亂.1 OK/NG units and waiting for inspection / checked pass units are well separated in different easy distinguishable or well labeled containers to avoid mix up.OK/NG部件以及待檢或檢驗通過的部件分別以已標示容器盛載,以免混淆.2 (1) + Relevant containers are properly used with no exception.(1) + 相關的容器毫無例外地正确使用.3 (2) + Regular audit for proper storage and handling by third party (e.g. IPQC).(2) + 有第三個体(如:IPQC)定期審核儲存處理是否正確.A2.2Parts identification 部件的標識0 No or incomplete identification of used parts information, including parts name, parts number, specification, etc.沒有或不全面地對所使用部件作有效標籤,包括部件名稱,部件號碼,規格等等.1 Parts number is well identified and labeled on relevant containers.部件資料於相關容器上有有效標示部件號碼.2 (1) + Indirect materials information (e.g. glue, cleaning reagent) is well identified and labeled.(1) + 生產輔料(如:膠水,清潔劑)資料作有效標識.3 Labeled shelf life for storage sensitive material outside warehouse.倉外存放有使用期限物料均作好標識標明期限.A2.3Non-conforming marking in WIP/Finished Goods 半成品(WIP)/成品缺陷的標示0 No special requirement in non-conforming marking. Operator marks for non-conformities with informal means or even do not mark for purpose.對缺陷標記沒有特別要求,作業員對有缺陷的WIP只作非正式的標示或根本沒有要作標示的意識.1 Non-conformings are marked with formal but not defined means, such as pencil or tapes.對有缺陷品作正式但無定義的標示,例如用鉛筆或膠紙.2 Non-conforming are marked with effective way; such as red arrow label, or brief description for easy understanding. 以有效的方法標示有缺陷品,例如用紅箭頭貼紙或簡短的描述以令人更清楚明白.3 (2) + Requirements are well documented + marks accurately without exception.(2) + 作業要求有文件証明 + 標示經常正確無誤.A2.4Material handling operation within workstation area 工位內之物料處理. 0 Poor handling such as stacking too many parts/WIP, improper placement of WIP found.极差的處理水平,如零件及WIP(半成品)堆積太多和WIP放置不當.1 Parts / WIP are well managed and handled within working area, without causing potential drop or unnecessary cosmetic defects.工位內處理零件和半成品作業良好,無潛在性的掉落或導致不必要的外觀不良現象.2 (1) + Regular audit for proper storage and handling by third party (e.g. IPQC).(1) + 有第三個体(如:IPQC)定期審核及評估儲存處理是否正確.3 (2) + Regular training of operators for proper material handling.(2) + 對員工定期進行物料處理知識培訓.Section B: Quality Management and ControlB部分: 品質管理和控制B1 Incoming inspection (IQC) 來料檢驗(IQC)B1.1 Inspection scope 檢驗范圍0 Incoming materials inspection is not performed systematically.對來料檢驗沒有明確系統化進行.1 Checklist & specifications or relevant materials to be all listed in instruction documents.點檢清單及規格或相關資料都詳細列明在指引文件內.2 (1) + Operation correct, records complete.(1) + 作業正確, 紀錄完整.3 (2) + Ship-to-stock material list is regularly reviewed, approved, for updated and proper application.(2) + 對免檢(直接)入倉物料之清單作定期檢討, 批核,更新資料并有效使用.B1.2Inspection Instructions 檢查指引0 No instruction or instructions such as sampling level (AQL) and acceptance criteria are not well defined.沒有指引或指引沒有明確定義,如抽樣水平(AQL)及接收標准.1 Important guidelines such as sampling level, acceptance criteria and inspection instructions are clearly defined and documented.重要指引如抽樣水平,接收標准和檢查說明清析定義并有文件証明.2 (1) + Follow the guidelines and record results accordingly, with no exception.(1) + 每次都依照指引檢查并紀錄其結果.未有例外情況發現.3 (2) + Inspectors are regularly trained and tested for inspection know-how.(2) + 對檢查員進行定期培訓及考核其檢查知識.B1.3Inspection records檢驗紀錄0 Insufficient information on report due to report format deficiencies, such as no designated space for filling sampling AQL, inspected items, etc.由于報告格式不完善導致報告所紀錄資料不足,例如沒有定位置填寫AQL和檢驗項目等.1 Inspection results are accurately recorded on reports. 檢驗結果准確紀錄在報告上.2 (1) + Inspection report is able to trace to related documents such as SCAR #, MRB report #, etc.(1) + 檢驗報告及相關文均件有很好的可追溯性,如SCAR號碼,MRB報告號碼等.3 (2) + Inspection reports and relevant documents are well filed and maintained with good condition and traceability.(2) + 檢驗報告和相關文件均妥善地整理歸案并維持其可追溯性.B1.4Inspection / Testing equipment 檢驗/測試設備0 Testing equipment and measuring instrument is not calibrated. 沒有校正測試設備和測量儀器.1 Testing equipment and measuring instrument is well calibrated, labeled and maintained.測試設備和測量儀器均作有效校正,標示和維護.2 (1) + Inspectors use the instrument / equipment properly without causing damage (e.g. putting the caliper back in box after usage).(1) + 檢查員正確地使用儀器/設備,防止做成損壞.(如:卡尺使用完畢,隨手放回卡尺盒.)3 (2) + Enough testing equipment / instrument & adequate accuracy.(2) + 足夠測試儀器/設備,且準確度足夠.B1.5Inspection environment 檢驗環境0 Poor inspection environment such as insufficient lighting, improper magnifying equipment, etc.較差的檢驗環境,如燈光及放大倍數條件不足等.1 Good inspection conditions are provided to enhance inspectors judgment performance.良好的檢驗環境有助于提高檢查員的判斷能力.2 (1) + Well-managed and tidy inspection workstation maintained by inspectors during inspection. Testing instruction and supporting documents in place.(1) + 檢查員保持檢驗其間有整潔有序的檢驗環境,測試儀器和相關文件均整齊放置.3 (2) + Requirements are well management. (2) + 作業要求有管理方法.B1.6 Parts status identification 部件狀態識別0 No special requirements for clear separation and identification of OK/NG units and waiting for inspection / checked pass units, easily leading to material mix up. 沒有特別要求清楚區分和識別OK/NG部件和待檢/已通過檢驗的部件,容易引致材料混淆.1 OK/NG parts and waiting for inspection / checked pass parts are well separated in different easily distinguishable or well labeled container to avoid mix up.OK/NG的部件和待檢及檢驗通過的部件分別以不同及容易辨認之標簽容器盛載,防止做成物料混亂.2 (1)+Relevant containers are properly used with no exception. (1)+相關容器無例外地正確使用.3 (2) + Regular audit by third party (e.g. IPQC). (2) + 有第三個体(如:IPQC)定期審核. B1.7Expiry date management (for critical chemical such as glue, painting, flux, solder paste) 有效期管理 (主要化學物品如:膠水,油漆, 松香,錫膏等)0 No checking of expiry dates in incoming inspection or direct ship to stock.對來料時未有檢查物料有效期,就直接進倉.1 Expiry date is clearly indicated and checked on material package of each lot.對每批來料包裝上之有效日期均清楚標示及作檢查.2 (1) + Inspection results are clearly reported. Label for expiry date if necessary. (1) + 清楚報告檢驗結果. 如需要加貼到期貼紙.3 (2) + Systematic regular review is able to stop the use of expired material & review by MRB.(2) + 系統會要求過期物料停用, 並交MRB檢討.B1.8 Manufacturer CAR follow up 對供應商的改善跟進0 No request or informal request for CA, such as fax or e-mail, from the manufacturer. 對供應商改善行動沒有要求或非正式要求,例如以傳真或電子郵件方式執行.1 Formal SCAR system in place, with proper addressing to manufacturers CA.有正式的SCAR系統,並能有效及針對性地要求供應商相關之改善行動.2 (1) + Requested CA reply due date is specified in most cases. Systematic follow up and manufacturers can respond to correct the root courses per request. (1) + 要求改善行動回覆日期有清楚註明, 系統化跟進, 並於大部份情況下能如期回覆.3 (2) + Containment & CA by manufacturer is well followed up and recorded.(2) + 有效地跟進并記錄供應商圍堵及改善行動的執行情況.B1.9 Disposition of rejected lots 拒收的處理0 Return to Vendor is the program, with awareness and approval by single party (usually QA).在單一部門(通常為QA)知會及批准的情況下便將物料退回供應商.1 Formal Material Review Board (MRB) or similar system in place to deal with rejected material disposition, including “scrap”, “rework”, “RTV”, “UAI”, etc.有正式的物料檢討系統(如MRB),處理拒收物料,包括“報廢”, “返工”, “退貨”, “可用”等等.2 (1) + Relevant procedure is well documented + add working instruction if necessary. (1) + 相關程序有文件証明 + 如需要加上作業指導.3 (2) + Every rejected lot is properly handled with no exception.(2) + 對所有拒收材都毫無例外地按序合理處理. B2 In-process inspection and monitoring (IPQC) 制程的檢驗和監督.B2.1In-process Control Instructions 製程控制指引NAOperation not applicable. 此作業不适用.0 No special documented guidelines for in-process control, random checking.沒有文件指引對制程的控制,只作隨機性的抽檢.1 Critical processes or areas are well addressed and identified for IPQC inspection and monitoring.重要制程或工位均有明確指出予IPQC作檢查及監察.2 (1) + All sampling requirements (sample frequency, quantity, checking parameters, etc.) well specified and documented.(1) + 所有抽樣要求(抽樣頻率,數量,檢驗項目及參數等)都有詳細說明和有文件証明.3 (2) + Process management plan (PMP) in place, with controls (charts or checklist).(2) + 制程管理計划清楚界定各重要制程及控制(圖表或核查單).B2.2In-process Control Records 製程控制紀錄NAOperation not applicable. 此作業不适用.0 No checklist, or informal record (raw data) only. 沒有核查單或只有非正式紀錄.1 Formal record in place which indicates relevant process name, machine number, inspector name, time interval, inspected items, judgment, etc.正規紀錄清楚註明相關工序之名稱,機器號碼,檢查員名字,時段,檢驗項目,判定等.2 (1) + Checklist format is well followed and used with no exception. Sampling plan and activities are well set and implemented respectively.(1) + 毫無例外地跟按核查單執行,建立良好的抽樣計划及實施相關活動.3 (2) + Inspection records are well filed and kept with good traceability.(2) + 檢驗紀錄能有效存檔保持良好之可追溯性.B2.3CAR system for continuous improvement 改善行動要求(CAR)系統以達至連續改善NAOperation not applicable. 此作業不适用.0 Record not complete or no feedback of in-process defect situation.生產中的缺陷點紀錄不存或沒有反饋.1 Non-conforming material report (NCMR) / internal corrective action request (ICAR) system in place to feedback in-process defect situation.物料異常報告/內部改善行動要求書(NCMR/ ICAR)体系适當地反饋生產中的缺陷點.2 (1) + Issued reports are well replied by responsible departments on time and appropriately. Relevant action items are well followed for effectiveness.(1) + 有關部門准時适當地回复報告並能有效地跟進相關改善行動的有效性. 3 (2) + Documented “stop line” criteria in place whenever defect rate exceeds set target.(2) + “停線”作業指引文件,指定線上壞品率超出指定目標情況下需執行“停線”要求.B2.4First piece approval for mass production 大量生產前之首件批核.0 No such procedure at all.沒有此程序.1 First article approval procedure is well performed for defined critical processes.各重要制程之生產樣品批核程序較好地執行良好.2 (1) + Procedure well documented and records well maintained.(1) + 程序有明文規定及保存紀錄良好.3 (2) + Approval samples are well identified, maintained and displayed in the place of use.(2) + 有關批核樣品作清楚標識,維護及使用於工位中.B2.5Functional verification & maintenance (by golden sample) on testing equipment, fixture(用金樣品) 對測試設備,治具之功能確認,檢查及維護0 No verification or informal checking.沒有檢測或非正式的檢查.1 Formal routine (normally daily) verification procedure in place with appropriate records.常規檢查(一般為每天)程序有效執行及記錄.2 (1) + Relevant procedure is well documented.(1) + 相關程序有明文規定.3 (2) + Regular proper maintenance with good results & record supporting.(2) + 定期維護, 效果明顯且有報告支持. B2.6 Inspection environment 檢驗環境0 Poor inspection environment such as insufficient lighting, proper magnifying, etc.檢驗環境欠佳,例如燈光及放大倍數條件不足等.1 Good inspection conditions are provided to enhance inspectors judgement performance.提供理想檢驗環境有助于提高檢查員的判定能力. 2 (1) + Tidy workplace maintained. Testing instruction and supporting documents in place.(1) + 整潔有序的檢驗環境, 檢測指引及(相關)支持文件放置於工位作參考使用.3 (2) + Operation is well managed.(2) + 作業有完善管理.B3 Finished Goods Quality Control (FQC) 成品檢驗(FQC)B3.1Inspection Instructions 檢查指引0 Guidelines such as sampling level (AQL) and acceptance criteria are not well defined.指引沒有清析定義如抽樣水平(AQL),接收標准等事項.1 Important guidelines such as sampling level acceptance criteria and inspection instruction are clearly defined and documented.重要指引資料清晰定義,如抽樣水平,接收標准,檢驗說明等事項,有文件証明.2 (1) + Inspectors well follow the guidelines and record results accordingly, with no exceptions.(1) + 檢查員毫無例外地依照指引進行檢查并紀錄結果.3 (2) + Inspectors are regularly trained and tested for inspection know-how.(2) + 對檢查員定期進行培訓及考核其檢查知識. B3.2Inspection records 檢驗記錄0 Insufficient information on report due to report format deficiencies, such as no designated space for filling sampling AQL, inspected items, etc.因報告格式未完善導致記錄資料不足,例如:沒有指定位置填寫抽樣AQL,檢驗項目等.1 Inspection results are accurately recorded on reports. 檢驗結果準確地記錄在報告上.2 (1) + Inspection reports have good traceability to related documents such as MCAR no., MRB report no., etc.(1) + 檢驗報告能有效追溯各有關文件資料,如:MCAR號碼及MRB號碼等等.3 (2) + Inspection reports and related documents are well filed and maintained with good condition and traceability.(2) + 檢驗報告及相關文件均存檔良好,並於適當保存條件及有效追溯能力下執行. B3.3Inspection / Testing equipment 檢驗/測試設備0 Testing equipment / measuring instrument is not calibrated. 測試設備/儀器沒有校正. 1 Each testing equipment / measuring instrument is well calibrated, labeled and maintained.每個測試設備/儀器都校正好,并作有效標示及保護.2 (1) + Inspectors use the instrument / equipment properly without causing damage (e.g. putting the caliper back to box after usage).(1) + 檢查員能正確地使用設備/儀器,避免引致損壞(如:卡尺用畢,隨手放回卡尺盒內).3 (2) + Enough testing equipment / instrument & adequate accuracy.(2) + 足夠測試儀器/設備,且準確度足夠.B3.4Inspection environment 檢驗環境0 Poor inspection environment such as insufficient lighting, proper magnifying, etc.檢驗環境欠佳,例如:燈光及放大倍數條件不足等.1 Good inspection c