试制零件质量控制流程SGM版100201.doc

TS-090-0051.0008/10/2010试制零件质量控制流程Pre-production Part Quality Procedure1. 目的规范试制零件质量控制过程，确保试制零件质量满足工程样车试制活动要求。2. 适用范围适用于样车试制科进行的各阶段(包括IV/IVR/IV2/OTS等)工程样车试制活动中所涉及的试制零件。3. 权责3.1 试制质量工程师：负责整个PPQP活动、跟踪并审核试制关键零件、抽检试制非关键零件、负责交样文件的归档工作。3.2 试制物料管理员：审核交样文件并接收物料。3.3 试制计划工程师：接受并批准试制零件清单更改申请。3.4 设计发布工程师：支持并参与整个PPQP活动、跟踪并审核试制零件状态。3.5 子系统认证工程师：跟踪试制零件的试验进度并审核零件试验认证状态。3.6 材料工程师：确认试制零件的材料符合设计要求。3.7 供应商质量工程师：确认分供方/材料信息的真实性，及尺寸检验的真实性（PT零件除外）。3.8 SMT高级经理：帮助设计发布工程师对存在偏差的零件进行偏差认可。3.9 项目尺寸经理：负责制定试制关键零件清单及过程控制计划。4. 定义 4.1 PPQP: 试制零件质量控制流程4.2 PDT: 产品开发小组4.3 ADVP&R: 认证计划及报告4.4 SVE: 子系统认证工程师 5. 相关文件5.1 T&V-ISO-WI-37 试制物料控制流程5.2 T&V-ISO-WI-38试制BOM生成及维护流程6. 记录6.1 试制零件清单6.2 试制零件清单更改申请表7. 程序内容7.1 流程图试制零件质量控制流程（详见附件1）。7.2 流程描述7.2.1 试制计划工程师负责维护试制零件清单，接收并审核试制零件清单更改申请表。7.2.2 设计发布工程师在释放零件时需明确每个零件来源的信息，包括借用件、采购件等以及该零件在工程认可流程中的状态。7.2.3 生成需要PPQP认证的试制零件清单。7.2.3.1 试制质量工程师根据需要PPQP认证零件的识别原则，结合零件来源、状态等信息生成需要PPQP认证的零件清单。7.2.3.2 需要PPQP认证零件的识别原则: 未通过工程认可的零件 开发过程中的紧固件（包括螺栓、螺母、螺钉等） PT PPO自行采购的其他类零件7.2.4 生成PPQP试制关键零件清单7.2.4.1 项目尺寸经理组织试制质量工程师及各SMT代表等在BOM冻结前根据项目关键零件清单（附件4）讨论确定试制关键零件清单。7.2.4.2 试制关键零件的识别原则： 由于质量问题可能造成PPO停线的零件 由于质量问题可能造成试验延误的零件 由于质量问题可能造成GCA较大分值(分值10)的零件 供应商能力或口碑较差的零件7.2.5 制定试制关键零件的过程控制计划7.2.5.1 关键零件评审小组包括：设计发布工程师、试制质量工程师、供应商质量工程师、材料工程师、尺寸工程师、子系统认证工程师等。7.2.5.2 评审小组制定关键零件过程控制计划： 前期过程控制采用定期开会形式,评审小组定期组织供应商开会讨论模具、检测设备、检测方法、生产进度等进展情况。 后期过程控制采用现场零件验收形式，评审小组走访供应商，现场审核零件状态、检测结果、文件准备情况等。7.2.6 试制质量工程师根据零件的特性及供应商的能力等因素在试制非关键零件清单中以一定的比例抽取零件，形成试制非关键零件的抽检清单。7.2.7 评审小组确定零件检测方法及内容： IVER阶段: 测量方法（以模代检、三坐标、检具、白光等），测点图，认证计划等由供应商负责编写，由PATAC审批。 OTS阶段:测量方法、测点图，认证计划等由SGM输入给供应商7.2.8 供应商生产零件7.2.8.1供应商严格按照SOR中的要求按时、高质量地生产出零件。7.2.8.2 供应商在生产过程中遇到问题，应及时与评审小组有效沟通。7.2.8.3评审小组成员积极帮助供应商解决问题，克服困难。7.2.9 供应商检验零件 7.2.9.1 供应商按照评审小组既定的检测方法进行检验工作，检验工作包括以下3方面： 零件尺寸检测： 供应商按照评审小组确定的测量方法及测点图进行检测。 材料性能检测：a 提供材料质保书b 供应商在不能够提供材料质保书的情况下，需要进行材料性能试验，并提供性能试验报告。 零件性能试验： 供应商按照子系统认证工程师确认的认证计划进行零件性能试验。7.2.9.2 供应商在检验过程中遇到问题，应及时与评审小组有效沟通。7.2.10 供应商制作交样文件7.2.10.1 供应商按照泛亚提供的交样文件模板制作交样文件，交样文件模板见附件7-13。7.2.10.2 供应商将零件生产、检验等相关数据真实、准确、完整的填入交样文件模板中。7.2.10.3 供应商将相关的原始检验报告（包括测量报告、材料报告和试验报告等）附在交样文件中一并提交。7.2.11 零件首次交样7.2.11.1 试制关键零件，评审小组去供应商现场验收零件，验收内容包括: 零件状态: 确保零件状态符合数模要求。 检测方法及检测结果:确保供应商采用的检测方法与评审小组制定的检测方法一致,并分析检测结果。 交样文件的准备情况:确保所有必需的信息都在交样文件中体现。7.2.11.2 试制非关键零件, 供应商按照SOR自行评审零件状态。7.2.12 零件非首次交样7.2.12.1 交货理由有: a. 追加数量 b. 差错纠正c. 工程更改7.2.12.2 对于差错纠正和工程更改两类零件，需要重新评审该批零件的状态。7.2.12.3 根据不同的交货理由，准备不同类型的交样文件。a. 交货理由为追加数量，需要提交供应商产品质量保证书并更新认证计划及报告。b. 交货理由为差错纠正，需要提交供应商产品质量保证书以及与 差错纠正相关的文件，并更新整改计划及认证计划及报告。c. 交货理由为工程更改，需要提交供应商产品质量保证书以及与 工程更改相关的文件，并更新整 改计划及认证计划及报告。7.2.13 评审小组根据附件2中合格件的标准，判断该零件是否为合格件。7.2.14 对于不符合合格件标准的试制零件，评审小组帮助供应商查找不符合项的根本原因，制定整改计划。7.2.15 评审小组根据附件2中临时认可件的标准，判断该零件是否可以临时认可。7.2.15.1 评审小组有条件接受存在缺陷的零件将视为“临时认可件”用于试制造车活动。评审小组需督促供应商按照整改计划要求进行后期整改，并在时间节点前提供新状态的样件。7.2.15.2 评审小组不可接受存在缺陷的零件，供应商需重新安排生产、检验工作。待零件完成后,评审小组需再次评审零件，直至评审小组能接受该零件。7.2.16 交样文件的签署7.2.16.1 评审小组接受零件状态后（包括合格件与临时认可件），对交样文件进行签字确认（签署要求详见附2）。7.2.16.2 高级经理对不符合附件2中最低尺寸要求及试验失效的零件进行缺陷认可。7.2.17 供应商在交样零件上挂上泛亚规定的标牌，将交样零件与交样文件一同按照采购订单上规定的货地点发运。7.2.18 PPO物料管理员审阅交样文件是否完整且已被签署。7.2.18.1 交样文件完整且全部签署完毕, PPO仓库管理员清点交样零件数量，办理入库手续。7.2.18.2 交样文件不完整或未全部签署完毕，PPO仓库管理员将拒绝接受物料，供应商负责将零件运回，待交样文件完整且全部签署完毕，再重新交样。7.2.19 试制质量工程师根据试制非关键零件抽检清单，办理相关零件的出库手续，进行抽检工作。7.2.20 试制质量工程师将抽检结果与交样文件进行对比。7.2.20.1 抽检结果与交样文件上相关数据一致，零件可进入制造现场并办理交样文件的存档手续。7.2.20.2 抽检结果与交样文件上相关数据不一致: 首先，隔离已交样的零件； 其次，供应商查明原因且填写整改计划； 然后，相关工程师对零件进行认可，认可通过后，零件方可进入制造 现场； 最后，PPO试制质量工程师将相关问题反馈给SQE,SQE协助推动供应商进行整改。7.2.21 试制质量工程师负责PPQP文件的归档工作。 8. 附件附件1：试制零件质量控制流程附件2：合格件/临时认可件的标准附件3：文件签署要求附件4：项目关键零件清单附件5：试制零件清单更改申请表附件6：交样零件标签模板附件7：检查清单附件8：供应商产品质量保证书附件9：零件尺寸检验报告附件10：材料审核报告附件11：材料及分供方清单附件12：整改计划附件13：认证计划及报告1. PurposeThe procedure is documented to standardized pre-production part control process, to ensure pre-production part adequately meet pre-production operation requirement.2. ApplicabilityIt is applicable to the parts which are being used in pre-production operation (including IV/IVR/IV2/OTS phase).3. Activity and Personnel Responsible3.1 PPO Quality Engineer: Responsible for PPQP activity, track and check pre-production critical parts, Pre-production Non-critical parts spot check, responsible for archiving PPQP documents.3.2 PPO Material Operator: Check PPQP document and accept material.3.3 PPO Planning Engineer: Receive and approve BOM Change Request.3.4 Design Release Engineer: Support and participate in the PPQP activity, track and validate pre-production parts.3.5 Sub-system Validation Engineer: Track pre-production part ADV process and check the ADV result.3.6 Material Engineer: Confirm part material meet design request.3.7 Supplier Quality Engineer: Ensure the authenticity of subcontractor , material and dimension information (except PT parts)3.8 SMT Senior Manager: Help DRE to confirm the defect part.3.9 Dimension Program Manager: Responsible to make the critical parts list and critical parts process controlling plan. 4. Definitions 4.1 Pre-production Part Quality Process4.2 Production Development Team4.3 Analysis/Development/Validation Plan & Report4.4 Sub-system Validation Engineer5. Related Documents5.1 T&V-ISO-WI-37PPO Material Control Process5.2 T&V-ISO-WI-38PPO BOM Development Process6. Records6.1 PPO Bill of Material 6.2 BOM Change Request7. Contents7.1 FlowchartPre-production Part Quality Process (See Appendix 1).7.2 Process Description7.2.1 PPO plan engineer is responsible to maintain BOM, receive, check and approve BCR.7.2.2 DRE need to confirm part sourcing information when releasing the part including Carry Over part, Purchasing part, etc. And also the part status during the process of engineering approval.7.2.3 Make the part list that needs to be validated by PPQP process.7.2.3.1 PPO quality engineer make the part list that needs to be validated by PPQP process according to PPQP recognition principle and the part sourcing, status information from DRE.7.2.3.2 PPQP recognition principle: The parts have not been approved by Engineering Approval The fastener in development (including bolt, nut and screw, etc.) Other parts bought by PT PPO7.2.4 Make the PPQP critical part list.7.2.4.1 DPM leads PPO quality engineer and SMT representative to make critical part list according to “Program critical part list (See Appendix 4)” before BOM frozen.7.2.4.2 Critical part recognition principle: Part quality issue may cause that PPO will shut down. Part quality issue may cause that vehicle test will delay. Part quality issue may cause great factor in GCA（GCA factor 10）. Bad responsibility of supplier.7.2.5 Make critical part process controlling plan.7.2.5.1 PDT including: DRE, PPO quality engineer, SQE, material engineer, dimension engineer, SVE and so on.7.2.5.2 PDT make critical parts process controlling plan: In advanced process control phase, PDT organize regular meeting with suppliers for discussing molding, checking fixture, checking method, product progress, etc. In post-process control phase, PDT visit to supplier to check the part status, inspection result and document preparation on site.7.2.6 PPO quality engineer make non-critical parts spot checking plan as a certain proportion from non-critical parts list according to the part feature and suppliers ability.7.2.7 PDT confirm part checking method and content: IVER phase: supplier prepare for checking method (inspect on molding instead of check fixture, CMM, checking fixture, white-light and so on), measurement point drawing, ADV plan and PATAC approve them. OTS phase: SGM input checking method, measurement point drawing and ADV plan and so on to supplier.7.2.8 Supplier produce part7.2.8.1 Supplier produces part on time and with high quality strictly according to SOR.7.2.8.2 Supplier effectively communicates issues with PDT in time in product process.7.2.8.3 PDT support supplier to solve issues and overcome difficulties actively.7.2.9 Supplier check part 7.2.9.1 Supplier checks the part strictly according to the checking method approved by PDT. Checking content including 3 points: Part Dimension Inspection: supplier check part strictly according to checking method and measurement point drawing approved by PDT. Material performance test :a Provide warrant of material.b Supplier implement material performance test without warrant of material. Part functional test: supplier implement part functional test according to ADV plan approved by SVE.7.2.9.2 Supplier effectively communicates issues with PDT in time in inspection process.7.2.10 Supplier prepare for PPQP document7.2.10.1 Supplier prepare for PPQP document according to PATAC PPQP document template, refer to Appendix 7-13 for PPQP document template.7.2.10.2 Supplier fills the data of product and inspection process in PPQP document template truly, exactly and completely.7.2.10.3 Supplier attaches related original inspection reports (including measurement report, material report and ADV report) to PPQP documents.7.2.11 Part initial submission7.2.11.1 For critical parts, PDT check and accept parts on site, including: Part status: confirm that part status accord with its math data. Checking method and result: confirm that checking method implemented by supplier accord with it approved by PDT, and analyze checking result. PPQP document preparation status: confirm that all the required information has been filled in PPQP document.7.2.11.2 For non-critical part, Suppliers check the part by themselves according to SOR.7.2.12 Part non-initial submission7.2.12.1 Reason for submission: a. Additional Quantities b. Correction of Discrepancyc. Engineering Change7.2.12.2 For the part that Correction of Discrepancy or Engineering Change checks part status again.7.2.12.3 Prepare various PPQP documents according to various submission reasons.a. When reason for submission is Additional Quantities, supplier submit”SUPPLIER PARTS QUALITY WARRANT”, and update “ANALYSIS/DEVELOPMENT/VALIDATION PLAN &REPORT”.b. When reason for submission is Correction of Discrepancy, supplier submit “SUPPLIER PARTS QUALITY WARRANT” and related documents about Correction of Discrepancy, and update the “CORRECTIVE ACTION PLAN” and ”ANALYSIS/DEVELOPMENT/VALIDATION PLAN &REPORT”.c. When reason for submission is Engineering Change, supplier submit “SUPPLIER PARTS QUALITY WARRANT” and related documents about Engineering Change, and update “CORRECTIVE ACTION PLAN” and ”ANALYSIS/DEVELOPMENT/VALIDATION PLAN &REPORT”.7.2.13 PDT judge whether part is OK or not according to criterion of Appendix 2.7.2.14 For the part can not meet OK part standard, PDT help supplier to find out the root cause, make long term and short term solution and their break points, and fill these information in “CORRECTIVE ACTION PLAN”.7.2.15 PDT judge whether part is useable or not according to criterion of Appendix 2.7.2.15.1 Part with defect that is accepted by PDT as “useable part” for pre-production operation. PDT push supplier to correct part according to “CORRECTIVE ACTION PLAN” and provide new status part before break point.7.2.15.2 Part rejected by PDT must be reproduced and inspected. PDT checks the reproduction until PDT can accept the part.7.2.16 Sign off PPQP document7.2.16.1 PDT sign off PPQP document when accepting the part (including OK part and useable part), see attachment 2 for sign off requirement.7.2.16.2 SMT senior manager evaluate and approve the part that all measurement points pass rate cannot meet Appendix 2 or ADV test failed.7.2.17 Supplier attach the label specified by PATAC to every part that is to part, and ship the part and PPQP document to the place appointed by PR.7.2.18 PPO material operators check whether PPQP documents are completed and signed-off or not.7.2.18.1 When PPQP documents are completed and signed-off, PPO material coordinator check and count the parts, and then stock in part.7.2.18.2 When PPQP documents are not completed or signed-off PPO material coordinator rejects the parts. Supplier is responsible to ship the parts back, and submit the parts again until PPQP documents are completed and signed-off.7.2.19 PPO quality engineer stock out parts accordingnon-critical parts list and do spot check for non-Critical parts.7.2.20 PPO qu