塑胶件外观标准.doc

XBOX Plastic PartWorkmanship StandardsDocument Number: D00015Revision: CApril 11, 2006ConfidentialDisclaimerThe information contained hereon is confidential, is submitted in confidence, and is proprietary information of Microsoft Corporation, and shall only be used in the furtherance of, the contract of which this document forms a part, and shall not, without Microsoft Corporations prior written approval, be reproduced or in any way used in whole or in part in connection with services or equipment offered for sale or furnished to others. The information contained hereon may not be disclosed to a third party without consent of Microsoft Corporation, and then, only pursuant to a Microsoft approved nondisclosure agreement.Published by Xbox Hardware DevelopmentMicrosoft Corporation One Microsoft Way Redmond, WA 98052-6399Revision HistoryRevisionDateECODescriptionAuthor/Revised byPreliminary3/7/01CreationJeff ReentsA8/4/01Note Change to LightingJeff ReentsB9/7/01Change Viewing TimeJeff ReentsC4/10/06Change Level classifications to Class classificationJeff ReentsApprovalsTitleSignatureDateMechanical Engineering:Jeff Reents4/10/06Mechanical Comodity Manager:Quality/Manufacturing Engineer:Section Page1.0Purpose/Scope52.0Definitions/References53.0Definition of Surface Levels and Inspection Criteria74.0Printed Legends, Logo and Icons105.0Enclosures131.0Purpose/ScopeApplies to all XBOX Plastic parts unless otherwise specified by Microsoft Corporation drawings or specifications or deviations/waivers.The intent of this standard is to provide a cost effective, cosmetically acceptable product for our customers. It is written to work in conjunction with Product Specification and other referenced Microsoft workmanship specifications. This document has precedence over customer detail drawings and workmanship specifications. 2.0Definitions/References2.1DefinitionsABRASIONS: Surface imperfections that appear as a scuff (handling damage) but are not deep enough to be considered as scratches.BLUSH/SPLAY: A change in gloss in the surface texture that doesnt match the surrounding area.BURN MARKS: Black or brown marks on the surface of a part.COSMETIC: Product qualities having to do with appearance.CONTAMINATION: Foreign matter of any kind visible on or in the material.CRACKS AND CRAZING: Fine cracks, which may extend in a pattern on or between the surface or through a layer of material.CUT MARKS: A small scratch where material is displaced during a trimming operation or handling method.DIMPLE: A raised bump on the top of a keycap that indicates home row or finger position.FLASH: Excess plastic material around the parting line edges of the part.GATE MARK or VESTIGE: A protrusion extending from the keycap or piece part at the point of injection.HEAT MARK or GHOSTING: A localized change in gloss or texture caused from the excessive heat and/or pressure applied during the heat transfer decorating process.INCLUSION: A solid foreign body enclosed by plastic or spray overcoat.KNIT LINES: The line in plastic piece parts where two separate material flow fronts merge. Refer to weld lines.LIGHT SOURCE: Florescent cool white lighting of approximately 80-120 ft candles shall be used. Light should be perpendicular to the surface being inspected.LIMIT SAMPLE: A product sample that depicts lowest limit of acceptability for a specific quality criteria attribute.MARBLING: A noticeable color change or streak on a surface.NICK: A depression, small notch or groove where material is displaced.RAISED BAR: A home row or key surface identification (see Dimple.)ROCKING an assembled keyboard that does not sit flat on the desktop and is characterized by rocking or vibration when the keyboard is used. SCRATCH: A shallow groove characterized by its long length relative to its depth and width.SHORT SHOT: A part that is missing material, a molding defect.SINKS: A surface depression or dimple caused by material shrink.SKIRT: The bottom boarder or edge of keycapSMEARS/SPOTS/DOTS: Presence of ink not called for on artwork.TEXTURE: A molded surface finish that meets specifications or drawing requirements. May range from gloss to matte or rough.ULTRASONIC WELDING, HEAT/COLD STAKING AND SOLVENT BONDING: Alternate methods of attaching plastic surfaces to each other instead of using a mechanical fastener.VIEWING PLANE: The naked eye shall be focused on the product surface through a span of 60 degrees ( 30 degrees) from a perpendicular line from the surface being viewed. This plane applies to the surface being viewed.VOIDS: An unfilled space in legends, icons, logos or letters on the keycap or enclosure.WARPAGE: Dimensional distortion that may occur in a piece part after molding or after assembly of several piece parts.WELD LINE: Line where molten plastic joins to form a part. A weld line usually appears as a noticeable line across the surface of a part.2.2ReferencesInternal Specifications(900-300-076)MS Plastic Case Parts Workmanship Standard-ECO Added Reference)900-300-077Product Graphic Workmanship Standards900-300-079Color Correctness Evaluation900-300-444Pad Transfer Ink Performance SpecH00388Painted Product Workmanship and Test Spec3.0 Definition of Surface Levels and Inspection Criteria3.1Surface Cosmetic LevelsClass A:All surfaces that are in continuous view of the user. The top and front of the enclosure .Class B:Surfaces that are in occasional view of the user where imperfections will not compromise quality.Class C:Surfaces that are in seldom view of the user where imperfections will not compromise quality. Class D:Surfaces not visible to the user where imperfections will not degrade the functionality and the assembly characteristics of the part or sub-assembly.3.2Visual Inspection: The inspection or audit area used will be free of dust and dirt, surface shall be flat. There are many cosmetic workmanship details that are difficult to define. A specific limit sample is often needed in these instances to define the quality limits. The limit samples are to be approved by Microsoft prior to implementation.a) Lighting: Uniform daylight or uniform cool white fluorescent lighting of approximately 80 to 120 foot-candles. Inspection part to be positioned such that no shadows are cast onto the viewing area.b) Viewing Distance: 18 to 22 inches from surface under inspection.c) Viewing Plane: Normal usage plane of approximately 45 degrees from the inspection surface. The part under inspection will be rotated to view all exposed surfaces.d) Inspector Qualifications: Inspection must be made by individual with non-magnified 20-20 vision (normal or corrected). No tinted lenses are allowed.e) Viewing Time: 10 seconds per unit. f) Inspection Aids: No magnifying devices are permitted (other than the normal corrective lenses as required). Defect comparator or other measuring devices may be used to determine size of defects.3.3 Color Inspection: All molded parts must comply with the color specified and be in the acceptable limits defined on a Microsoft color tolerance standards set or a specific limit sample approved by Microsoft as referenced in individual product specifications, and/or detail component drawings. Color Tolerance: All plastic parts must be held to a tolerance Delta E of 1.00 as compared to the Microsoft approved color chip standard and measured with an approved color meter. All raw resin will be held to a Delta E of .75 as compared to the Microsoft approved color standard and supplied by the Resin Manufacture to the Molder. Certification of the color measurement of the resin must be supplied by the resin manufacture with each lot, and keep on file at the molder, along with the mechanical testing certification, which is also supplied with each lot.3.4 Texture Inspection: All molded parts must comply with the texture specified in the individual product drawing specification. All texture must be acceptable as visually compared against a sample panel or specific limit sample part (molded in the same material) approved by Microsoft, and defined by the detail component drawings.3.5 Texture Wear: Retained samples from each cavity will be keep on record at the molder and will be available for Microsoft inspection against current molded samples on a quarterly basis for monitoring of texture wear. Quarterly samples will be retained for ongoing texture wear evaluation and history (four sets of plastic parts retained per year). Samples maybe measured for texture wear or evaluated visually per Microsoft discretion. Decision for tooling re-texture will be made by resonsible Microsoft Tooling Engineer and coordinated with Microsoft comodity team to insure no disruption to production part delivery. Texture wear evaluation and decision for re-texture is subjective.4.0Printed Legends, Logo and IconsThis standard applies to laser, sublimation, heat transfer and pad-printed legends and icons. 4.1Character Height:Heights shall be as specified in the artwork. Measurement of the artwork positive may be required. Character height variation is acceptable, if within the line width tolerance, or 15% of the character height.4.2Character Line Width:Character widths shall be specified in the artwork. Measurement of the artwork positive may be required.a.Indicia line widths less than .020 lines: acceptable, +/ .002 b.Indicia line widths more than or equal to .020 lines/or equal: acceptable, + .008, .004 4.3Character Spacing:Refer to artwork.4.4Single Character and Icon Tilt:Acceptable, maximum of .005”G4.6Legend (multiple characters) and Logo Tilt:a.1/2 or less in length: acceptable, max. .007b.Greater than 1/2 to 1 in length: acceptable, max. .010c.Greater than 1” in length: acceptable, max. .0130”4.7Character Voids:Acceptable, one void per character is acceptable provided it does not exceed .010” (0,25 mm) in width.4.8Character Smear:For pad printed indicia, one smear per character is acceptable provided it does not exceed .005” in width from legend edge.AcceptableNot acceptableEELess than .005”More than .005”5.0Enclosures5.1Abrasions:a. Level 1: Not acceptable. b. Level 2: Acceptable, 2 or less abrasions, less than .040 inch2 (25.8 mm2).c. Level 3: Acceptable, 4 or less abrasions, less than .062 inch2 (40 mm2).d. Level 4: Acceptable.5.2Blush/Splay:a.Class A, B and C: Acceptable, if not visible under normally diffused non-reflected light, or if the blush/splay disappears when the viewing plane is altered by + 30 degrees or as approved by Microsoft.b.Class D: acceptable5.3Burns:a.Class A, B and C: not acceptable.b.Class D: acceptable, 1 burn less than .250 x .250 if part is functional.5.4Color Variation:a.Class A, B and C: finished parts should be of a generally even color with minor color variations allowed. The total color variation across the part must be within DE of 1.00 to the Microsoft approved color chip (Refer to Microsoft document on Color Correctness Evaluation 900-300-079).b. Class D: acceptable, Delta E of 2.005.5Contamination, inclusion, molded-in contamination:Note: particles smaller than .010 are considered not visible.a.Class A: acceptable, one particle .015 or less every 10 linear inches.b.Class B and C: acceptable, multiple particles .015 or less; or, one particle .025 or less every 3 linear inches.c.Class D: no restrictions if part is functional.5.6Cracks and Crazing:Not acceptable.5.8Flash:No Flash trimming allowed without written prior approval from Microsoft. All allowed trimmed parts must meet dimensional requirements per the CAD database or engineering drawings. In addition, flash shall not exceed the following parameters.a. Class A, B and C: acceptable if less than .004.b. Class D: acceptable if less than .008”.5.9 Foreign Material: a.Class A, B and C: acceptable: a loose airborne particulate or piece of packaging material that is removable by wiping with clean cloth or by using air jet.c. Not acceptable: contamination with oil, ink, hand cream, or other foreign material that is visible, or alters feel, or impairs manufacture of the assembly (e.g. legend printing, affixing labels).d. Class D: Acceptable if does not alter function of part.5.10Gate Marks:a.Class A: Not acceptable.b. Class B, C and D: acceptable if part is functional and does not exceed limit Sample. 5.11Knit/Weld Line:a. Class A, B and C: