新产品试生产控制程序New-Product-Introduction-Trial-Run-Control-ProcedurHiP-WSHT-IOP-Q047V2.1

赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 1 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 修订记录修订记录 Revision History 编制人编制人日期日期修订内容修订内容版本号版本号 AuthorDateChange DescriptionRev Lai Denghong 24 Nov 200 5 First Release1 0 Lai Denghong 7 Dec 2005 Correct document title and add mold test report 试模报告试模报告 2 0 He YaFengChange Document Format2 1 批准批准 Approvals 职位职位姓名姓名签名签名日期日期 PositionNameSignatureDate 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 2 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 1 目标目标 1 PURPOSE 1 1 对新产品前期的注塑 喷涂 装配等的过程试验 调试及优化缩短新产品引进过程的周期 确保按 时交货 并为新产品进入大批量生产制定优化工艺及程序 1 1 Set up optimize process in Molding Painting and Assembly to ensure delivery on time and shortest cycle time for new product introduction and ramp up 2 范围范围 2 SCOPE 2 1 适用于本公司所有试生产的通讯塑胶电子类产品 2 1 Applicable to all wireless new plastic products 3 职责职责 3 RESPONSIBILITIES 3 1 注塑负责公司制造或外来注塑模具的注塑过程 3 1 Molding department is in charge of new product molding process 3 2 喷涂负责新产品喷涂移印过程 3 2 Spray painting department is in charge of new product spray painting and pad printing process 3 3 装配负责新产品装配过程 3 3 Assembly department is in charge of new product assembling process 3 4 物流部负责提供试生产所需要的原辅材料 3 4 Logistic department is in charge of supplying all raw materials for trial run 3 5 物流部计划负责制定 下达试生产计划 3 5 Logistic planning department is in charge of new product planning and issuing trial run plan 3 6 工艺工程师负责生产工艺的制定 调整 3 6 Process engineer is in charge of setting and improving the process parameter and technology 3 7 注塑 喷涂 装配技术员负责按作业计划 根据工艺文件要求进行控制 并及时的掌握信息 反馈 给制程工程师 质量部 并负责所使用的现场清洁 负责试生产产品的入库 3 7 Molding spray painting assembly technician is in charge of operating according to trial run plan controlling the process according to WI providing the feedback information to process engineer and QA in time keeping the cleanliness of line and sending trial run products to store on time 3 8 质量部负责现场量具和检测设备的控制 检验并确认产品的质量 3 8 QA department is in charge of all measuring fixture gages and testers and ensure product quality meet specification 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 3 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 3 9工业工程设备人员负责提供适宜的设备 并对之进行保养 维护 检修 保障能源的供应 工业工 程设计人员负责工装夹治具 包装材料方式等的设计及导入工作 3 9 IE department industrial engineer is in charge of providing and maintaining suitable equipment for produce and ensuring energy supply design engineer in charge of jig fixture package designing and introducing 3 10 注塑 喷涂 装配部文员负责接物流部试生产计划 安排领料等试生产准备工作 3 10 Engineering clerk is in charge of receiving producing plan and preparing for trial run 4 定义定义 4 DEFINITION 4 1 PM Project Management 4 2 ESI Early Supplier Involvement 4 3 PE Process Engineer for Molding Spray Painting Assembly 4 4 IE Industrial Engineering including Package Design Equipment Plan 4 5 FOT First of Trial Run 4 6 CPK Run Index of Process Capability Run 4 7 EOL End of Life 4 8 WI Work Instruction 4 9 特殊过程 Special Process a 产品质量不能通过后续的监视或测量加以验证的工序 a Product produced in the process cannot be qualified by subsequent monitoring or testing method b 产品质量需要进行破坏性试验或采用复杂 昂贵的方法才能测量或只能进行间接监视的工作 b Qualification of the product produced in the process be tested by destroying method or expensive test or indirect monitoring c 该工序产品仅在产品交付使用之后 不合格的质量特性才能暴露出来 c Product produced in the process reveal the quality character only after be put in use 5 作业标准作业标准 5 STANDARD OPERATION PROCEDURE 流程流程 Flow 程序程序 Procedure表单表单 Form 相关部门相关部门 Related Dept 总则 Principle 根据客户要求 及时完成新产品的导入 According to customer requirement complete new production on time 流程流程 Flow 程序程序 Procedure表单表单 Form 相关部门相关部门 Related Dept 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 4 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 供应商前 期介入 ESI PM 提供新产品相关资料 包括产品图纸 材料表等 PM provide related file about new product including technical drawings material form etc PE IE 进行过程成本及可行性分析 包括注塑 喷 涂和装配过程 PE IE carry out the cost and feasibility analysis of molding spray painting assembly PM 组织新产品导入起动会议 PM organize new product introduce kick off meeting 可行性评估表 Feasibility report 注塑生产估价表 Molding CR 喷涂生产估价表 Spray painting CR 装配生产估价表 Assembly CR 项目部 PM dept 工程部 Engineering 新项目产 品导入过 程 New Product introductio n PM 提供新产品的数据资料和新产品实施的计划表 PM provide new product file and implement plan PE IE 和 PM 进行新产品技术研究及计划实施讨论 包括相关工装治具 夹具 包装的设计 制程工艺技 术检讨等 PE IE and PM discuss new product technology and implementing plan including jig fixture package design and process technology review 对所做的设计方案进行内部检讨 审核及改进 Engineering will review check and improve the design 提交设计方案给客户确认 Submit the design to customer for confirmation 如客户对提交的设计有更改要求时 则修改相应的 设计方案 直至客户满意 Revise the design until customer satisfied 项目部 PM dept 工程部 Engineering dept 新产品首 次运行测 试 FOT 物流部根据 PM 要求排定 FOT 计划 确认相关机器 材料到位后 提前下达生产计划给工程部 质量部 Logistic dept arrange FOT plan according to PM s requirement delivery the plan to engineering department and QA after confirmation of machine and material is ready 注塑 喷涂 装配 质量部接到计划后 进行首次 生产测试准备 领取首次生产测试资料 包括包材 原材料 客户图纸 原材料物性表 工装夹治具等 After receiving FOT plan Molding spray painting assembly and QA prepare raw materials packages technical drawings BOM jig fixture etc for trial run 首次生产测试进行 PE 做出原始工艺参数 试模报 告等 质量部根据客户要求做出品质控制计划 检验 计划等 工程部生产出工程样品 客户样品 如有 及 提样品给质量部进行首件检查 Carry out the FOT PE work out technical parameters mold test report etc QA work out quality control plan and inspection plan according to customer s requirement Engineering department produce samples and submit to QA for inspection QA inspect the set up samples and will refer to 加料记录 试模报告 注塑质量日报表 装配生产跟踪记录 表 外观检测报告 过程检验记录 喷漆外观检验记录 调漆记录 喷漆记录 喷枪设定记录 包装文件 Molding Process Data Sheet Tracker Material feeding record Mold test report Molding quality daily report 物流部 项目部 工程部 质量部 Logistic Dept PMD Engineering Dept QA 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 5 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P customer sample if any 注塑 喷涂 装配部门生产中做好生产日报表 Molding Spray painting Assembly departments take product record 样品提交并记录 PE 保留工程样品 3 模 其中 1 模提 供给 IE 制定包装文件及相关资料 Submit samples and record PE keep 3 shots of samples one of the shots is submitted to IE for setting up package document and related files 质量部根据客户要求及检验计划做出首件检验报告 MFI 报告及 CAV 报告等 QA submit inspection report of first piece MFI report and CAV report etc according to customer s requirement PE 通过 FOT 做出 WI 项目 TRACKER IE 制定包 装文件 PE work out WI and project tracker according to FOT IE work out packaging instruction document 参照 ECN PCN 或新产品再改进 如有 If there is ECN PCN follow according if any Assembly track record Appearance inspect report Process inspect record Spray painting appearance inspect record Paint mix record Painting record Spray gun set up record packaging instruction Tracker 试生产 Trial run 物流部根据 PM 要求排定试生产 计划 确认相关机器 材料到位后 提前下达生产计划给工程部 质量部 Logistic dept arrange trial run according to PM s requirement and deliver the plan to engineering department and QA after confirmation of machine and material is ready 注塑 喷涂 装配 质量部接到计划后 进行试生 产测试准备 领取试生产测试资料 包括包材 原材 料 原材料物性表 工装夹治具等 After receiving Trial run plan Molding spray painting assembly and QA get raw materials packaging material Technical data sheet jig fixture etc for carrying out the trial run 工程部技术员根据指导文件进行工艺设置及调整 生 产出的首件样品送质量部确认 OK 后开始试生产 不 合格及时反馈给工程部技术员 PE 和工程部技术员 进行重新调试 Technicians set up and adjust technical parameters according to WI Start trial run after confirmation of set up samples by QA If this set up sample fail QA will review the process with PE and reproduce set up sample for confirmation 将检查好的产品按照 塑件包装要求单 进行包装 Qualified products pack according to Plastic Part Packaging instruction Sheet 特殊过程控制 Special process control 试生产过程中的注塑过程 喷漆过程 装配 焊 装配产品试生产申 请表 注塑质量日报表 装配生产跟踪记 录表 外观检测报告 试模报告 过程检验记录 喷漆外观检验记 录 调漆记录 塑件包装要求单 喷枪设定记录 喷漆记录 喷漆工艺参数表 良率报告 MOLDING TRIAL RUN REQUEST FORM SPRAY PAINTING TRIAL REQUEST FORM Logistic PMD Engineering QA 物流部 项目部 工程部 质量部 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 6 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 接过程属于特殊过程 Including molding spray painting Assembly Ultrasonic welding processes 对特殊过程的控制参照相应的作业指导书 注塑过程参照 塑胶产品作业指导书 喷漆过程参照 喷漆工程试样作业指导书 装配过程参照 超声波焊接通用作业指导书 装配作业指导书 For these special processes refer the corresponding WI Molding process refer to Plastic product WI spay painting process refer to Spray painting trial run WI assembly process refer to Ultrasonic welding general WI and Assembly WI 试生产产品由质量部按照 塑件类产品的监视和测 量控制程序 进行检验 检验合格后 注塑 喷涂 装配将试生产产品入库 所产生的不合格品按 塑件 类不合格品控制程序 执行 产品的标识按照 塑件 类产品标识和可追溯性控制程序 执行 Trial run products are inspected according to Plastic Product Monitor and Test Control Procedure and flow to warehouse if qualified Unqualified products are dealt according to Unqualified Plastic Products Control Procedure Product mark set up according to Plastic Product Mark and tracking Control Procedure PE 做出工艺参数 试模报告 并保留工程样品 3 模 客户样品提交质量部 PE work out technical parameters and mold test report and keep 3 shots of samples samples for customer are submitted to QA 试生产结束后 相关部门对试生产过程中发现的问 题做出试生产反馈 项目部追踪问题的解决 After trial run related departments feedback problems found in trial run PMD track until the problems are resolved 试生产检验过程中发现的异常 按照 纠正和预防 措施控制程序 执行 If abnormal situations found during trial run implement according to Rectify and Preventive Measures Control Procedure 参照 ECN PCN 或新产品再改进 如有 If there is ECN PCN follow according if any Molding Process Data Sheet Tracker Yield rate report CPK 试生 产 CPK trial run 工程部在试生产过程中根据 PM 要求同时进行 CPK 测试 Engineering carry out CPK trial run according to the requirement of PM during trial run 注塑 喷涂 装配根据计划进行 CPK 测试 做出生 产日报表 产品的标识按照 塑件类产品标识和可追 CPK report CPK 报告 物流部 工程部 质量部 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 7 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 溯性控制程序 执行 Molding spray painting assembly department carry out CPK test work out daily product report and set up product mark according to Plastic Product Mark and tracking Control Procedure 质量部根据客户要求对生产产品 CPK 数据测试及收 集 并做出 CPK 报告 FAI 报告及 MFI 报告 QA collect CPK test data and work out CPK report FAI report MFI report according to the requirements of customer CPK 测试产品经质量部确认 OK 后入库 所产生的 不合格品按 塑件类不合格品控制程序 执行 CPK trial run product is checked by QA ok product is send to store unqualified product is disposed according to Unqualified Plastic Products Control Procedure CPK 数据处理 如 OK 进入下一步 NG 则须再调 整改进 If CPK report data is OK proceed to the next stage if not OK repeat CPK trial run process with improvement plan Logistic dept ENGINEERIN G QA 新产品导 入后期 EOL 新产品转移主制造工厂生产 New product transferred to factory for mass production 工程部进行量产支持 量率达成 解决问题 Engineering support mass production to achieve target yield rate and resolve problems 当问题解决后 此新产品导入工程结束 End of NPI mission after every problem be resolved 量率报告 问题跟踪报告 Yield rate report Tracker 制造工厂 工程部 各部门 Factory Engineering 6 SUPPORTING DOCUMENTS 6 相关文件相关文件 6 1 HiP WSHT IOP Q025 产品标识规定 6 2 HiP WSHT IOP Q027 产品可追溯制度 6 3 HiP WSHT IOP Q002 不合格品控制程序 6 4 HiP WSHT QEH004 纠正预防措施程序 6 6 HIP WSH WI EN 003 包装通用标准 6 7 HIP WSH WI EN 004 包装检测说明 6 8 HIP WSH R 533 2005 0 试生产跟踪记录表 6 9 HIP WSH 704 2005 0Preliminary Contract Review Record Injection Moulded Parts 6 10 HIP WSH 705 2005 0Preliminary Contract Review Record Pad printing parts 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 8 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 6 11 HIP WSH 706 2005 0Preliminary Contract Review Record Painted parts 6 12 HIP WSH 707 2005 0Preliminary Contract Review Record Assembly parts 6 13 HIP WSH 703 2005 0 Contract Review 6 14 HIP WSH 701 2005 0 BD form 6 15 HIP WSH R7 5 2 010 2005 1 Molding Process Data Sheet 6 16 HIP WSH 710 711 Molding Yield rate report 6 17 HIP WSH 712 713 Painting Yield rate report 6 18 HIP WSH 714 715 Assembly Yield rate report 6 19 HIP WSH R 716 2005 0 MOLDING TRIAL RUN REQUEST FORM 6 20 HIP WSH R 717 2005 0 SPRAY PAINTING TRIAL REQUEST FORM 6 21 HIP WSH R 718 2005 0 装配产品试生产申请表 6 22 HIP WSH R7 5 2 002 2005 0 喷枪设定记录 6 23 HIP WSH R7 5 2 001 2005 0Spray painting record 6 24 HIP WSH WI EN 001 Process change management work instruction 6 25 HIP WSH WI EN 002 Engineering change management work instruction 6 26 HIP WSH WI AS 003 超声波焊通用作业指导书 6 27 HIP WSH R 613 试模报告 7 FLOW CHART 7 流程图流程图 7 1 ESI process flow 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 9 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 7 1 ESI 流程 职责 Responsibility 流程 Procedure 相关文件和记录 Doc Record PMD ENGINEERING Molding CR Spray painting CR Assembly CR Feasibility analysis form PMD PMD PMD ENGINEERING PMD ENGINEERING New product data file and implement plan New product related files Cost and feasibility analysis New product introduce kick off meeting Design jig fixture package technical process Review audit improve of design plan Go to FOT process Customer confirmation No Yes 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 10 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P 7 2 FOT 流程 职责 Responsibility 流程 Procedure 相关文件和记录 Doc Recorder PMD PMD ENGINEERING Customer drawing Logistic dept Material performance form Logistic dept Trial run weekly plan form ENGINEERING material receiving form customer drawing Deliver FOT requirement Prepare related file document FOT plan deliver to IED Get related files and raw materials ECN or improve if needed otherwise internal project transfer and carry out trial run and confirm procedure Set up technical parameters and begin FOT Submit sample and keep engineering sample Set up WI PI design and set up robot arm up First piece inspection 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Control Procedur 文件编号文件编号 NO HiP WSHT IOP Q017 版本号版本号 Rev 2 1 发布日期发布日期 Released Date 页次页次 Page 11 of 13 未经赫比公司书面许可 不得将本文件之全部或部分内容透露予无权阅读本文件之机构或个人 This confidential information must not be disclosed to others without prior written consent of Hi P Logistic dept Technical process flow Material feeding record ENGINEERING Molding Process Data Sheet Mold test report PE IE Molding quality daily report Assembly track record form QA Process inspection record Painting appearance inspection record PE IE PE IE ECN TOOLING 7 3 Trial run and qualification flow 职责 Responsibility 流程 Procedure 相关文件和记录 Doc Record PMD Molding trail run request form Spray painting trial run request form Assembly trial run request form PMDPrepare related files and raw materials for producing Deliver trial run request 赫比 上海 通讯科技有限公司赫比 上海 通讯科技有限公司 Hi P SHANGHAI TECHNOLOGY CO LTD 内部作业程序内部作业程序 Internal Operation Procedure 文件名文件名 Title 新产品试生产控制程序新产品试生产控制程序 New Product Introduction Trial Run Con