质量手册中文译本.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(目录) 1 QUALITY ASSURANCE REQUIREMENTS质量保证要求1.1 Factory General Requirements (工厂一般要求)- P4A. I.C.T.I. Compliance(符合I.C.T.I)- P4B. Personnel Requirements(职员要求) - P4C. Equipment Requirements(设备要求) - P41.2 Safety and Reliability Tests(安全&可靠性测试)- P7A. Safety Tests(安全性测试)- P7 (revised)B. Reliability Tests(可靠性测试)- P9 (revised)C. Electronic Toys Additional Tests(电子玩具的附加测试)- P12 (revised)1.3 Factory Quality System(工厂质量系统)- P17 A. Factory Incoming QC Requirements -P17 (revised)工厂来料质量控制要求B. Factory WIP QC Requirements - P18 (revised) 工厂生产过程质量控制要求1.4 New Color Development Procedure(新色发展程序)- P21 (revised)1.5 EPS Testing Procedure(工程产品规格测试程序)- P23 (revised)1.6 Risk Assessment Procedure(风险评估程序)- P241.7 Quality Plan Development Requirement (质量计划发展要求)- P25 (revised)1.8 Date Coding and Lot Tracking Requirement - P27 (revised) (日期码和批量追踪要求)1.9 Packaging Validation Requirement (包装确认要求)- P291.10 Labeling Requirements(标签要求)- P30 A. Regular Products Labeling(一般标签要求)- P30 (revised)B. Direct Ship Labeling(直接走货标签要求) - P34C. Special Order Labeling(特殊订单标签要求)- P341.11Pilot Run Requirements - P35 (revised)1.12Lab Testing Procedure(实验室测试程序)- P382 QUALITY CONTROL REQUIREMENTS 质量控制要求2.1 Overall Mega Bloks Quality Vision 美高QC全部要求- P39 2.2 Incoming Quality Control Requirements(来料质量控制要求)- P402.3 Molding Quality Control Requirements (模具质量控制要求)- P412.4 Spray Paint & Other Surface Finish Quality Requirements - P43 (revised)(喷油&其它表面涂层质量要求)2.5 Other Operations Quality Requirements (其它操作质量要求)- P442.6 Final Assembly Quality Control Requirements (最终装配质量控制要求) P45 (revised)2.7 AQL Criteria Acceptable Quality Level - P46 (revised)2.8 Defect Classification (次品分类)- P482.9 Pull Force Standards for Blocks (积木的拉力要求)- P521.1Factory General Requirements (工厂一般要求)It 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.所有美高供应商（在玩具包装上美高标识）有必须符合下列条件。A - I.C.T.I. Compliance(符合I.C.T.I)The 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.美高评估中国国内加工商所使用的标准是基于玩具行业的国标标准。我们期望所有的加工商符合这些标准。同时，在我们的制造业协定和方针声明中，所有与我们合作的伙伴在运作上要符合当地的法律法规。如果我们的加工商被发现有违反上述条例，我们希望他们马上采取矫正行动。滥用或违反这些条例会导致我们生意关系的终止。附件是最新的ICTI审核报告。B-Personnel Requirements(职员要求)As 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.在我们的制造业协定和方针声明中，我们期望所有中国国内的工厂在下列部门有英语翻译：计划部，工程部，质量控制部，生产部。当然，销售和市场部也是需要用英语沟通。请查阅附页中的供应商联系人列表，美高积木中国部会定期更新该表。C-Equipment Requirements(设备要求)In 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.为了确保国内的工厂能控制产品的质量，确保这些产品符合安全和性能要求，工厂必须配备我们在表格1列出的仪器设备。我们也强烈推荐工厂配备表格2列出的仪器设备。附页中有一份工厂设备检查清单，要求所有工厂填写该表并发回美高中国公司。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.为了着重强调我们产品的安全要求，我们要求所有(生产任何部件)的工厂在产品的生产过程中，不得使用具有可折断刀刃的刀或其它任何切断工具(见下页图片)。这点要求也包括在我们的制造业协定中，我们国内的职员会定期审核加工商的工厂以确保他们符合这一要求。 返回目录1 返回目录2 返回目录1 返回目录2TABLE 1: CRITICAL EQUIPMENT鉴定设备Equipment设备Parameters & requirement 参数和要求Transit testing machine振台220-250 rpm, 1 inch oscillation, size to accommodate full range of master carton sizes转速220-250转，振幅1英寸，有相关调节开关使振台围栏适合所有卡通箱的尺寸Oven烤炉Can provide stable temperature at 55-57 degree, 48 hrs above, size must be able to accommodate full master cartons. 稳定温度范围55-57度，时间48个小时以上，侧边可以调整来装入整个卡通箱Ice Box冰箱Size must be able to accommodate full master cartons of all items produced and can provide stable temperature of -17C 能稳定提供零下17度的温度，侧边可以调整来装入任何产品的整个卡通箱 Humidity container潮湿炉Can provide 20-40 degree stable temperature, 48hrs or more, in adjustable relative humidity from 20-95% 稳定温度范围20-40度，时间48个小时或以上，湿度调节范围20-95%Pull & push scale压力&推力刻度计Range: 0-60 lbs, must meet minimum range, some tests require very small forces (0.5 kgs)范围：0-60磅，要符合最小范围(有些测试要求0.5kgs的刻度)Torque screw driver螺丝扭力计Torque range: 0-6 kgf.cm扭力计范围：0-6千克力厘米Small part gage小物体测量器Refer to ASTM and EN-71 standards参考ASTM和EN71标准Sharp edge tester利边测试仪Refer to ASTM and EN-71 standards参考ASTM和EN71标准Sharp point tester尖点测试仪Refer to ASTM and EN-71 standards参考ASTM和EN71标准Sound level meter声音水平仪Mechanical tape recommended推荐机器型号UPC Bar Code Tester产品条形码测试仪Must check quality and readability of bar codes能测试出条形码的质量和可读性返回目录1 返回目录2TABLE 2: RECOMMENDED EQUIPMENT推荐设备 Equipment设备Parameters & requirement参数和要求Torque tester扭力计0-10 kgf.cm扭力计范围：0-10千克力厘米Drop Test Table跌落台Refer to ASTM and EN-71 standards参考ASTM和EN71标准Preschool play figurine test gauge学龄前儿童公仔测试仪Refer to ASTM and EN-71 standards参考ASTM和EN71标准Supplemental gauge for bulbous end球形末端玩具的补充测试仪Refer to ASTM and EN-71 standards参考ASTM和EN71标准Accessibility probe可接触探针Refer to ASTM and EN-71 standards参考ASTM和EN71标准Zebra Bar Code Label Printer and Software条形码标签打印机和软件Must be capable of printing bar code labels conforming to standards enclosed in this report打印出来的条形码标签能符合本文件的标准 1.2Safety & Reliability Tests(安全&可靠性测试)It 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.我们国内工厂制造的产品符合所有颁布的和公认的安全标准是至关重要的。美高大多数的标准比一般标准更严格。这是因为以对于我们产品质量我们非常自信，坚持实行更高的标准，更高标准的产品质量。下面列表是美高公司的可靠和安全性测试的标准。多数时候，其中某些或所有的这些要求会在EPS（工程产品规格）中重述。美高中国公司QA要求工厂一收到产品的EPS，马上填好所有的安全和可靠性测试追踪表(包含在本文件中附页)并发回美高中国公司。 返回目录1 返回目录2A. SAFETY TESTS安全测试 Test Description测试描述 Performance & Requirement 执行标准S/S & Cycle 抽样和周期PRODUCT DROP (IMPACT) TEST产品跌落(撞击)测试Comply with EN-71, ASTM, CANADAIAN, AUSTRALIAN standards.符合EN-71, ASTM,加拿大，澳洲标准。Every lot shipped, every time when start the production, change the supplier, or a new order.2 units per lot周期-每个走货订单/换供应商/新订单，开始生产的时候；抽样每次抽2套SMALL PARTS CHECK小物件检查Use the small part checking cylinder (inside diameter31.7mm), as per ASTM and EN-71参考EN-71, ASTM，用内径为31.7mm的小物件圆筒Every lot shipped, every time when start the production. 2 units per lot. 周期-每个走货订单，开始生产的时候；抽样每订单抽2套SHARP POINT CHECK 尖点检查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. 参考EN-71, ASTM的尖点测试仪。直径小于2mm的金属丝被认为是尖点Every lot shipped, every time when start the production. 2 units per lot. 周期-每个走货订单，开始生产的时候；抽样每订单抽2套SHARP EDGE CHECK利边检查 Use the sharp edge tester, as per ASTM and EN-71. 参考EN-71, ASTM的利边测试仪Every lot shipped, every time when start the production. 2 units per lot周期-每个走货订单，开始生产的时候；抽样每订单抽2套TENSION TEST拉力测试Comply with EN-71, ASTM, CANADAIAN, AUSTRALIAN standards. 符合EN-71, ASTM,加拿大，澳洲标准。Every lot shipped, every time when start the production, change the supplier, or a new order. 2 units per lot 同跌落测试TORQUE TEST扭力测试Comply with EN-71, ASTM, CANADAIAN, AUSTRALIAN standards. 符合EN-71, ASTM,加拿大，澳洲标准。Every lot shipped, every time when start the production, change the supplier, or a new order. 2 units per lot同跌落测试POLYBAG STANDARD胶袋标准1 - All polybags, regardless of size, will have a material thickness of 0.0197” or 0.050mm.所有胶袋(不管什么尺寸)，要有0.0197英寸或0.050毫米的厚度2 - If finished bag size is less than 2.75” (70mm) X 1.5” (38mm), there is no need for ventilation holes所有成品胶袋尺寸小于2.75英寸(70毫米)x1.5英寸(38毫米)的，不需要通风孔3 All sizes above this will have ventilation holes (2-4 holes), the holes diameter should be 3-5mm所有成品胶袋尺寸大于2.75英寸(70毫米)x1.5英寸(38毫米)的，需要2-4个通风孔，孔径为3-5毫米。4 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.如果胶袋含有小物体会从通风孔掉出，该小物件要用小胶袋或另外的方法包装。NOTE: these standards are more stringent than ASTM and EN-71 standards.这些标准比ASTM和EN-71更严格Every lot shipped, every time when start the production, change the supplier, or a new order. 2 units per lot周期-每个走货订单/换供应商/新订单，开始生产的时候；抽样每次抽2套PVC CONTENT STANDARDPVC部件标准DEHP content less than 0.05%DEHP含量小于0.05%EEC less than 0.01% EEC含量小于0.01%PVC heavy metal soluble content (ASTM)PVC可溶重金属含量参考ASTMOverall Phthalates less than 0.1%; 所有邻苯二甲酸盐含量小于0.1%CARTON WEIGHT LIMIT卡通箱重量限制Maximum weight of any carton shipped to Mega Bloks is 40lbs (18kgs)任何走货箱的最大重量为40磅(18公斤)Determined at time of product design产品设计时确定 返回目录1 返回目录2 返回目录1 返回目录2B. RELIABILITY TESTS可靠测试Test Description测试描述Performance & Requirement 执行标准S/S & Cycle抽样和周期AGING TEST老化Parts are to be removed from packaging for this test, and in a state as used by the end consumer(some assembled, some not)取下包装，以最终顾客使用状态入炉(某些是装配状态) Oven 55C, 48hrs. Then check(烤炉55C,放48小时,然后检查)：1) Product must pass the drop, pressure, torque test etc all normal and abuse tests, no crack, no broken pieces allowed.产品必须符合跌落,压力,拉力等正常和滥用测试,不能有部件裂或断2) Injected parts, spray paint, pad print, and label no color fading.注塑件,喷油件,移印件和贴纸不能有褪色.3) Spray paints, pad print, label: must pass the tape adhesion test. 喷油件, 移印件和贴纸要符合粘油和粘性测试。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).贴纸：不能有分离/翘起/气泡(有轻微空气在贴纸下，用手重贴后没有气泡则可接受)6 pcs, as per requirement根据工程产品规格抽6个RELIABILITY DROP可靠性跌落Toy is to be removed from final packaging and in assembled state, as if in use by the end consumer. 取下包装，以最终顾客使用状态测试(如部件是装配状态，则以最终装配状态测试)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 3.30英寸高跌4次(跌4个不同方向，第1个方向跌最薄弱位置，其它3个方向任意)Repeat this procedure 2 times each sample同样样办重复2次测试1) If any safety issue (refer to International safety norms in section A above): critical defect. 任何安全问题(参考上述章节A的国际安全标准)：极严重次品2) If any function issue on electronics: Major defect.任何电子功能问题：严重次品3) If any function requirements not met as per EPS requirements, Major defect任何功能不符合工程产品规格要求：严重次品6 pcs, as per EPS requirement根据工程产品规格抽6个ENVIROMENT SIMULATED TEST (or PRE-CONDITION TEST)环境模拟测试（预处理）Parts must be in final packaging for this test, and any change in packaging method must be validated by re-performing this test产品或部件以最终包装状态入炉，如果包装方法有更改，同样要重新入炉验证4) 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.入烤炉55C放4小时，自然冷却4小时；再零下17C放4小时，后自然冷却4小时。该过程重复一次。5) Check same points as the requirements on Aging test.检查项目同老化测试6 pcs, as per EPS requirement根据工程产品规格抽6个HUMUIDITY TEST潮湿测试1） 21-24.5C, 20-70% relative humidity for 4 hrs.温度21-24.5C，相对湿度20-70%放4小时2） 35-40C, 90-95% relative humidity for 48 hrs. 温度35-40C，相对湿度90-95%放48小时3） Check same points as the requirements on Aging Test 检查项目同老化测试6 pcs, as per EPS requirement根据工程产品规格抽6个TAPE ADHESION TEST (Chrome parts)粘油(铬合金部件)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.将3M公司的898胶带(3/4英寸宽)粘在铬合金的表面，用手指压平保证胶带和部件表面的充分接触， 2) Within 90 seconds of application, grasp the loose end of tape and pull off quickly at 90o to the chromed surface.90秒后以90o方向向上迅速拉胶带的自由端3) Some chrome parts come off Major B任何铬合金部件的剥落记严重次品BERASER ABRASION TEST (Chrome parts)擦油(铬合金部件)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.使用Staedler Mars Plastic #52650 擦油笔，正常的力用笔在涂层表面纵向擦10次，然后用手指甲在擦油位置刮10次2) Chrome must not come off, plastic below coating should not be visible Major B不能有任何铬合金部件的剥落，不能有涂层下的胶件可见，否则记严重次品BCROSSHATCH TEST (Spray Painted and Pad Printed parts)界油测试(喷油件或移印件)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.用锋利的刀刃划6条间隔为1/16英寸的平行线，再划6条间隔为1/16英寸的平行线与之前的平行线相关为45度角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. 将3M公司的898胶带(3/4英寸宽)粘在刮痕表面，用手指压平保证胶带与之的充分接触，胶带留一定长度的自由端以便操作3) Within 90 seconds of application, grasp the loose end of tape and pull off quickly at 90o to the paint surface. 90秒后以90o方向向上迅速拉胶带的自由端4) 1 or 2 diamonds removed Minor有1或2个的格子的涂层剥离，记轻微次品5) 3 or more diamonds removed Major B有3或以上的格子的涂层剥离，记严重次品BLABEL ADHESION TEST贴纸粘性测试Using 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%, minor3M公司的898胶带，胶带留一定长度的自由端以便操作；90秒后，拉开胶带。贴纸有等于或大于5%面积的剥离不接受，剥离面积小于5%记轻微次品6 pcs, as per EPS requirement根据工程产品规格抽6个LIFE TEST寿命测试Must comply with EPS必须符合工程产品规格6 units6个TRANSIT TEST运输测试Transit test: 220RPM for 1hr, then turn the carton 90 and test 1 hr.每分钟220转，振1小时，然后将卡通箱翻转90度再振1小时Full master carton走货状态箱STATIC LOAD TEST静态负荷测试(压箱测试) 1) Weigh box and measure box height.量箱的重量和高度2) Divide 144” by the box height (in inches), to obtain multiple of how many boxes needed to reach height of 144”计算多少个箱的叠起高度可以达到144英寸3) Multiply weight of box by the number obtained in step 2)根据步骤2算出的箱数计算总的重量4) Apply weight obtained in 3)