PMP制程管理计划.ppt

,Processmanagementplan,產品制程穩定性品質保證Preparedby:QSMCSQERickMiaoNov242003revision01,-ProductProcessStablizationQualityAssurance,NewprojecttransfercreatedbyPEteam.由PE小組制定的新項目移轉MassproductionPMPupdatebasedonissueandcustomerrequirement.量產機種因異常和客戶要求而進行的PMP更新QA,JQEandauditteamtoauditprocessreferencePMP.QA.JQE與稽核人員稽核制程之依據PMPcoverfromIQCtoOQCoverallprocess.PMP涵蓋到從進料檢驗到出貨檢驗的全部制程PMPgenerallytodriveprocessandQAsystemtocontrolcriticalstationwithkeyparameter.PMP通常用以推動製程和品質保證系統使用相關的關鍵參數管控重要站別PMPupdateguideline.-PMP修改准則Preventiveactiontake.採取新的預防措施Systemimprovement.系統得到改進Lessonlearnreview.所獲得經驗的回顧QCandProcesscontrolenhancement.品管和製程控制得到加強,PMPfunctionandcontrolPMP功能與管制,PPAPProductionPartApprovalProcess,零/部件承認程序,NewprojectPMPcreation,新機種PMP的建立,MPPMPupdateandaudit,量產階段PMP修改與稽核,ProductProcessStabilizationQualityAssurance,1.PSQAconception:Productprocessparameterstabilizationqualityassurance,meaningwithkeyprocessparameterconditioncontroltoensureproductqualitystably.ProductsSpec.stabilizationlieonprocessparameterSpec.stabilization.Approvalforprocessesnotmeetingrequirement.2.ProcessQA:1)Partsassurance:afterproductionQCtocheckpartswithdimension,cosmeticandfunction.ifoutofSpec.totracktheprocessparameterandmakeadjustmentfollowexperience.incaseofprocessparameterbigdeviationwillbelotsoffailureparts.thereforewithhighrisk.2)Processassurance:InprocessmonitoredbyproductionlineandQApersonforpartsCharacteristicandprocessparameter.Anydeviationshouldfollowgoldprocessparametertosetup.Therebycancatchfailureinearlyperiodtomaketherealprevention.Goldprocessparametercomefromtrialrunpartshaveapprovedbycustomers(itshouldfixedandcontrolledbyMEandQAteam)Anyprocessparameterschangeoutofgoldprocessparametersshouldbeapprovedbycustomer.(Approvedbysuppliersthemselvesatfirst)-Doublecheckpartsdimension,functionandcosmeticmeetcustomerSpecornot.-ProcessparameterneedstudyreasonabletoleranceandconfirmedwithpartsSpec.andCustomers.,產品製程穩定性品質保證,1.PSQA的概念：產品製程參數穩定性的品質保證，意即採用關鍵製程參數設定的管控以保證產品質量的穩定性。產品規格穩定性基於製程關鍵參數規格的穩定性。對製程不能滿足需求的承認。2.製程品質保證：1)產品保證：品管對產品進行尺寸、外觀和功能等方面的檢驗，如果超出規格，須追蹤製程參數並依據經驗進行調整。如果關鍵製程參數嚴重偏離，將會導致大量不良品產生，並造成嚴重的浪費和損失。2)製程保證：在製程中，生産人員和品質保證人員對產品的特性和製程參數進行監視。任何偏移應遵照最佳製程參數進行設置，從而能夠在早期即發現異常，並從真正意義上做到異常的預防。最佳製程參數來源于被客戶承認的試產產品(該參數應被製程和品保小組修正和管控)任何與最佳製程參數有偏移的製程參數均須被客戶承認(在被客戶承認之前應首先被供應商自己承認)-再一次對產品的尺寸、功能和外觀是否符合客戶的規格進行確認。-製程參數應考慮到合適的公差，並與產品的規格和客戶進行確認。,PSQAparametercontrolProcessParametercontrol,TrailrunProcessParameter,Paintinga)pre-mixedb)Paintingparameterc)Bakecondition,Injectiona)Injectionconditionb)Resinbaketemp.timeC)MFISpec,Suppliersapproved,Customerapproved,MPProcessParameter,PE-functionandAssyQA-FAIandCosmetic,PE-functionandAssyQA-FAIandCosmetic,Fail,Fail,Re-trailagain,UpdatetoPMPAndSop(specialfordifficultassembly,gapandstep)Movablepartschecking-withsimulationtesting(asbutton,hook,sometinesneedbecheckedwithfixture)Illustration(describethekeycheckpointormotion)ECNchangerecord(latest3months)Customerqualityissuehistoryrecord(latest3months),SIP中的關鍵參數,信息-產品料號/版本，核准狀態，版本級別，尺寸-P尺寸或工程小組相關尺寸(至少須符合客供正式圖紙的規範)外觀-符合客供正式版本的外觀標準或樣品標準(明確的標準公差)功能-信賴性和功能測試項目(如程序測試，扭力測試，MFI測試和拉力測試)系統配合度-在客戶端生産綫組裝的單出料件(尤其指難以組裝，易產生間隙和斷差的料件)可動部分的檢查-進行模擬測試(如按鍵，轉軸，部分產品需要治具進行檢驗)圖示(描述關鍵的檢驗點和檢驗動作)工程變更記錄(至少3個月内的變更項目)客戶端品質異常履歷記錄(至少3個月内的異常項目),SOPkeyparameters,Processflow-Processandpartscontrolstation.Processcontrol:forcriticalmanufacturedtestingmachinestation.(processwithclasswithS-safetycritical,M-majordefect,O-minordefectandKPC-keycont,charct)Partscontrol:forcriticalfinalinspectionandQCsamplesizestation.(ProcesswithclasswithS-safetycritical,M-majordefect,O-minordefectandKPC-keycont.charct)MachineandDevice,jigtoolsformanufactureCharacteristicsProcessparameter-keyoperationmanufactureparameterswillimpactproductsqualityorSpecifdeviationsofoutofspec.(keyoperationparametermonitoring.)Productcharacteristic-CustomerapprovedSpec,ofdimension,cosmetic,functionandreliabilitytesting,ORT(keycontrolcharacteristicsmonitoring)MethodCriticalproduct/processspecificationwithtolerance.Update.Measurementtechnique-withwhatkindsoftechniqueorinstrumenttomeasure(suchasAQL,visualorcolormeter)Samplesizeorfreq.-100%inspectionorsamlingsizewithfrequencydefinitions.Analysismethod-UsewhatkindofmethodtomarkFAiffailurecatchfrominspection.(Porto,CLCA,SCAR,SPCandCPK)Reactionplan-outofcontrolconditionareencounteredassameasCA.(suchasstopline,holdlots,re-studytheprocessparameterandscrap),PMP中的關鍵參數,製造流程-製程和料件的管控站別a)製程管控：指重點地生産用測試機器的站別(製程中以S-安全臨界級，M-主要不良，O-次要不良和KPC-關鍵控制特性)b)料件管控：指重點的最終檢驗和品管樣本大小的站別(製程中以S-安全臨界級，M-主要不良，O-次要不良和KPC-關鍵控制特性)用於生産的機器、裝置、治具特性a)製程參數-關鍵作業的工藝參數會對產品的質量造成影響，若其偏移導致了超出規格，則對產品的規格亦會造成影響(關鍵作業參數的監控)b)產品特性-客戶承認的尺寸、外觀、功能和信賴性測試的規格方法a)關鍵產品/製程(包括公差)的規範及其更新b)量測技術-使用何種類型的技術或設備進行量測(如允收級別，視覺或顔色計量)c)樣本大小或採樣頻率-全檢或定義其樣品大小和採樣頻率d)分析方