新产品引进程序

1、QUALITY PROCEDURE主题(Title):新产品引进程序NEW PRODUCT INTRODUCTIONPROCEDURE文件编号 ：MEP-07Procedure No版本号：04Rev. No总页数：18Total Pages实施日Effective Da期te08/14/00编制H.L. NgaOrigi nator审核Lai Beng AngApproved By相关部门批准APPROVALS / CONCURRENCE生产部：日期：Man ufacturi ngDate品 保部：日期：Quality Assura neeDate工程部：日期：MFG Engin eeri

2、ngDate物 料部：日期：MaterialDate商 务部：日期：ProgramDate财 务部：日期：FinanceDate人 事部：日期：Huma n ResourcesDateQUALITY PROCEDUREMEP-07文件修改记录REVISION HISTORY版本号Rev.修改内容Descripti on/Cha nges修改人Origi nator日期Date01First Issue首次发行Paul Skeha n11/01/9902Men ti on Deviati on Procedure and In crease NPI review time. 提岀工艺更改及增加N

3、PI的审查时间Paul Skeha n11/23/9903Update Checklist for Data Collection Functions,ESD,modify CPK statement 更新数据收集功能的检验表格,ESD，并修改CPK的状态Paul Skeha n03/15/0004Revise to in clude process gen eric flowchart, process man ageme nt pla n, definitions of responsibilities, use of statistical technique in NPI and sa

4、mple NPI report.增加了产品通用的流程图，工艺管理计划，NPI报告，各部门责任，统计技术在NPI的运用。H.L. Nga07/26/001.0 PURPOSE / 目的The purpose of this procedure is to provide the guideli nes to en sure quality and productivity are pla nned and built版本号：04Rev. No审核：Lai Beng AngApproved By页数:：1of18Pagein the process pla n and layout in the

5、impleme ntati on of a New Product In troducti on into the Flextro nics In dustrial (Zhuhai) man ufactur ing facilities.本程序制定了新产品引进的指导方针，以确保在新的产品导入伟创力实业(珠海)时，产品品质和产量在制程规划和布局阶段得以充分考量和实现。2.0 SCOPE/ 范围This procedure is applicable to introduction of any new product to the manufacturing operation in the F

6、lextronics In dustrial (Zhuhai). The procedure cover the resp on sibilities, the required activities , the gen eric new product flowchart and the gen eric NPI checklist for in troducti on of any new product.本程序适用于任何规划导入伟创力实业(珠海)生产制造的新产品，涵盖了新产品引进过程中，各部门的责任，需完成的工作，通用的新产品工艺流程图和通用的NPI查检表。3.0 RESPONSIBIL

7、ITIES 职责3.1 Program 商务3.1.1 Orga nize , coord in ate and commu ni cate with customer to en sure the receipt of complete customer docume nts and in formatio n's.docume nt t组织、协调、联络客户确保收到完整的客户文件和信息。3.1.2 Initiate the first NPI meeting upon receipt of sufficient customers present the project inform

8、ation and select a NPI leader当相关客户文件齐备后，启动第一次NPI会议介绍新产品的信息，并选定NPI领导者。3.1.3 Liase and coord in ate with customer on delivery on any con sig ned materials, fixtures, test program and samples.协调客户取得客户提供的物料、夹具、测试程序和样本。3.2 NPI Leader NPI 领导者。3.2.1 Prepare and update milest one chart for the project.制作并更新

9、新项目的计划图。3.2.2 Coord in ate , con trol and mon itor to en sure the executi on of activities in the Gan tt chart for pilot run can meet the deadli ne.协调，监控以确保试产甘特图的各项工作得以按时执行。3.2.3 Liase with IE to check and con firm sufficie nt capacity for mass producti on.协同IE确保有足够的生产能力满足量产需要。3.2.4 Liaise with proc

10、ess to check and con firm capability of machi nes for mass producti on.协同工艺工程师检查并确认设备有足够的产能满足量产。3.2.5 Prepare NPI report base on the process plan and collected data during the pilot run.在制程计划和试作收集数据的基础上，制作NPI报告。3.3 NPI Process & Support Process版本号： 04Rev. No审核： Lai Beng AngApproved By页数:：2 of 18

11、Page321 Prepare and en sure that the process pla n which in elude work and in structi on, process flow chart, process man ageme nt pla n can meet the deadli ne, quality, yield and productivity requireme nt.制订工艺相关文件，包括WI、艺流程图、工艺管理计划，并确保上述文件满足品质产能的需求，并保证及时工完成。3.2.2 Gen erate in ter nal BOM base on cus

12、tomers BOM.将客户BOM转化为内部BOM3.2.3 Prepare and en sure that all jigs and fixtures requireme nt which in clude ste ncils, comp onent preform fixtures, man ual insert fixtures and fixtures for any box-up process are available dur ing the pilot run.准备并确保所有工夹具在试作以前准备齐全，包括网板、零件成型夹具、 手插件夹具，以及组装流程所需设备。3.2.4 Pe

13、rform process verificati ons which in clude trai ning the operator and en sure the process capability at every stations during the pilot run.在试作时，进行具体的制程确认，包括员工培训，各工位的产能是否足够3.2.5 Follow up and close all issues which are found for improveme nt duri ng the pilot run.针对试作阶段发行的各种问题，跟进相应的改善对策并确保完成。3.4 NP

14、I Test & Support Test3.4.1 Prepare and en sure test pla n and in structi ons are ready for pilot run.准备并确保测试计划和作业指示在试作前完成。3.4.2 Prepare and ensure the fixtures and program for ICT and functional is ready for pilot run.准备并确认ICT测试和功能测试夹具和测试程序在试作前完成。3.2.3 Perform test process verificati on duri ng

15、all stages of run for docume ntati on correct ness and process adequacy to meet expectati on.在试作时检查测试的各个阶段，调整测试文件和制程以满足生产需要。3.2.4 Capture test performa nee and debug results.调试测试程序，提 高测试效率。3.2.5 Follow up and close all issues found duri ng the run where improveme nt acti on or cha nge is n ecessary

16、after the run.针对试作发现的测试问题，跟进改善措施并确保完成。3.5 NPI Equipment & Support Equipment for Pilot Run3.5.1 Implement the layout of machines and line from IE when require按照IE的规划，执行 机器设备和生产 线的布局。3.5.2 Prepare and en sure that program for chips and IC placeme nts is ready for pilot run.准备并确保试作用的 SMT占片机程序完备。版本号

17、：04Rev. No审核：Lai Beng AngApproved By页数:：3of18Page3.5.3Prepare and ensure that there is sufficient feeders for materials. 准备并确保有足够的SM供料器。3.6 PMC3.6.1For con sig ned materials, confirm correct and sufficie nt materials base oninternal BOM and pilot run qua ntity.对客户提供的物料，根据内部BOM口试作数量，确认物料正确性，数量足够3.6.2

18、For purchase materials , buyer / material pla nner shall study delivery requireme nts, lead time and place order of materials accord in gly.对于采购的物料，采购员物料计划员 根据生产要求，物料 购入时间，正确 地下定单购买物料。3.6.3Buyer or procureme nt engin eer may propose alter native suppliers for any materials if necessary, subject to c

19、ustomer' s approval and qualification. Nodeviation of parts from AVL is acceptable until customer' s approval isreceived.如果部分物料有需要得 话，米购员和米购工程师可以建议其他供应商给客 户评审。如果未经 客户批准，不得采购任何没有列入AVL的物料。3.6.4All material issues and purchas ing related matters can be referred to customer via program coord ina

20、tor or program manager.任何物料 问题与米购问 题可以通过商务 助理或经理与客户联系。3.7. QA3.7.1Provide Q-plan and instruction for verification during pilot run.提供试作所需品质计划和作业指示3.7.2Capture all run results and prese nt to team members dur ing review meeti ng. 收集试作时所有数据，并在总结会议上提出。3.7.3Provide quality pla n for incoming in specti o

21、n and outgo ing quality assura nee.提供进料检验和出货品质保证计划4.0 REFERENCE DOCUMENTS 参考文件4.1. MEP-03 Ge neric Man factur ing Process Flow Chart4.2. MEP-06 En gi neer ing Cha nge Order Con trol Procedure5.0 APPENDIXS 附录5.1.APPENDIX A-New Product In troducti on Flowchart.APPENDIX BAPPENDIX C-Project Lau n

22、ch Customer In formatio n Checklist sample -New Product In troducti on Checklist sample5.4 APPENDIX D5.5 APPENDIX E5.6 APPENDIX F-Gen eric Process flowchart sample -Process Man ageme nt Pla n sample -NPI report sample版本号：04Rev. No审核：Lai Beng AngApproved By页数:：4of18Page6.0 TOOLS / EQUIPMENT 工具 / 设备6.

23、1. Base on the process pla n.基于制程计划。7.0 DEFINITION 定义7.1PM-Programs Manager. 商务 经理7.2NPI-New Product In troducti on新产品引进7.3QA-Quality Assura nee.品质保证7.4DCC-Document Control Center 文件控制中 心7.5PMC-Production Material Co ntroller生产物料控制7.6TQC-Total Quality Con trol. 全面质量控制7.7OMS-Operational Method Sheet操

24、作方法表7.8AVL-Approved ven dor list 被认可的供应商清单8.0 PROCEDURES 程序8.1. New Product In troducti on meeti ng and PM preparati onNPI会议和商务部经理准备相应资料8.1.1.The gen eric NPI flowchart which con ta in the in formatio n on the NPI flow, area resp on sibilities and NPI activities is show n in appe ndix A.The PM (or n

25、omin ated represe ntative / assista nt) resp on sible for a project will collect and check all n ecessary information listed in the Customer Information Checklist (Appendix B).附录A通用得NPI流程图包 含了 NPI的过程，职责分工， NPI的具体工作。商务 经 理(或提名代理者/助理)负责收集和检查 该项目所需 资料并列于客户资料清单上( 见附录B)。8.1.2.Base on project schedule and

26、 information availability / adequacy, the PM will organize an NPI meeting. The first NPI meeting will be attended by representatives from Programs, Engineering (Product, Test, Process, Equipment),NPI, QA, DCC, PMC and Purchas ing. Depe nding on the situati on the In dustrial Engin eer and a represe

27、ntative from the Facilities may also be required to attend the meeting. These people will form a project team and an NPI leader will be named during this meeting.基于项目的进 度表和资料的有效性/适用性，商务经理组织NPI会议。首次NPI会 议由商务、工程(产品、测试、工艺、设备)、NPI、QA、DCC、PMC、采购代 表参加。根据情况IE和工夹具负责人也要参加。在会议期间 这些人来自于项目中 并指定NPI领导者。8.1.3The P

28、M will brief all project team members on any information regarding new product. 商务经理要将任何有关新产品的信息通报给项目相关的所有人员。版本号：04Rev. No审核：Lai Beng AngApproved By页数:：5of18Page8.1.4The NPI leader, usi ng the NPI Checklist (Appe ndix C), will allocate the activities to be performed . The NPI team will commit to a c

29、ompletion date of pilot run. NPI activities may be short listed as follows:NPI领导者用NPI清单(附录C)分配各项工作。NPI成员须按期完成 交给的任务。N PI活动简要如下：. Production line layout and setup 生产线的布置和建设。. Machi ne software programs gen erati on. (Automatic assembly and test programs)机器程序的输入(自动组装和测试程序)。. Produ

30、ct defi ni tion on MRP system (Item Masters, Product Structure AVL)产品定义于MRP系统(主要项目产品 结构、客户核准供 应商的 清单). Desktop gen erated man ufacturi ng docume ntati on, i.e. Quality, Test and Assembly plan (TQC OMS)生产用的文件，如品质、测试和组装计划仃QC、OMS)。. Specificati on, purchas ing and expedit ing of tooli ng,

31、 jigs and fixtures. 工夹具的规格、购买、分配。. Materials expedit ing and Customs Lice nse Applicati on物料分配与客户特许的请求。8.1.5.The NPI Openin g-Meet ing porti on of the NPI checklist has to be sig ned by the representatives from the various departments. Thereafter, the original copy of the checklist should be

32、sent to DCC.各部门负责人于NPI清单的签名然后将原始的清单发送到文控中 心。8.1.6.Project team members with any specific question or information requirement can be brought to the attention of PM and/or NPI leader during or after this meeting.在会议后 或期间，项目成员将任何特殊问题或资料需求告 之商务经理或NPI领导者8.1.7.The NPI leader will decide the actual NPI dat

33、e dur ing this meet ing. This date is usually based on either the tooling or material due dates.NPI领导者在会议期间 决定实际的NPI日期。这个日期取决于其他加工或物料收 到期。8.1.8.A project lau nch Milest one / Gantt chart will the n be gen erated by the NPI leader using either MS Excel or MS Project (depends on availability).项目进度的里程碑

34、/甘特图由NPI领导者用Excel或MS Project方式发岀。8.1.9.Subseque nt NPI meeti ng to discuss about project related matters could be orga ni zed by the PM or NPI leader as and whe n required. Preferably, it should be done on a regular basis prior to the actual NPI day.后续的NPI会议应该在试 作前，由商务部经理或NPI领导者主 持召 开， 讨论与项目相关工作的完成情

35、况。8.1.10.All questions or clarifications of information are to be handled by the PM and/or NPI leader by going to appropriate customer con tact or any other suitable pers on. The information thus obtained will then be given to the respective team members. 所有问题和资料的澄清由商务经理或NPI领导者联络客户 或适当的人员。 信息获得后将给各个

36、成员版本号：04Rev. No审核：Lai Beng Ang页数:：6of18Approved ByPageQUALITY PROCEDUREMEP-0704QUALITY PROCEDUREMEP-078...9.版本号:Rev. No8.1.11.PM submit all customer ' s documents to DCC for distribution to project team members. 商务经理将客户文件 交文控中心，由文控中心发放给项目成员。IE will carry out a capacity stu

37、dy to check any requireme nt of new line to accommodate the mass production of the new product. The NPI and Support equipment will set- up the new line if the loadingof new product require it.IE担负产能研究以适应新产品量产需求。如有必要NPI和支持设备者将 建设新线。The process engin eer will gen erate internal Bom which will be in pu

38、t into MRP system by DCC andrelease to system upon verificati on by the process engin eer. For non con sig ned parts, purchas ing willsource all parts that are tape and reel which meet the requireme nt of SMT feeders. e.g., SMT, A.I., as fullreels and the appropriate packagi ng.工艺工程师 建立内部BOM，由DCC输入M

39、RP系统，完成后 交工艺工程师审核。非客供物料，采购确认物料的包装 形式以满足SMT进料器的要求，如SMT、A丄、整卷和相应的包装。PMC will expedite and receive materials, attempting to have all parts in house 48 hours before NPI kit is due to be issued.PMC分配和发放物料，所有物料 尽量在NPI发料48小时之前入仓。The PMC departme nt represe ntative should regularly commu ni cate with the st

40、ore represe ntative whowill be picking the“ brown box ” 1 week before planned NPI date. When the NPI assembly is clean-to-build, the store representative will pick kit to“ brown box ” using the pick-list.PMC项目负责人应当通知货仓负 责人在试作前一 星期开始准备“棕色箱”。当生产 线准备好进行 生产时，货仓负责人根据发料单发出“棕色箱”.The "Brow n box"

41、i ncludes the followi ng:"棕色箱” 包括:...8.6.5.Parts from store locations.内部零件的 储存位置。Parts from external store locations.来自外 部零件的 储存位置。 Programmed IC ' s (i.e. not blanl输)入程序后的 IC (无空白) Printed labels (i.e. not blanks)打印 的标签(无空白)Packaging (e.g. bags, boxes)包装(盒、箱)Producti o

42、n Supervisor will con firm item by item and the n sig ns to ack no wledge possessi on of all items in“ brown box ” . The “ brown box ” should be complete and on the floor at the time agreed during the NPI meeti ng.生产主管 逐项检验所有“棕色箱”并签名。“棕色箱”必须 于NPI会议同意的日期完成。After the “ brown box ” arrives on the floor

43、, the QA Representative will audit its integrity based on the Customer BOM.“棕色箱”发岀之后，QA负责人根据客户BOM仔细检查物料。The Production Representative also will audit the“ brown box ” to ensure the correct quantity has beenissued. Both these representatives will then retrieve the NPI checklist from DCC and sign for

44、the completeness of the audits. This checklist is then presented for verification to the NPI leader.生产负责人仔细检查“棕色箱”确保物料数量足够。相关负责人检查完成 之后，应当从DCC取回NPI查检表并签名，然后，NPI查检表送交NPI领导者确认。审核： Lai Beng AngApproved By页数:Page7 of 1804QUALITY PROCEDUREMEP-078.10. Producti on will set up the line with the material. Th

45、is should be done before the NPI start time, so that product building can start at or as soon as possible after the planned NPI starting time生产部要将物料 安放到生产线上。由于这项工作需要在试产 之前完成，所以NPI启动时， 相应的准备工作 就可以开始。8.11. To en sure set-up and other preparati ons can take place prior to NPI, the Assembly, Test and Qu

46、ality documentation should be available at the same time as the brown-box issue time. The Process / Product Engineer will validate the documentation ensuring that visual aids are clear and un ambiguous and that in structi ons are effective.为了确保所有的准备工作可以在试产前完成，工艺，测试，品管的相应文件应当在“棕色箱”发岀前完成。产品工艺工程师应当确保文件

47、的图 片指示清楚明白，指示明确有效。8.12. The producti on will build the pilot run base on the TQC OMS work in structi on. Each operator will be tra ined to un dersta nd and follow the work in structi on which is display in each stati on.产品的试作 应以TQC、OMS工作指导 书为基础，所有的作业员需经过训练并且能确实依照现场的作业指导书作业。8.13. The process engin ee

48、r will be prese nt in the line duri ng the pilot run to assist in tra ining and show ing the operator the correct methods of assembly and cauti ons poi nts to take n ote and verify for stati on quality .当产品试产时工艺工程师需在现场协助，指导作业员 正确的操作及注意事项，并确认制程品质。8.14. NPI process and Support Process will prepare and

49、 en sure that the process flowchart, process man ageme nt pla n, works in structi on s, jigs and fixtures are ready to support NPI build which processes can include SMT, PTH, component preparation, manual stuffing, box-up and final assembly. A sample of process flowchart which provide the in formati

50、 on on the detail process flow of the new product is show n in appe ndix D. A sample of process man ageme nt pla n which provide the information on the process plan and control of key parameters to ensure built in stati on quality is show n in appe ndix E.NPI工艺工程师 应确保生产流程图，工艺管理计划，作业指导书，测试夹具 均已准备完毕以确

51、保 正式生产正常进行，正式生产还包括SMT、PTH、零件、手插件、 外壳组装、最终 组装。生产流程图提供了新产品流程的详细信息（格式参考附件D）;工艺管理计划 则包含工艺计划， 关键参数的控制的有关信息，以确保各工位的品质（格式参考附件E）8.15QA and the process engin eer will carry out the process verificati on to confirm the capability ofeach stati on and to note dow n any issues to resolve for con ti nuous in the

52、mass producti on.QA及工艺工程师 应对流程进行确认以确保各工位符合产能规划，并记录 下各种异常并在量产前加以解决。8.16. NPI Test / Support Test Engin eer ing will setup test equipme nt, fixtures, programs and testinstructions so that it is ready on time for the pilot run.QA and test engineer will perform test verification on the ICT and functiona

53、l testing. Any issues will be no ted dow n for corrective acti ons to be impleme nted in mass producti on for con ti nuos improveme nt.产品试生产时，NPI测试工程师 应准时准备好测试设备、夹具，测试程序及测试作业指导 书。QA及测试工程师 应确认ICT和功能测试的有 效性，记录下各种异常并采取改善行动 以确保量产的 顺利进行，并 持续改善。8.17. The PMC represe ntatives should be available to provide

54、 priority support for any materials issuesand to be a sin gle point of con tact for materials issues.PMC对所有的原料应优先安排，任何的原料异常需反映回PMC。版本号：04Rev. No审核：Lai Beng AngApproved By页数:：8of18Page8.18. The NPI leader will mo nitor the NPI build. Normally, the NPI leader will be on the line for atleast the first

55、quantity of units through the process. The NPI leader should be available throughout the durati on of preparati ons for and build ing of the NPI un its to resolve any product issues that may occur.NPIleader应监控整个NPI的生产，正常情况下，NPIleader需在生产现 场监控至少第一片 板的生产并确认 其品质。此外NPIleader应参与NPI的各个准备阶段并对 可能发生的 问题 加以解决

56、。8.19. All NPI products will be audited / in spected by QA to en sure total quality built in before shipme nt to customer.所有的NPI产品在岀 货给客户之前需经过QA的品质确认。8.20. If there is an on site pre-shipme nt customer audit, the n the Quality Departme nt will beresponsible for the submission of the NPI lot to the auditor. Quality will ensure that the needs of the customer auditor are looked after and that he is provided access to requested equipme nt an d/or in format