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1、Supplier approvalProcess / description 机器、设备、工装、夹具Equipment, jigs, fixturecharacteristic number特殊特性分类Special characteristics CategoryEvaluation/measurement method样本容量Sample size样本频率Sample frequencyIncoming material inspectionQuantity外层白色塑料袋,密封包装,无破损,无明显积灰或其他油液污染White packing, airproof, no damage, oi

2、l strain and dusts.包装/规格/批次号/外观Packing/Specifications/Serial number/AppearanceSerial number consistent with the delivery note抽取同批次3包材料Sampling should3 batches per lotPurchasing material inspection record 隔离通知相关人员联系供应商退换货并整改Containment/contact the supplier and arrange returning 检查项目(玻纤含量、弯曲强度,缺口冲击强度等

3、)Inspection item (glass fiber, tensile strength, notch impact strength etc)Electronic Tester抽取同批次3包材料,每包材料各取样1Kg,混合均匀后制作样条Choose 3 bags per lot, 1 kg per bag, mixed and then mold the test samples抽取同批次3包材料Choose 3 bags per lotCorresponds to the Purchase Order符合订单Purchased Material Inspection Record外层

4、茶色牛皮纸袋Brown outer-layer paper packageBlack Resin,Even particle size,No Resin Clinging,No contaminationblack颗粒,颗粒大小均匀,无连粒,无杂质钢套压出方向上无冷插飞边残留压装孔无开裂破损钢套无Appearance异常 There are no flashes on the item surface after the limiter installed.The limiter bores have no cracks.No abnormality of the limiter appear

5、ance清理Trimming 追溯,重新清理Traceability and re-trimming 铜螺母热插-1燃油轨安装螺母*2*M8MAP安装螺母*1*M6Nut inserts1oil trail nut inserts *2*M8Map nut inserts*1*M6钢套两端面低于塑料表面0-0.3mm 总成GaugeInspection 钢套位置度钢套两端面低于塑料表面0-0.3mm 总成GaugeInspection 钢套位置度The installed limiters should be 0-0.3mm beneath the plastic surface at two

6、 ends. After installation gauge should be used to exam the positions of the limiters百分表Micrometer返工Return and rework钢套挤出力Tensile tester热插1作业指导书Operation instruction for the nut insert 1和指示灯Per shift 开机Before the start of every shift1个M6,2个M8热插螺母装入热插头One M6 nut insert and two M8 nut inserts are place

7、d into the inserting arm螺纹无漏加工或加工不完整安装到底,方向正确,不能反装First ensure the threads on the nuts are in good conditions, then press the nuts into the bottom of the inserting arm slot, the direction should be correct.重装螺母Place the nuts again漏装、反装热插螺母防错Inspection Error proof measures to ensure the nut are not m

8、issing and are not placed in reverse direction.没有漏装、反装No nut missing and nut in reverse direction设备自动防错控制Automotive error proofing measures of the equipment补装/改正Place the nuts agi铜螺母热插-2支架安装螺母*1*M6Purge阀螺母*2*M6支架安装螺母*2*M8 Nut inserts-2Bracket installation nut *1*M6Purge spigot nut *2*M6Bracket insta

9、llation nut *2*M8二维码自动扫描2D CODE can be automatically scanned能扫出二维码,自动判定前工序操作合格,可以开始生产能扫出二维码,自动判定前工序操作合格,可以开始生产The 2D code can be scanned, 能扫出二维码,自动判定前工序操作合格,可以开始生产The 2D code is automatically scanned, and the system will automatically validate that the previous process is properly finished and then

10、the next process can be allowed to start热插后Appearance Appearance after inserting热插螺母端面不能低于热插孔塑料表面,表面不能有高于热插件端面的塑料溢料;热插件无明显的倾斜、偏心、错位;热插件不能有裂痕和破损;The inserted nut can not be lower than the plastic surface; on the plastic surface no flashes higher than the nuts are allowed. Inserted nuts have no obviou

11、s deformation, misalignment and displacement; no cracks on the inserted nuts are allowed.清理Clean热插后高度Qingdao Meitai Plastics 质量保证单Quality WarrantyPacking方式符合要求,Packing无破损; Quantity正确;Packing上标签符合要求;The packing method should conform to the spec., no package damage, correct quantity, correct labels游标卡

12、尺Vernier calipersMicrometer按照零件来料检验指导书表面清洁,无油污,磕碰印Clean surface, no oil stain, no bumping mark注塑件无明显飞边毛刺,摇臂孔内无凸出的飞边;膜片安装均匀,无异常挤压变形,整圈卡口无脱口松开;橡胶管安装卡夹内务明显飞边毛刺残留The molded parts have no visible burrs and flashes, 每次交货 Every delivery Salt Spray testerEvery year 3月/9月March and September of every year摇臂孔内

13、无凸出的飞边;膜片安装均匀,无异常挤压变形,整圈卡口无脱口松开;橡胶管安装卡夹内务明显飞边毛刺残留There are no flashes inside the arm orifice, the installation of membrane is evenly, and there are no abnormal deformation. The clip is firmly fixed, and There are no flashes inside the hose clips.Inner diameter Of the arm orifice 7.2+0.05/-0.1; The a

14、rm wall thickness 5.8+0/-0.2; Actual length of the installation slot 17+0.3/+0.1;clip width 26.2-0.2/-0.4;29.8+0.1/-0.2;Screw bore Inner diameter 8+0.2/-0;11+0.2/-0The arm按照零件来料检验指导书按照零件来料检验指导书Incoming Material Inspection sheetSupplier Self - Test Report密封性-66.7KPa下,泄漏不得大于2cc/min; 作动(开启压力,开始动,到下限压力)

15、,复位良好Air tightness: 66.7KPa, leakage no more than 2cc/min, Correct actuationActuator 耐久性试验,100万次无故障;(年度型式试验)Actuator Endurance test : one million times without interruption (Yearly test)5件 5 piecesPacking方式符合要求,Packing无破损; Quantity正确;Packing上标签符合要求;The packing method should conform to the spec. no p

16、ackage damage, The quantity is correct, the labeling should conform to the spec.表面无灰尘、杂质或其他污染,注塑件Appearance:无磕碰印,无飞边毛刺,插座无断裂或裂纹,2根插针无歪/断/缺,管嘴&卡扣无断裂,破损;进气口防尘帽无漏装No dusts, debris or any other contamination, the appearance of the molded part: No bumping mark, no flashes and burrs. No bracket cracks, Tw

17、o pins are straight, clips& hose nozzle has no cracks. The dust proofing plug of inlet port is installed.Electromagnetic valve卡槽宽度Wire slot width通电、断电下气密测试符合泄漏要求(600mmHg下不大于2SCCM)Leakage under charged and uncharged conditions conforms to leakage requirements (600mmHg no more than 2SCCM)耐久性试验,100万次无故

18、障;(年度型式试验)Packing方式符合要求,Packing无破损; Quantity正确;Packing上标签符合要求;Packing方式符合要求,Packing无破损; Quantity正确;Packing上标签符合要求;Material: SUS304;表面清洁,不允许有油污、毛刺、两端倒角和毛刺,不可生锈Material: SUS304;surface clean,oil stain, burrs, fillets on two ends and rust are not allowed不允许有油污、毛刺、两端倒角和毛刺,不可生锈Packing方式符合要求,Packing无破损; Q

19、uantity正确;Packing上标签符合要求;Appearance洁净,无裂纹、无毛刺、飞边;分型凸起不得大于0.20.3mm;颜色为black,色泽均匀Clean surface, no cracks, no burrs and flashes, the parting bump should be less than 0.20.3mm; Black, even color.壁厚均匀,无明显偏心Even wall thickness, no apparent misalignment 表面光滑;伞形面完整,无破损;无明显飞边毛刺;根部无裂纹Smooth surface, umbrella

20、 surface intact, no damage and burrs, no cracks at the end of the valve. Umbrella diameter14.60.2;ball diameter3.50.07;end diameter:2.560.1;slot diameter 2.230.13Umbrella diameterPacking内零件摆放整齐,无错位变形;表面无油污,锈迹,焊缝/焊点均匀、焊点无穿孔,焊缝缺口、管口无毛刺,管内无杂物 etc. ;管段表面无磕碰伤/变形客户端法兰面平整,无损伤变形,无明显划痕;与中心孔不允许有贯穿性划痕;零件形状一致,无

21、明显变形或位置差异;回火杯法兰镀锌blackThe pipes are placed orderly inside the package, no deformation and dislocation; No oil stain, rust, and welding seam/ welding spot is even, The pipe nozzle has no burrs, no foreign objects are inside the pipes etc. The pipes have no bumping marks and deformation. The flange su

22、rface for customer connection is smooth and even, no obvious scratches; no linear scratches leading to the center are allowed, the geometry is constant, Flange galvanized black.安装孔相对位置The positioning of installation holesThe customer installation hole diameter:2-7+0.2/-0; Distance between holes360.2

23、;Wall thickness :50.2;Bolt hole diameter 2-7+0.2/-0; Distance between holes 500.2; Outside Diameter 260.2;表面镀锌,black,颜色均匀,镀锌层光滑,无锈蚀或镀锌层腐蚀现象;零件清洁,表面无油污、金属碎屑或其他杂质残留;螺纹完整,牙型整齐,螺牙无磕碰伤、变形 etc. 缺陷;梅花槽完整,无变形或其他异常Surface finish: Zinc plating, black, even color, smooth Zinc surface, no rust or corrosion.The

24、components are clean, no oil stain, metallic debris or any other objects; the thread is intact, no deformation etc. the Torx is in good condition.盐雾试验48小时不得有白锈, 240小时不得有红锈White rust should not be seen within 48hours during the salt spraying test, and red rust should not be seen within 240 hours.表面镀白

25、锌,无明显凹凸不平,不允许有油污、毛刺、不可生锈;折弯处无裂纹生产准备-加料烘干(集中供料)Material drying (centralized material feeding) 首次加料加料量The amount of material for the first adding加满烘料料桶,除湿干燥,详见烘料作业指导书The material should completely fill the drying oven, details see Drying operation Instruction Sheet真空吸料,自动控制加料,加满料桶,详见烘料作业指导书Vacuum suct

26、ion, automatic control of feeding, details see Drying operation Instruction Sheet加料设备检查Feeding Equipment checking Equipment instrument panel开机检查Check before every shift异常管理规定Equipment Abnormality Rule1.For the first feeding必须烘2小时以上2.2小时后测量含水率; 含水率0.2%为合格3.使用集中供料装置1. At least 2 hours of drying For th

27、e first feeding.2. Check the water content after 2 hours of drying, if the water content is less than 0.2%, then it will be considered OK.3. Feeding is done by the centralized feeding system.Moisture measuring instrument执行器增加长橡胶管固定管夹,更新长橡胶管安装步骤A fixing clip for the long hose was added to the actuato

28、r, and thereby the installation instruction of hose was renewed.直角弯管焊接强度控制要求变更The requirement of the welding strength of the rectangular hose was renewed.增加阀片注塑后相关包装内容The packing requirements for the molded valve discs were added.增加气密初检工序Map/Purge孔堵塞防错验证The error proofing measure to prevent blockage

29、 of Map/Purge holes were added增加弯管接头注塑贯通孔检查The checking of molded rectangular hose was added零件完整,无缺料;4个卡爪完整,无断裂;1个线束安装孔无堵塞、断裂;制品四周毛边修平,浇口修平,表面顶杆处无溢料,顶杆印不高于表面。不许有缺料、流痕、气花、缩凹、杂质、油污 etc. Appearance缺陷;MAP孔&弯管接头孔贯通,孔内无明显飞边;MAP孔孔壁光滑,无可见的划痕或影响密封的其他缺陷;The molded part is complete, no insufficient injection,

30、4 clips are in good condition, the wire orifice is not blocked, there are no burrs, residues, debris, oil stain and flashes, the injection marks are minimum.Map hole & rectangular hose is not blocked, no flashes are inside the orifice.The surface of map hole is smooth, no visible scratches or any ot

31、her defects affecting air tightness.热插螺母端面高于热插孔塑料面0-0.3mmThe inserted nuts are 0-0.3mm higher than the plastic surface.热插件拔脱力Insert nut pull off force热插件旋转扭矩Inserted nut screwing torque3个M6,2个M8热插螺母装入热插头Three M6 and two M8 nuts should be placed into the inserting arm热插件位置度The position of inserted nu

32、t将歧管放入夹具Place intake manifold into the fixture位置度 (全部热插完成后Inspection /总成GaugeInspection 总成)Position ( after all the nuts are inserted, the positioning will be checked by assembly gauge)6个M6热插螺母装入热插头Six M6 nuts are placed onto the inserting arm铜螺母热插-3 Throttle body 螺母*4*M6钣金支架安装螺母*2*M6Nut inserts-3Th

33、rottle body nuts*4*M6Bracket nuts*2*M6设备自动防错控制安装真空Hose (短管)Install vacuum hose (short hose)真空Hose (短管)插入真空腔管嘴Vacuum hose (short hose) is inserted into the vacuum cavity spigot1.两个插入端蘸WD-40润滑油,两端蘸油 Depth 不超过10mm,胶管内壁无明显油液残留2.装配到管嘴底端;1. Two ends of the hose dip WD-40 lubricant, lubricant depth less th

34、an 10mm, and the inner surface of the hose should have no obvious lubricant residue.2. the hose should be inserted into the bottom of the orifice.更换油脂Change lubricant type轴密封环外圈涂脂Lubricant should be applied on the outer surface of the axle seals整圈涂脂,覆盖外圈凹槽表面(尽量不高出)The lubricant should be applied ont

35、o the whole outer surface of the seals.安装到位,无松动错位扳动右手侧气动夹紧扳手,气动压板夹紧歧管,夹紧定位准确,无异常Turn the pneumatic switch on the right side and the manifold should be fixed firmly Replacement,if parts are damaged, discard as scraps安装EGR管密封圈Install EGR pipe seals密封圈有凸起侧向下,平面侧向上放入安装槽内,方向不能搞错The seals are placed into

36、the slot with the protruding side downwards and flat side upwards, the direction can not be reversed.EGR密封圈&EGR管装配EGR seals& EGR pipe installation电动力矩螺刀转角控制仪装配工作台Electric wrenchRotation controllerAssembly workbench安装EGR管Install 回火杯侧管嘴对准EGR管孔插入到底,尽量避免EGR管口碰到密封圈;使直管段支架上的螺栓安装孔与壳体上自攻钉孔对齐;The EGR pipe sh

37、ould be inserted to the bottom of the EGR orifice, and the end of the EGR pipe should no touch the seals; The bracket installation holes should align with the self-tapping screws.拔出EGR管,Inspection 密封圈,如有异常, Discard as scraps 并更换新密封圈Re-installation拔出EGR管,Inspection 密封圈,如有异常, Discard as scraps 并更换新密封圈

38、Re-installationRemove EGR pipe and exam the seals, if abnormality is found, then discard as scraps, change new seals and re-install.更换正确的M6 螺刀头Switch to the correct M6 screw head螺刀头Specifications正确;在电动扭矩枪上安装到位;Switch to the correct M6 screw head and it is firmly fixed onto the electric wrench.设备自动切换

39、控制扭矩和转角要求The equipment should automatically switch to the corresponding torque and rotation angle.重新更换安装Re-install报警拧入4个M6 EGR管固定自攻螺栓Screw the four M6 self-tapping screws to fix the EGR pipe先拧入直管段支架上的两个螺栓并锁紧;re-将回火杯处的法兰片定位后;拧入另外两颗螺栓并锁紧;First screw the two screws for the bracket; then fix the flange;

40、 finally firmly screw the remaining two screws.电动力矩螺刀Electric torque wrench设备自动监控扭矩&转角The equipment can self-monitor the torque & rotation angle.4个螺栓安装扭矩The screwing torque of four screws4个螺栓扭矩转角The rotation angle of four screws螺栓花键槽无损伤,变形;螺栓头部和法兰面无冷镦开裂、缺料或其他异常螺栓安装无倾斜;螺栓拧紧到底,无悬空(法兰面与支架端面紧密贴合,无间隙)螺栓花

41、键槽无损伤,变形;螺栓头部和法兰面无冷镦开裂、缺料或其他异常螺栓安装无倾斜;螺栓拧紧到底,无悬空(法兰面与支架端面紧密贴合,无间隙)1.The screw cap is in good condition2. The screw head is in good condition.3. The screw is upstraight, no leaning.4. The screw is fixed firmly to the bottom, no clearance between flange surface and bracket.歧管安装夹具翻转The intake manifold

42、fixture is overturned.扳动左手侧气动夹紧扳手,松开翻转夹具逆时针翻转夹具90;re-次扳动左手侧气动夹紧扳手,夹紧翻转夹具Turn the pneumatic switch in the left side and release the manifold, then turn the fixture counterclockwise 90; Turn the pneumatic switch again and fix the manifold firmly.重新定位锁紧Position the fixture again and fasten the manifold

43、摆臂方孔与阀片方孔对齐,摆臂方向正确Align the rocker arm orifice and valve disc orifice, make sure the rocker direction is correct.摆臂插装到底,与方轴配合无松动或无过紧无法顺利插装到底Insert the rocker arm into the bottom, no loosing or getting stuck.Actuator 定位孔与壳体上定位销安装到位Actuator locating orifice and house locating pin are installed Actuato

44、r 组件&压盖装配Actuator component & assembly电动力矩螺刀转角控制仪装配工作台摆臂盖安装定位正确,无反装错位The rocker cover is installed into the right position, no reverse installation顺序拧入2颗M4自攻螺栓(先装 Actuator 侧螺栓)Install two M4 self-tapping screws (screws at the actuator side should be installed first)M4螺栓安装扭矩M4 screw installation torq

45、ueM4螺栓扭矩转角M4 screw rotation angle松开歧管固定压板,取出零件Release the manifold fastening plate and remove the manifold扳动右手侧气动夹紧扳手,气动压板松开,取出歧管,注意避免磕碰EGR管和歧管表面的凸出卡销 etc. 扳动右手侧气动夹紧扳手,气动压板松开,取出歧管,注意避免磕碰EGR管和歧管表面的凸出卡销 etc. Turn the pneumatic switch in the right side and release the manifold, care should be taken to

46、avoid knocking against EGR pipe and the manifold.钣金支架Inspection 钣金支架Inspection Inspect the metal plate bracket表面无锈蚀、镀层无异常,支架无变形,无明显飞边毛刺表面无锈蚀、镀层无异常,支架无变形,无明显飞边毛刺No obvious rust and burrs, no abnormality on the plated area, no deformation of bracket 装配钣金支架、装配节气门法兰密封圈、缸盖法兰密封圈Install metal bracket, thro

47、ttle body gasket and cylinder cover flange gasket.电动力矩螺刀转角控制仪装配工作台Electric torque wrenchRotation angle controllerAssembly workbenchM6螺栓安装扭矩M6 blots installation torqueM6螺栓扭矩转角M6 blots rotation angle 更换正确的M4 螺刀头Switch to the correct 1个M6,2个M4螺栓安装后AppearanceAppearance after the installation of one M6

48、and two M4 screws螺栓花键槽无损伤,变形;螺栓头部和法兰面无冷镦开裂、缺料或其他异常螺栓安装无倾斜;螺栓拧紧到底,无悬空(法兰面与塑料端面紧密贴合,无间隙)真空Hose (短管)另一端插入 Electromagnetic valve 连接管嘴The other end of vacuum hose ( short hose) is inserted into the Electromagnetic valve connector管嘴连接正确;装配到管嘴底端;The connector is connected to the hose properly;The hose is i

49、nstalled into the bottom of the connector扳动左手侧气动夹紧扳手,松开翻转夹具顺时针翻转夹具90;re-次扳动左手侧气动夹紧扳手,夹紧翻转夹具2个螺栓组件InspectionCheck two bolt componentsWasher无漏装,螺纹胶无漏涂,涂胶位置正确Washers are installed, and emulsion sealant is applied on the right place2个螺栓拧入 Depth2个螺栓拧入 DepthScrewing depth of the two screws保留4mm以上间隙;漏装防错In

50、spectionMissing component error-proofing inspection冷插套无漏装The limiters are not missing防错Inspection 装置Error-proofing device气密性测试条件Air-tightness requirements测试压力:0.5bar下泄漏量50 cc/min, Actuator 动作5次为合格Test pressure: leakage rate50 cc/min 0.5bar, Actuator can perform action five times气密性Air-tightness0.5ba

51、r下泄漏量50 cc/min,Actuator 作动Inspection Actuator can perform action切断负压后, Actuator 能连续动作5次,每次动作, Actuator 返回时间符合要求Without negative pressure, the actuator can perform action five times and the return time is within the time requirement.Actuator 动作Inspection 装置Actuator inspection equipmentInspection 合格打点

52、Appearance After inspection qualified parts will be labeled 自动打点,标记形状符合,清晰、有效Automatically label, the mark is clear, readable and effective更换打点头Replace marking pin保留4mm以上间隙;Maintain a clearance of at least 4mm.电动螺刀头的机械限位控制End stops for the movement range of the electric wrench装入1个节气门密封圈装入4个缸盖密封圈Inst

53、all one throttle body gasket and four cylinder head gaskets密封圈无破损和其他Appearance缺陷;无漏装,安装到位,无翘起松脱,用专用滚轮将密封圈滚平零件表面清洁,无灰尘或其他杂质残留;The part surface is clean, no debris and any other dust;二维码信息清晰,序列编号正确;2D code is clear and the serial number is correct;Product Appearance 不允许有缺料、流痕、气花、缩凹、杂质、油污 etc. 注塑缺陷;No

54、short shot, flow mark, trapped air, shrinkage, oil stain etc on the molded parts;焊缝处无明显溢料,无焊接异常,明显错位;No obvious flashes, displacement, and welding abnormality.产品表面无明显磕碰伤,支架 etc. 无断裂损伤;No obvious bumping damage and cracks.冷热插件无漏装,Appearance符合要求,无溢料飞边残留,金属件高度无异常;Nut Inserts and limiters are not missin

55、g and in good condition, no flashes and the inserting depth is normal密封圈无漏装,无裂纹,油污 etc. 缺陷;The gaskets are not missing, no cracks, oil stain or any other defects etc各附件不允许漏装和不满足要求的缺陷;The sub-components are not allowed to be missing and no defects should be found螺栓安装到位,螺栓无损伤,漏装;The bolts are installed into places, no damages and missingEGR管客户安装法兰无变形/明显错位;The c

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