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1、Process management planProcess management plan產品制程穩定性品質保證Prepared by: QSMC SQE Rick MiaoPrepared by: QSMC SQE Rick MiaoNov 24 2003 revision 01 Nov 24 2003 revision 01-Product Process -Product Process StablizationStablization Quality Assurance Quality AssuranceNew project transfer created by PE team.
2、 由PE小組制定的新項目移轉 Mass production PMP update based on issue and customer requirement. 量產機種因異常和客戶要求而進行的PMP更新 QA ,JQE and audit team to audit process reference PMP. QA.JQE與稽核人員稽核制程之依據 PMP cover from IQC to OQC overall process. PMP涵蓋到從進料檢驗到出貨檢驗的全部制程 PMP generally to drive process and QA system to control
3、critical station with key parameter. 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PMP update guideline.-PMP修改准則Preventive action take .採取新的預防措施System improvement .系統得到改進Lesson learn review.所獲得經驗的回顧 QC and Process control enhancement.品管和製程控制得到加強 PMP function and control PMP功能與管制 PPAP Production Part Approval Pro
4、cess零/部件承認程序New project PMP creation APQP teamPPAP teamPPAP leader approvedDefine process road map (PE host)QA quality concern. Customer RD designfunction concern PE process control concernInputOutputQuality control Process controlfailPFMEA creation (PE work with RD)ST and PTTrail run report -qualit
5、y yield rate -issue highlightPMP creation -PFMEA and -Roadmap-Customer control concern.-Lesson learn . (QT building)Self-review(JQE and PPAP team apprroved by PPAP leaderSIP and SOPcreationCustomer SQE reviewUpdate customer oncernQA品質相關 客戶RD設計功能相關 PE製程控制相關輸入定義製程路綫圖 (PE主導)輸出品質管制 製程管制PFMEA的建立 (PE與RD負責
6、) 在ST和PT階段完成試產報告 -品質量率統計 -問題點曝光PMP的建立 -PFMEA和路綫圖 -客戶管制相關内容 -經驗的獲得(QT階段 )SIP和SOP的建立自審 (JQE和由 PPAP領導核 准的PPAP小 組)更新客戶對相關 内容的要求客戶 SQE審 核未獲通過先期品質規劃小組PPAP領導核准PPAP小組新機種PMP的建立 MP PMP update and audit品質異常PE所獲得的經驗更新PMP更新SOP和SIP内部審核異常結案根據PMP進 行製程稽核未獲通過來自QA文管中心稽核組量產階段PMP修改與稽核 Product Process Stabilization Quali
7、ty Assurance 1.PSQA conception: Product process parameter stabilization quality assurance,meaning with key process parameter condition control to ensure product quality stably.Products Spec. stabilization lie on process parameter Spec. stabilization.Approval for processes not meeting requirement.2.P
8、rocess QA :1) Parts assurance: after production QC to check parts with dimension, cosmetic and function.if out of Spec. to track the process parameter and make adjustment follow experience.in case of process parameter big deviation will be lots of failure parts.therefore with high risk .2) Process a
9、ssurance: In process monitored by production line and QA person for parts Characteristic and process parameter. Any deviation should follow gold process parameter to set up. Thereby can catch failure in early period to make the real prevention. Gold process parameter come from trial run parts have a
10、pproved by customers( it should fixed and controlled by ME and QA team) Any process parameters change out of gold process parameters should be approved by customer.( Approved by suppliers themselves at first)-Double check parts dimension, function and cosmetic meet customer Spec or not.-Process para
11、meter need study reasonable tolerance and confirmed with parts Spec. and Customers.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
12、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。PSQA parameter controlProcess Parameter controlTrail run Process Parameter Painting a
13、)pre-mixed b)Painting parameter c)Bake condition Injection a)Injection condition b)Resin bake temp.time C)MFI Spec Suppliers approvedCustomer approvedMP ProcessParameter PE-function and Assy QA-FAI and Cosmetic PE-function and Assy QA-FAI and Cosmetic FailFailRe-trail againUpdate to PMP And Sop(spec
14、ial for difficult assembly,gap and step) Movable parts checking-with simulation testing (as button,hook,sometines need be checked with fixture) Illustration(describe the key checkpoint or motion) ECN change record(latest 3 months) Customer quality issue history record(latest 3 months)SIP中的關鍵參數 信息- 產
15、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)SOP key parametersProcess flow-Pr
16、ocess and parts control station. Process control:for critical manufactured testing machine station.(process with class with S-safety critical,M-major defect,O-minor defect and KPC-key cont,charct) Parts control:for critical final inspection and QC sample size station.(Process with class with S-safety critical,M-major defe
