鋼簾線質(zhì)量控制系統(tǒng)介紹

1、- 1 -鋼簾線質(zhì)量控制系統(tǒng)簡介鋼簾線質(zhì)量控制系統(tǒng)簡介Introduction of XingDa QA QC System- 2 - 質(zhì)量管理體系認(rèn)證質(zhì)量管理體系認(rèn)證 鋼簾線生產(chǎn)流程圖鋼簾線生產(chǎn)流程圖 鋼簾線質(zhì)量特性影響因素鋼簾線質(zhì)量特性影響因素 過程控制點及控制系統(tǒng)過程控制點及控制系統(tǒng) 不良品處置及可追溯性不良品處置及可追溯性 TPM/SPC的應(yīng)用的應(yīng)用 預(yù)防糾正及預(yù)防糾正及8D分析分析 交付應(yīng)急計劃交付應(yīng)急計劃 質(zhì)量方針質(zhì)量方針目錄 Catalog QA System CertificationManufacturing Process Key Characteristics of Qu

2、alityProcess Control Point and SystemDisposition of No Conformityand Product Traceability TPM/SPC Error Proofing and 8D AnalysisContingency PlanQuality Policy - 3 - 1998年5月通過ISO9002:1994質(zhì)量認(rèn)證； 2004年5月通過了由中國汽車工業(yè)質(zhì)量體系認(rèn)證中心組織的QS9000/ISO9001:2000質(zhì)量管理體系和ISO14001環(huán)境管理體系認(rèn)證； 2006年1月開展ISO/TS16949:2002體系認(rèn)證咨詢評估，20

3、07年1月份通過艾肯錫天津華誠認(rèn)證公司的認(rèn)證，預(yù)計于2007年5月份獲得ISO/TS16949:2002證書； 目前正在開展實驗室ISO/IEC17025:2005管理體系工作，預(yù)計于今年三季度通過認(rèn)證。 1998.5-ISO9002:1994 Audit 2004.5-QS9000/ISO9001:2000&ISO14001 Audit 2006.1-ISO/TS16949:2002 Audit Start. 2007.5-ISO/TS16949:2002 Certification will be obtained ISO/IEC17025:2005 is in process n

4、ow，and 3rd party audit will be in the 3rd quarter。質(zhì)量管理體系認(rèn)證 QA System Certificate- 4 -鋼簾線生產(chǎn)流程示意圖鋼簾線生產(chǎn)流程示意圖 PRODUCING PROCESS OF STEEL TYRE CORDCheck PointCheck PointCheck PointRobIQCPreparation-Coarse DrawingHeat Treatment-PlatingCheck Point2nd-DrawingCheck PointWet DrawingTwistingCheck PointPackagin

5、gDeliveringHeat Treatment- 5 -質(zhì)量特性(Properties)影 響 因 素(Influencing Factors)控制點(Control Piont)粘合力adhesion鍍層銅含量、鍍層重量、表面質(zhì)量Copper Content, Coating weight, surface檢驗5、7、85、7、8破斷力Broken Force原材料、熱處理工藝、單絲直徑及破斷力Raw Material, Heat Treating, Filament Diameter, Broken Force檢驗1、5、61、5、6直徑Diameter單絲直徑Filament Dia

6、meter檢驗6、76、7線密度Linear Density單絲直徑Filament Diameter檢驗6、76、7捻距/向Lay L/D捻股機交換齒輪Gear of Twisting Machine檢驗77殘余應(yīng)力Residual Torsion捻股機校直器、過捻器Killing Roller, Over Twister檢驗77鍍層銅含量及重量Cu%、W鍍槽電流值、鍍液成份、作業(yè)速度Current, Component, Speed檢驗5、75、7定長Length on spool計米器Length Counter檢驗77焊點Welding Point焊接機Welding Machine檢

7、驗77表面質(zhì)量Surface放線張力、校直器Lay off tension, Killing Roller檢驗77鋼簾線質(zhì)量特性影響因素 Key Characteristics for Properties- 6 -不良品處置流程不良品處置流程 Disposition Chart of No Conformity不良品 No Conformity Product標(biāo)識隔離 Isolation/ Label專職處置員按標(biāo)準(zhǔn)實施處置Identification by QC Stuff 返工 Redo報廢 Scrap讓步接受 Concession檢驗、判定 Inspection定向定機床處置Dispo

8、se on spot合格Qualified定向定機床流轉(zhuǎn)Special flowing不合格NO Qualified- 7 -可追溯性流程可追溯性流程 Traceability Product捻股生產(chǎn)記錄 Twisting record重卷生產(chǎn)記錄Rewinding Record電鍍生產(chǎn)記錄Plating Record鍍銅絲領(lǐng)用記錄Coated Cord Using Record中拉絲領(lǐng)用記錄2nd drawing Cord Using Record中拉生產(chǎn)記錄2nd Drawing Record熱處理生產(chǎn)記錄Heat Treating Record熱處理絲領(lǐng)用記錄Heat Treated C

9、ord Using Record粗拉生產(chǎn)記錄Coarse Drawing Record粗拉絲領(lǐng)用記錄Coarse Drawing Record原材料投用記錄Raw Material Using Record入庫檢驗報告Receiving Inspection Report不良品處置記錄No Conformity Record濕拉生產(chǎn)記錄Wet Drawing record原材料Raw Material產(chǎn)成品標(biāo)識 Final Product Label單絲領(lǐng)用記錄Filament Using Record不良品處置記錄No Conformity Record不良品處置記錄No Conformit

10、y Record不良品處置記錄No Conformity Record不良品處置記錄No Conformity Record不良品處置記錄No Conformity Record- 8 -TPM的應(yīng)用的應(yīng)用(一一) TPM 日常點檢日常點檢 操作工每天班前用聽、看、摸等方法，按點檢標(biāo)準(zhǔn)對設(shè)備進行檢查，確保設(shè)備正常運轉(zhuǎn)，不發(fā)生故障。點檢的主要內(nèi)容有：異聲、漏油、振動、溫度、潤滑和調(diào)整。 定期檢查定期檢查 維修工按計劃定期對重點設(shè)備進行檢查，確保設(shè)備達到規(guī)定的性能。檢查工作包括：測定設(shè)備的劣化程度、確定設(shè)備性能、調(diào)整設(shè)備等。 計劃修理計劃修理 根據(jù)日常點檢、定期檢查的結(jié)果所提出的設(shè)備修理委托書、維

11、修報告、機床性能檢查記錄等資料編制的計劃，定期進行修理。 Daily Inspection Operators carry out inspections at the beginning of each shift for sound, leakage, shake, temperature, lube, adjust. Planed Inspection Main machines are inspected periodically to maintain functions. Check items are: deterioration, regular function, adjus

12、t Preventive Maintain According to above inspections result, maintenance is carried out.- 9 -TPM的應(yīng)用的應(yīng)用(二二) TPM改善修理改善修理 對設(shè)備的某些結(jié)構(gòu)進行改進修理，主要用于經(jīng)常重復(fù)發(fā)生故障的設(shè)備。故障修理故障修理 當(dāng)設(shè)備突然發(fā)生故障或由于設(shè)備原因造成廢品時立即組織搶修。維修記錄分析維修記錄分析 維修記錄分析是全面生產(chǎn)維修的一項重要內(nèi)容，尤其是“平均故障間隔時間”分析。Improving RepairRepair some equipments that have problems frequ

13、ently.Shut Down Maintenancewhen troubles occur suddenly or abnormity occurs shut down maintenance is carried out.Maintenance Record Analysis It is one of the important items especially for Mean Time Between Failures.- 10 -SPC的應(yīng)用的應(yīng)用 SPC 分析應(yīng)用分析應(yīng)用 主要應(yīng)用于對生產(chǎn)過程所需資源進行分析;用生產(chǎn)過程收集的數(shù)據(jù),繪制成分析用控制圖、直方圖，或進行過程能力分析，檢

14、驗生產(chǎn)過程是否處于穩(wěn)定、以及過程能力是否滿足。 監(jiān)控應(yīng)用監(jiān)控應(yīng)用 監(jiān)控應(yīng)用主要是使用控制圖進行過程監(jiān)控。生產(chǎn)過程的數(shù)據(jù)及時繪制到控制圖上，觀察控制圖中點的波動情況可以顯示出過程受控或失控。 Analysis Application It is used to Analysis the recourse in the whole process. Make controlling chart by product values. Calculate Cpk to check if the producing is stable, or if Cpk is attained. Monitor Ap

15、plication Monitor process by applying control chart. Positioning producing values on this chart to observe the fluctuation which shows regularly or not.- 11 -SPC分析異常點Out range Analysis by SPC預(yù)防措施流程預(yù)防措施流程 Error Proofing 質(zhì)量控制 Quality Control質(zhì)監(jiān)部組織分析原因Analysis by Quality.D設(shè)備控制 Equipment Control設(shè)備部組織分析原因

16、Analysis by Equip.D制定預(yù)防措施 Precaution Established責(zé)任部門組織實施 Implemented by responsibility Dept.跟蹤驗證實施效果 Follow up and Confirm形成作業(yè)文件SOP工藝控制 Process Control技術(shù)部組織分析原因Analysis by Tech.D無效No effective有效Effective- 12 -NoNookok8、恭喜成功獎勵Congratulation2、緊急措施Temporary Corrective Measure 3、根本原因分析Root Cause Analysi

17、s選擇最佳處理方案 Best strategy5、驗證 Verification6、控制 Controlling7、預(yù)防 Prevention8D分析流程分析流程 8D Chart1、描述問題 Problem Description檢驗處理方案效果 Effect Verification4、實施永久措施 Permanent Plan- 13 -交付應(yīng)急計劃交付應(yīng)急計劃 Contingency Plan 建立安全庫存建立安全庫存 根據(jù)規(guī)格銷售量，建立合理的安全庫存，確保交付期不受影響，滿足客戶需求。生產(chǎn)區(qū)域調(diào)整生產(chǎn)區(qū)域調(diào)整 合理利用柔性化生產(chǎn)方式，若遇突發(fā)情況會提前通知客戶，在得到客戶認(rèn)可的前提下,我司可調(diào)整生產(chǎn)區(qū)域滿足客戶交付要求。Stock According to Delivering PlanEstablish the stock according to merchandise planning. Ensure 100% OTD.Flexibility of Production Establish a flexible style of producing through SOP.