钣金、焊接和喷涂品质管控计划

结构件厂（钣金、焊接和喷涂）第38周品质周报结构件厂：崔世新2014年9月19日1东莞阳天电子科技有限公司DongguanYangtianElectronTechnologiesCo.,Ltd.目录2一、钣金厂各车间质量数据1.焊接产品合格率2.喷涂产品合格率二、钣金厂各工序质量数据1.NC冲一次合格率及改善措施2.折弯一次合格率及改善措施3.普冲一次合格率及改善措施4.压铆一次合格率及改善措施三、钣金厂三防稽查1.三防稽查数据2.三防问题点描述3.污水处理状况4.电导率数据四、钣金厂制程异常1.制程异常单汇总2.制程异常首件汇总五、下周工作重点3一、钣金厂各车间质量数据一、钣金厂各车间数据注：达标的数据用黑色字体，未达标的数据用红色字体。各工序产品一次合格率质量目标修改后的目标第32周第33周第34周第35周第36周第37周第38周第39周平均值喷涂整体一次合格率（大件）≥99.0%≥99.0%89.25%87.24%80.65%82.47%80.19%85.22%93.70%92.90%喷涂整体一次合格率（中件）≥99.0%≥99.0%85.99%88.76%89.05%84.31%81.60%84.66%94.00%喷涂整体一次合格率（小件）≥99.0%≥99.6%84.56%88.75%89.16%87.68%82.43%84.77%91.00%打磨一次合格率（白班）≥99.0%≥99.0%98.95%90.14%97.49%98.37%95.48%97.75%98.13%98.10%打磨一次合格率（夜班）≥99.0%≥99.0%87.76%93.46%96.80%96.45%97.80%97.22%98.06%焊接一次合格率（白班)≥99.0%≥99.0%97.53%94.64%99.41%96.63%95.51%99.32%98.18%98.66%焊接一次合格率(夜班）≥99.0%≥99.0%97.53%94.64%97.35%98.16%96.36%97.35%99.13%普冲一次合格率（白班）≥99.0%≥99.6%97.05%97.31%98.12%97.54%93.99%97.24%97.14%97.14%普冲一次合格率（夜班≥99.0%≥99.6%93.35%88.61%97.25%97.84%95.31%96.52%------压铆一次合格率（白班）100.00%100.00%99.38%98.89%97.17%99.74%99.27%97.95%99.43%99.63%压铆一次合格率（夜班）100.00%100.00%99.63%98.89%97.73%99.01%98.96%99.39%99.83%钳工一次合格率（白班）≥99.0%≥99.6%99.09%95.94%97.20%-------------------------钳工一次合格率（夜班）≥99.0%≥99.6%95.82%94.71%95.82%---------------------折弯一次合格率（白班）≥99.0%≥99.6%98.95%97.71%97.63%99.33%97.13%97.33%98.42%98.61%折弯一次合格率（夜班）≥99.0%≥99.6%97.24%99.16%94.56%99.07%95.26%97.18%98.80%NC冲一次合格率（白班）≥99.0%≥99.6%99.64%98.11%98.19%98.42%95.17%95.91%96.45%95.83%NC冲一次合格率（夜班）≥99.0%≥99.6%97.83%95.46%89.74%91.03%94.77%99.15%95.21%导通率4二、钣金厂各工序质量合格率喷涂一次合格率及异常数据大件（白班）缺陷类别露底颗粒挂具印桔皮积粉飞粉漏撕保护漏保护划伤其他合计不良数量714137121198653203不良比率35.0%20.2%18.2%5.9%5.4%4.4%3.9%3.0%2.5%1.5%100%累计比率35.0%55.2%73.4%79.3%84.7%89.2%93.1%96.1%98.5%100.0%露底颗粒挂具印桔皮积粉飞粉漏撕保护漏保护划伤其他不良数量714137121198653累计比率35.0%55.2%73.4%79.3%84.7%89.2%93.1%96.1%98.5%100.0%71413712119865335.0%55.2%73.4%79.3%84.7%89.2%93.1%96.1%98.5%100.0%0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%020.340.660.981.2101.5121.8142.1162.4182.7203喷涂（大件）不良类别分布图序号问题描述原因分析改善措施责任人计划完成时间1露底喷粉工走枪不均匀对喷粉工加强培训陈俊9月19日5喷涂一次合格率及异常数据大件（夜班）二、钣金厂各工序质量合格率缺陷类别露底挂具印积粉飞粉毛刺漏撕保护划伤颗粒变形其他合计不良数量942421151385421187不良比率50.3%12.8%11.2%8.0%7.0%4.3%2.7%2.1%1.1%0.5%100%累计比率50.3%63.1%74.3%82.4%89.3%93.6%96.3%98.4%99.5%100.0%露底挂具印积粉飞粉毛刺漏撕保护划伤颗粒变形其他不良数量942421151385421累计比率50.3%63.1%74.3%82.4%89.3%93.6%96.3%98.4%99.5%100.0%94242115138542150.3%63.1%74.3%82.4%89.3%93.6%96.3%98.4%99.5%100.0%0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%018.737.456.174.893.5112.2130.9149.6168.3187喷涂（大件）不良类别分布图序号问题描述原因分析改善措施责任人计划完成时间1露底喷粉工走枪不均匀对喷粉工加强培训陈俊9月19日6喷涂不良分布中件（白班）二、钣金厂各工序质量合格率缺陷类别露底颗粒挂具印桔皮划伤漏撕保护飞粉其他合计不良数量53986653191不良比率58.2%9.9%8.8%6.6%6.6%5.5%3.3%1.1%100.0%累计比率58.2%68.1%76.9%83.5%90.1%95.6%98.9%100.0%露底颗粒挂具印桔皮划伤漏撕保护飞粉其他不良数量539866531累计比率58.2%68.1%76.9%83.5%90.1%95.6%98.9%100.0%53986653158.2%68.1%76.9%83.5%90.1%95.6%98.9%100.0%0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%09.118.227.336.445.554.663.772.881.991喷涂（中件）不良类别分布图序号问题描述原因分析改善措施责任人计划完成时间1露底零件结构复杂，构槽死角位不易上粉下挂前安排专人对不易上粉进行修补。周海成9月19日7喷涂一次合格率及异常数据中件（夜班）二、钣金厂各工序质量合格率缺陷类别挂具印露底漏撕保护积粉飞粉变形漏保护其他合计不良数量19976543255不良比率34.5%16.4%12.7%10.9%9.1%7.3%5.5%3.6%累计比率34.5%50.9%63.6%74.5%83.6%90.9%96.4%100.0%挂具印露底漏撕保护积粉飞粉变形漏保护其他不良数量199765432累计比率34.5%50.9%63.6%74.5%83.6%90.9%96.4%100.0%19976543234.5%50.9%63.6%74.5%83.6%90.9%96.4%100.0%0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%05.51116.52227.53338.54449.555喷涂（中件）不良类别分布图序号问题描述原因分析改善措施责任人计划完成时间1挂具印下挂后未安排人员对挂具印进行修补下挂后安排人员对挂具印用刀片修理后补自干漆再报检转序周海成9月19日8二、钣金厂各工序质量合格率喷涂不良分布小件（白班）缺陷类别露底漏撕保护飞粉颗粒划伤桔皮其他合计不良数量42241913540107不良比率39.3%22.4%17.8%12.1%4.7%3.7%0.0%100.0%累计比率39.3%61.7%79.4%91.6%96.3%100.0%100.0%露底漏撕保护飞粉颗粒划伤桔皮其他不良数量42241913540累计比率39.3%61.7%79.4%91.6%96.3%100.0%100.0%4224191354039.3%61.7%79.4%91.6%96.3%100.0%100.0%0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%010.721.432.142.853.564.274.985.696.3107喷涂（小件）不良类别分布图序号问题描述原因分析改善措施计划完成时间1露底零件结构复杂，构槽死角位不易上粉下挂前安排专人对不易上粉进行修补。9月19日9喷涂不良分布小件（夜班）二、钣金厂各工序质量合格率缺陷类别挂具印露底毛刺积粉颗粒飞粉其他合计不良数量512313111075120不良比率42.5%19.2%10.8%9.2%8.3%5.8%4.2%100.0%累计比率42.5%61.7%72.5%81.7%90.0%95.8%100.0%序号问题描述原因分析改善措施责任人计划完成时间1挂具印下挂后未安排人员对挂具印进行修补下挂后安排人员对挂具印用刀片修理后补自干漆再报检转序周海成9月19日挂具印露底毛刺积粉颗粒飞粉其他不良数量512313111075累计比率42.5%61.7%72.5%81.7%90.0%95.8%100.0%51231311107542.5%61.7%72.5%81.7%90.0%95.8%100.0%0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%01224364860728496108120喷涂（小件）不良类别分布图101010二、钣金厂各工序质量合格率前处理不良分布（白班）缺陷类别划伤焊渣磷化液脏污生锈其他合计不良数量3516987479不良比率44.3%20.3%11.4%10.1%8.9%5.1%100.0%累计比率44.3%64.6%75.9%86.1%94.9%100.0%划伤焊渣磷化液脏污生锈其他100.0%35169874累计比率44.3%64.6%75.9%86.1%94.9%100.0%3516987444.3%64.6%75.9%86.1%94.9%100.0%0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%07.915.823.731.639.547.455.363.271.179前处理来料不良类别分布图序号问题描述原因分析改善措施责任人计划完成时间1划伤来料产品防护没有做好。对于来料没有做好防护的产品。一概拒收赵鲜9月19日11前处理不良分布（夜班）二、钣金厂各工序质量合格率缺陷类别生锈焊渣划伤脏污磷化液发黄变形其他合计不良数量74503026131086217不良比率34.1%23.0%13.8%12.0%6.0%4.6%3.7%2.8%100.0%累计比率34.1%57.1%71.0%82.9%88.9%93.5%97.2%100.0%生锈焊渣划伤脏污磷化液发黄变形其他不良数量74503026131086累计比率34.1%57.1%71.0%82.9%88.9%93.5%97.2%100.0%7