PMP制程管理计划

Processmanagementplan產品制程穩定性品質保證Preparedby:QSMCSQERickMiaoNov242003revision01---ProductProcessStablizationQualityAssuranceNewprojecttransfercreatedbyPEteam.由PE小組制定的新項目移轉MassproductionPMPupdatebasedonissueandcustomerrequirement.量產機種因異常和客戶要求而進行的PMP更新QA,JQEandauditteamtoauditprocessreferencePMP.QA.JQE與稽核人員稽核制程之依據PMPcoverfromIQCtoOQCoverallprocess.PMP涵蓋到從進料檢驗到出貨檢驗的全部制程PMPgenerallytodriveprocessandQAsystemtocontrolcriticalstationwithkeyparameter.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PMPupdateguideline.---PMP修改准則Preventiveactiontake.採取新的預防措施Systemimprovement.系統得到改進Lessonlearnreview.所獲得經驗的回顧QCandProcesscontrolenhancement.品管和製程控制得到加強PMPfunctionandcontrolPMP功能與管制•PPAPProductionPartApprovalProcess零/部件承認程序NewprojectPMPcreationAPQPteamPPAPteamPPAPleaderapprovedDefineprocessroadmap(PEhost)QAqualityconcern.CustomerRDdesignfunctionconcernPEprocesscontrolconcernInputOutputQualitycontrolProcesscontrolfailPFMEAcreation(PEworkwithRD)STandPTTrailrunreport-qualityyieldrate-issuehighlightPMPcreation-PFMEAand-Roadmap-Customercontrolconcern.-Lessonlearn.(QTbuilding)Self-review(JQEandPPAPteamapprrovedbyPPAPleaderSIPandSOPcreationCustomerSQEreviewUpdatecustomeroncernQA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)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MPPMPupdateandauditFromQADcccenterauditteamMPPMPUPDATEANDAUDITQualityIssueLessonlearntoPEInternalreviewUpdatePMPUpdateSOP&SIPFinalissueProcessauditwithPMPfail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ProductProcessStabilizationQualityAssurance1.PSQAconception:Productprocessparameterstabilizationqualityassurance,meaningwithkeyprocessparameterconditioncontroltoensureproductqualitystably.ProductsSpec.stabilizationlieonprocessparameterSpec.stabilization.Approvalforprocessesnotmeetingrequirement.2.ProcessQA:1)Partsassurance:afterproductionQCtocheckpartswithdimension,cosmeticandfunction.ifoutofSpec.totracktheprocessparameterandmakeadjustmentfollowexperience.incaseofprocessparameterbigdeviationwillbelotsoffailureparts.thereforewithhighrisk.2)Processassurance:InprocessmonitoredbyproductionlineandQApersonforpartsCharacteristicandprocessparameter.Anydeviationshouldfollowgoldprocessparametertosetup.Therebycancatchfailureinearlyperiodtomaketherealprevention.Goldprocessparametercomefromtrialrunpartshaveapprovedbycustomers(itshouldfixedandcontrolledbyMEandQAteam)Anyprocessparameterschangeoutofgoldprocessparametersshouldbeapprovedbycustomer.(Approvedbysuppliersthemselvesatfirst)-Doublecheckpartsdimension,functionandcosmeticmeetcustomerSpecornot.-ProcessparameterneedstudyreasonabletoleranceandconfirmedwithpartsSpec.andCustomers.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。PSQAparametercontrolProcessParametercontrolTrailrunProcessParameterPaintinga)pre-mixedb)Paintingparameterc)BakeconditionInjectiona)Injectionconditionb)Resinbaketemp.timeC)MFISpecSuppliersapprovedCustomerapprovedMPProcessParameterPE-functionandAssyQA-FAIandCosmeticPE-functionandAssyQA-FAIandCosmeticFailFailRe-trailagainUpdatetoPMPAndSop&SIPDCCissueofficallyProductionlineSetupIPQCFAIProductionQAauditWithPMPFailRe-adjusttoMPprocessparameterIPQCFAIFailProductionRecordadjustparameterRe-runtrailRunprocessFailPSQA製程參數管控QA根據PMP稽核未通過製造巡檢首件記錄生産綫設定文管中心異常記錄更新至PMP及SOP和SIP再次試產以驗證製程未通過重新調整里量產製程參數巡檢首件記錄未通過記錄生産參數的調整PE-功能組裝QA-FAI和外觀PE-功能組裝QA-FAI和外觀未通過未通過再次試產試產製程參數噴漆a)調漆b)噴漆參數c)烘烤條件成型a)成型條件b)塑膠粒烘烤溫度/時間c)熔融指數標準供應商核准客戶核准量產製程參數SOPkeyparameters•6majorportionsﭳDocument/ProductInformation-Productpartnumber/revision,processstep/name,approvalstatus,revisionlevel,…ﭳDirectmaterialsP/N,description,usage,anddesignator.ﭳWorkprocess/instructionforthestationﭳIllustrationﭳMachinename&stationnumber,machineprogramname/revistion,fixturesname/partnumber&revistion,tools/gagespartnumber/name,indirectmaterialswithdetaileddescrption,andtheirworkingconditions.ﭳCallouthighlights/specialnotesfortheoperationSOP中的關鍵參數•6個重要的部分：文件/產品的信息–產品的料號/版本，製程步驟/名稱，核准狀態，版本級別，……原料料號，描述，用途和標誌該站別的作業製程/指導圖示機器名稱和工站編號，機器程序名稱/版本，治具名稱/編號和版本，工具/量具編號/名稱，非直接物料的細節描述及其作業條件。著重強調並特別標註作業的注意事項SOPkeyparametersﭳInformation-productpartnumber/revision,approvalstatus,revisionlevel,…ﭳDimension---P-dimensionorengineeringteamconcerneddimension.(MeetcustomersofficialdrawingSPEC.atleast.)ﭳCosmetic---Meetcustomersofficialcosmeticorgoldsamplecriteria.(specificSpec.tolerance)ﭳFunction---reliabilityandfunctiontestingitems(suchasprogramtestingtorques,MFIandpullforcetesting)ﭳSystemmatching---forsomesinglepartswillbeassemblyatcustomersproductionline);(specialfordifficultassembl