Product exception handling process 1 purpose:
In order to make the treatment process of quality abnormity have evidence to follow, make the major quality abnormity be effectively improved within the specified time, prevent the same problem from happening again, reduce the quality cost and ensure the product quality meets the requirements.
2 scope:
Process control and delivery inspection
3 Definition: Major quality abnormality means that the quality problem is so serious that it is necessary to issue a contact list of quality abnormality, and QE/IPQC will handle it specially.
Follow up quality incidents.
3. When1process appearance defect reaches 10%, the Contact Sheet for Abnormal Quality shall be issued.
3.2 When the process performance is poor to 5%, the Abnormal Quality Contact Sheet shall be issued.
3.3 When the size of the defective process reaches 3%, the Abnormal Quality Contact Sheet will be issued.
3.4 The production line is stopped because there is no work instruction, no standard or the process conditions can't meet the process requirements.
3.5 If the quality problems are repeated for three consecutive days in the process, a Contact Sheet for Quality Abnormality shall be issued.
4 operation process:
4. 1 During the production process, the operator will notify the on-site IPQC and the on-site supervisor for confirmation as soon as possible when finding the product quality is abnormal. If there are no errors, IPQC will open the abnormal quality contact table. If there is any difference between IPQC and the site supervisor, it will immediately report to the superior supervisor for confirmation, and IPQC will continue to issue the contact list of abnormal quality.
4.2 After preliminary analysis of the abnormal causes by IPQC on site (if necessary, the abnormal causes should be analyzed together with the process technology), fill in the form.
Abnormal quality contact table
4.3 The contact list of quality abnormality must clearly indicate the date, time, place, batch number, abnormal number, defective rate, abnormal situation description and abnormal reason analysis.
4.4 After IPQC sends the Contact Sheet of Quality Abnormality to the supervisor of the department for review, the supervisor numbers the Contact Sheet of Quality Abnormality uniformly, then forwards it to the supervisor of the responsible department and signs the Follow-up Sheet of Quality Abnormality. Relevant personnel will give a reply within one working day after receiving the contact form.
4.5 After the site cause analysis is clear, the responsible department head shall formulate corrective measures according to the actual production situation, fill in the corrective measures description in the corrective measures column of the Quality Abnormal Contact Sheet, and IPQC shall conduct on-site follow-up verification;
4.6 The person in charge of the responsible department analyzes the root cause of quality abnormality and fills it in the corresponding cause analysis column of the Corrective/Preventive Measures Report.
4.7 The person in charge of the responsible department shall take preventive measures for the abnormal reasons in the corrective/preventive measures report within 48 hours.
4.8 QE shall track, verify and confirm the effect according to the Contact Sheet of Quality Abnormality and the Report of Corrective and Preventive Measures.
4.8. 1 Did the responsible department implement the improvement measures within the specified time limit 4.8.2 Did the responsible department complete the improvement measures within the specified time limit?
4.8.3 Whether the relevant personnel of the departments involved actively cooperate with the implementation of improvement measures;
5 reward and punishment system: 5. 1 punishment system:
5. 1. 1 The person in charge must make an improvement plan and specify the time limit for completion within 2 working days, otherwise 5 yuan will be punished/time;
5. 1.2 The improvement measures failed to complete the punishment given to 5 yuan/time within the limited time;
5. 1.3 The responsible department failed to fully implement the improvement measures, resulting in ineffective improvement, and the responsible person was fined 10 yuan/time; 5. 1.4 If the same abnormal point is repeated five times or more in the same department within one month, 20 yuan will be punished/month. 5.2 reward system:
5.2. 1 The person in charge of the abnormal problem takes effective measures to improve within a time limit and the same quality problem does not happen again;
5.2.2 The person in charge of the abnormality arrives at the site in time, and the improvement measures are implemented quickly and effectively (excluding temporary solutions such as process change and degradation treatment).
Note: The performance of the person responsible for the abnormal problems in the analysis and improvement of quality abnormal problems shall be summarized by the Quality Assurance Department at the end of the year and submitted to the General Manager for review, and then submitted to the Human Resources Department as the assessment item 6 of the year-end performance appraisal.
6. 1 quality abnormality tracking table 6.2 quality abnormality contact table 6.3 corrective/preventive measures report
Processes and methods for handling quality anomalies; Responsibilities of quality personnel.
1, familiar with the process flow within the controlled range.
2. Confirmation of incoming materials
3. Conduct inspection according to the work instruction (first inspection and inspection).
4. Make relevant quality records.
5. Find the abnormal quality situation in the feedback production in time, supervise the implementation of improvement measures on site and track its improvement effect.
6, special product tracking and quality records
7. Promptly remind the site to clearly identify all materials and finished products to avoid confusion.
8, timely correct the illegal operation of the operator, and urge them to work according to the work instruction.
9. Confirm the quality and identification of products transferred to the next working procedure.
Possible causes of abnormal quality
Abnormal quality on the production site mainly refers to the fact that incoming materials and self-made parts are found to be unqualified in batches or tend to be unqualified in batches during production. The reasons for abnormal quality are usually:
A unqualified incoming materials include unqualified incoming materials from previous processes and workshops.
B. The employee's operation is not standardized, and the new employee is not trained or does not meet the requirements.
C. inaccurate fixture positioning.
D. Equipment failure
E. mixing due to unclear identification
F. wrong drawings and technical documents.
General processing flow of abnormal quality
1. Judge the severity of abnormality (speak with data)
2. Timely feedback to the quality team leader and production extension, and jointly analyze the abnormal reasons (when the defective rate is high, immediately issue a notice to stop production).
3. After finding out the abnormal reasons, feedback to relevant departments.
(1) Process improvement based on incoming material feedback.
(2) Human operation factors are fed back to the production department for improvement.
(3) Machine Reason Feedback Equipment Department
(4) The process reason is fed back to the Engineering Department.
(5) Measurement error feedback measurement engineer
(6) feedback to the engineering department for unknown reasons
4. Relevant departments put forward improvement measures, and IPQC urged them to be implemented.