On site quality inspection takes the production site as the object, takes the control and management of relevant factors and quality behaviors affecting product quality on the production site as the core, identifies the process through effective process, establishes quality prevention system, establishes quality control points, and formulates strict on-site supervision, inspection and evaluation system and quality improvement system, Make the process quality in the whole production process under strict control, so as to ensure that the production site can stably produce qualified products and high-quality products.
What is on site quality inspection
Implementation involves human, machine, material, method, environment and measurement. It is a systematic project. Only when human, machine, material, method, environment and measurement meet the predetermined standards can the process be stable and controlled and the product consistency be good.
Do a good job in process identification and result application
Only when the requirements and interrelationship of each process and each post are clear, can the on-site quality management be effective. Therefore, thirteen questions about the process method should be answered clearly, that is, who is the customer of this process? Who is the supplier? What do you want to output / input? What is the measure of output / input? The requirements of sub processes, resources, human qualifications, methods, indicators, etc. are clear and understood only by the process they are engaged in.
As long as the process is a little uncontrolled or unstable, the output (result) will be unstable and will never be consistent; Constantly look for opportunities to find problems and find solutions to problems; Only when the results of process identification are applied to process, control plan, post responsibility statement and post operation instruction can it play an effective role.
Establish a quality prevention system
We should establish a set of monitoring system and indicators for the whole process of product realization, so as to truly realize timely problem early warning and timely deal with closed-loop problems.
1.Identify control items and requirements: List characteristic parameters / early warning items, process parameters, control requirements and control items to be controlled according to process / process flow; Determine the list of special characteristics of products and the list of special characteristics of processes; And formulate the control plan, and formulate the operation guidance document according to the control plan (specify the applied statistical technology and method, early warning items and early warning levels). Finally, it is formed according to the process flow
List of alert items in sequence.
- Define variation / early warning: determine the variation judgment criteria or early warning benchmark conditions of each early warning item and characteristic parameter and form a document. Define when each characteristic parameter / Alert item is variant / requires alert.
- Clarify the feedback process: formulate a level by level feedback responsibility table for quality early warning, clarify how to feed back and submit in case of variation / quality early warning, limit the time and clarify the responsible person.
- Clarify the disposal and closed-loop of early warning problems: formulate the disposal and closed-loop management methods of variation / early warning problems, clarify the responsibilities of each link (hierarchical processing feedback / submission, problem disposal and closed-loop), and submit them level by level if they cannot be handled.
- Manage the work of human, machine, material, method, environment and measurement.
- Personnel (operators and operators) management.
Clarify the ability needs of personnel in different positions to ensure that their ability is competent.
Pre job training (including new employees and transferred employees) shall be provided with post knowledge and skills, post skills and relevant technical documents. Carry out equipment operation certificate training for equipment operators, and pass the theoretical examination after training; Only after passing the on-site examination of safety, equipment, process and quality and obtaining the equipment operation certificate and work license can they be qualified for the post.
(Employees with certificates must be re examined and approved after changing their posts (more than 3 months away) in order to control the quality problems caused by random post change.
For the annual examination of operation certificate, an assessment team composed of equipment, quality and process personnel shall be organized once a year to conduct an on-site examination for all post producers (test questions shall be given for each specific post before the examination). All pass and continue to work normally, otherwise they must pass the training and re examination before they can work normally.
Quality awareness training, quality problem exposure and at least two successful and failed cases every year Training and sign quality agreement. Encourage employees to participate in site management to strengthen process control and improvement
Equipment management
Establish and improve equipment accounts and equipment archives, identify key equipment, and do a good job in three-level maintenance of equipment, equipment spot inspection, technical status identification, periodic verification of equipment accuracy, pre inspection and pre repair, major repair of equipment, equipment approval of special process, statistical analysis of equipment faults, etc.
Material management (including raw materials, semi-finished products and finished products).
Raw and auxiliary materials or purchased and outsourced parts shall be inspected as qualified; During picking and warehousing, the appearance quality and protection status shall be checked, the meaning of various marks shall be clarified, and the protection and transmission of marks shall be paid attention to. Work up and down check the appearance and key dimensions of materials. Do a good job in product protection and batch management; Inspection and for test status identification, traceability identification and circulation identification, pay attention to the distinction of the identification itself, which is not easy confused and not easy to fall off, relevant personnel must ensure that they can identify the identification, and some subsequent processes are not easy to identify identification shall be added for some processes that have been processed before.
Operation method management
The operation method shall be clear, and correct, complete, unified and clear product drawings, design documents, technical standards, engineering specifications, acceptance criteria and special characteristics, DFMEA documents and equipment operation shall be provided maintenance procedures, etc. The technical process document (temporary) change (renewal) shall be subject to closed-loop management, with emphasis on change. Is the communication in place? Did you execute it? Corresponding product identification requirements and relevant rework and repair shall be implemented? What are the problems, the handling of relevant documents, the deadline for temporary changes, recycling and inspection after recycling, etc.
Work environment management
Create environmental conditions that meet production needs and meet the requirements of environmental protection and occupational health and safety requirements of laws and regulations; Do a good job in safe production, civilized production, fixed location management, process health and current production field management
Measurement control management
(1) Establish the management system of inspection and test equipment, improve the spot inspection card of measuring tools, periodic verification of measuring tools use supervision, gauge update, measurement system analysis.
(2) Implement two “three inspection systems”: self inspection, special inspection and mutual inspection; First inspection, patrol inspection and completion inspection.
(3) Process monitoring: identification of process quality characteristics and process quality inspection; Application SPC, QAS and other systems to carry out statistical analysis of quality characteristics.
(4) Full staff monitoring: control each product quality characteristic by controlling each process characteristic, ensure zero defect of each part through zero problem of each product quality characteristic, and ensure zero fault of each complete machine with zero defect of each part. Formulate the detailed list of division of labor for full staff monitoring of process to clarify the monitoring content, monitoring frequency and evaluation frequency, Responsible person and position. Improve the control plan and three accounts, namely tooling account, equipment account and quality account.
Product and process validation
Product and process confirmation shall be done before batch production, including product full-scale inspection, reliability test, process verification, production capacity, process capacity, operator, etc.
Process evaluation and incentive
Establish a quality index control system, from product technical and economic indicators to post responsibility system, from statistical methods, assessment contents to reward and punishment system, which must reflect the idea of implementing quality management requirements and improving execution, enrich the content of on-site quality responsibility system, refine quality indicators, promote individual monthly post quality evaluation system, and clarify quality assessment regulations, Implement immediate employee incentive and quality contribution (star staff)
Incentives and other measures. There is a long way to go to improve the on-site quality management level and ensure product consistency. In order to implement this work, many methods will be applied, involving the whole product realization process. We believe that as long as we start from the most basic process and implement the requirements of each small process, the system will be in charge the consistency of our products will be better.