Where do Chinese auditors look when they visit factories?

[Kanye Z]

The last stage in choosing a supplier is approving the plant where manufacturing will take place. How are factories audited in China?

[Marian Wang]

After the inspection and control of incoming materials, we will talk about the process quality control. As we all know, the production process in the narrow sense is composed of 4M1E people, machines, materials, methods and rings. We will discuss these 5 aspects separately below;

1. Human, many people say that human is the biggest variation in the process and the biggest variable in management, which is true. Under the premise that all automation can not be realized, it is particularly important to improve the ability of front-line operators and grass-roots management personnel. Each enterprise will have its own training mode. Based on the author’s experience, this paper introduces a method that I think can be called best practice;

For operators, after regular induction training, HR shall assign appropriate posts according to their age, gender, education level, etc. before the formal launch, HR shall carry out practical operation of corresponding posts in HR’s practical training room. After passing the on-site examination, HR shall file in OA system, and then transfer to the production line for operation. After being assigned to the post, The on-site team leader will arrange skilled employees (more than 3 professional skills) to carry out on-the-job OJT training to ensure that they can keep up with the online speed and can carry out independent operation. After three months of independent operation, they can apply for the examination for professional skills. After obtaining three professional skills, they will automatically enter the multi-functional library as a reserve for the front-line grass-roots management personnel;

(Note: the post allowance will be increased by 50 yuan for each professional skill tested. The specific number of professional skills can be set according to specific products and processes)

For team leaders, inspectors and other grass-roots management personnel, all grass-roots management personnel must be selected from the multi-functional library. After passing a series of training and examinations, they can apply for job transfer interviews to become grass-roots management personnel. Among them, quality related courses are compulsory courses, such as the basic concept of quality, the seven major methods of new and old QC, and SPC introduction. For team leaders, training of manufacturing grade, such as IE related courses and 5S management courses, will be added, Comprehensively improve the skills and quality awareness of front-line grass-roots management personnel from all dimensions.

After the completion of these routine trainings, continuous rolling OJT trainers are indispensable. OJT training materials come from the LLC formed by customer complaints, customer audit findings and quality accidents in the manufacturing process. This material is used for rolling training to form a long-term mechanism, so as to improve the quality awareness of on-site personnel and finally form a quality control atmosphere for all employees.

2. Machine: in the process of process design and development, formulate acceptance standards for machines and equipment, conduct CMK analysis on process parameters related to special characteristics of products, and ensure sufficient process capacity; MSA analysis is required for measuring equipment, including instrument calibration and GR & R analysis;

3. Material is controlled by incoming materials, which will not be described here;

4. Method. The method is divided into operation method and control method. The operation method is embodied in SOP. The control method is defined by the control plan and controlled by various forms on the site, such as the start of shift check OK, equipment check list, parameter check list, PQC process patrol check, etc

5. Environment in the narrow sense refers to the working environment, including the temperature, humidity, light intensity, etc. of the site

In a broad sense, the environment includes the working atmosphere and interpersonal relationship within the organization;

The purpose of inspection is to find variation. Whether it is in incoming inspection, process inspection or finished product inspection, we are all to find variation, control variation and reduce variation. Where is the largest source of variation? Every factory has its own set of methods and processes for 4m change. Based on the author’s experience in the automotive industry for many years, foreign-funded Tier1 is cautious about 4m changes. A joint-venture main engine factory has shared all its market complaints in 2019, of which nearly 70% are caused by the supplier’s change management. The author once submitted an application for changing the supplier of parts, and the main engine factory took half a year to approve it. During this period, the whole PV test verification, on-line trial assembly and new project development were almost the same.

Do a good job in the four modules of incoming inspection control, process inspection control, finished product inspection control and change management, and the whole product quality control work will be relatively perfect. How to convert the inspection data into the input for quality improvement is a topic we will discuss in the future. Quality improvement!

[Author]

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