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1、精选优质文档-倾情为你奉上Prepared: Apex HeVerified: DepartmentVerified/DateDepartmentVerified/DateProductionQualitySQDWarehouseManufacturing Engineering Approved: Date:Sandvik Mining and Construction (China)Co.,Ltd.Assembly Center (Jiading)Nonconformity Control Procedure不合格品控制程序QP-10 专心-专注-专业Modification Record
2、Rev.&Mod. No.EffectiveDateDescriptionPreparedVerifiedApprovedCommentsR00V002013-6-8New releaseFrank ZhuSee main pageDaniel J Sun/R01V002014-3-14Revised with more specific sub-processes for Repair and Main ProcessesGordon GeSee main pageVictor TengMail approvalR01V012014-7-151. Update 4: NCR Main Pro
3、cess: delete the related process for PE function;2. Add 4.2: NCM Process for Assembly Cells;3. Add 8.6: reference records: REWORK/REPAIR Instruction.Frank ZhuSee main pageGordon Ge/R01V022014-7-28Update 4.1: Add one filter for all non-supplier issue NCR which need PE do assessment first.Frank ZhuSee
4、 main pageGordon GeMail approvalR01V032016-3-8Update 4.2 Handling for Physical Non-conforming PartsApex HeSee main pageGordon Ge/1. Purpose目的建立不合格品处理的流程，明确相关的责任人，规范不合格品的正确处置方式，提高不合格品处理的效率和质量。Setup Nonconformity control procedure to clarify relevant responsibility and standardize Nonconformity parts
5、handling method then make the handling process more efficient.2. Scope范围本程序适用于山特维克矿山工程机械（中国）有限公司嘉定装配中心矿山工程机械产品的实现过程中不合格品的发现和处理。This procedure covers all nonconformity parts handling which occurs during mining and construction products production in Sandvik Mining and Construction (China) Co., Ltd. J
6、iading Assembly Center.3. Definitions定义3.1 不合格/Nonconformity：未满足要求/not meet requirement；3.2 返工/Rework：为使不合格产品符合要求而对其采取的措施/method which make Nonconformity part to meet the requirement；3.3 返修/Repair：为使不合格产品满足预期用途而对其采取的措施/method which make Nonconformity part to meet original usage purpose；3.4 报废/Scrap：
7、为避免不合格产品原有的预期用途而对其所采取的措施/method to avoid original usage purpose which Nonconformity part can cause；3.5 让步/Concession：对使用或放行不符合规定要求的产品的许可/A permission to allow Nonconformity part to continuous use；3.6 退货/Reject：指买方将不满意的商品退还给卖方的过程，一般指经过检验后或使用后，发现不能满足预期使用需求而作出的处理方式/The method to return Nonconformity pa
8、rt to supplier when after inspection or usage nonconformity part detected；3.7 退PO/Return PO：PO即Purchase Order的缩写。退PO是指对已经收货的物料进行退货处理时在系统中退除已入库订单的操作。/ PO is Purchase Order. Return PO means to return already placed order in system after good receiving while reject process handling3.8 IQC: 来料质量控制/ inco
9、ming quality control3.9 PQC: 过程质量控制/ process quality control3.10 FQC: 最终质量控制/ Final quality control3.11 Production Engineer: 生产工程师3.12 Quality Controller: 质控人员3.13 CPA: 纠正预防措施/Corrective Preventive Actions3.14 RACI(R=responsible/责任人, A=accountable/负有责任的, C= consulted/需咨询, I=informed/被告知): R= 实施任务的人/
10、Who is doing this task?A= 任务执行时相应负有责任的人/Who is accountable that this task will be done?C=进入下一步流程前，需要被咨询的人/Who needs to be consulted before we can proceed to next process stepI=需要被告知的人/Who needs to be informed (=任务被执行时需要了解这些信息的人/Who needs this information to execute their own tasks?4. Process Chart流程
11、图4.1 NCR Main Process/ NCR主流程4.1.1 RACI职责Process 过程Task description任务描述Input/Source输入/资源Output/输出RACIHandling Time Request/处理期限要求Customer/客户R=responsible, A=accountable, C= consulted, I=informed24. Update of NCR更新NCRa. Update New Actions Plan to NCR for further follow up. 更新行动项a. Information from NC
12、R Disposition.NCR处置信息Customer/客户:NCR Receiver/NCR接受人Output/输出:NCR Actions PlanNCR行动项RQC1 dayAQuality SupervisorCINCR Receivers27. Need CPA from Relevant Depts相关部门需要回复纠正预防措施a. Judge according to NCR Root cause result to confirm whether need CPA from NCR Resp Dpt.根据原因分析结果判断是否需要相关部门提交纠正预防措施b. Condition
13、 Of Request CPA:需要纠正预防措施的条件1. Safety Issue/安全相关2. Functional Issue/功能相关3. Repeat issue /重复性问题a. NCR Investigation ResultNCR调查结果b. NCR Summary ListNCR汇总清单Output: CPA Report纠正预防措施报告Customer: NCR Resp DeptNCR责任部门RQCWithin 5 days NCR Resp party submit CPA to Quality Dpt责任单位需在五天内将纠正预防措施提交给质量部AQC Supervis
14、orCINCR ReceiversProcess 过程Task description任务描述Input/Source输入/资源Output/输出RACIHandling Time Request/处理期限要求Customer/客户R=responsible, A=accountable, C= consulted, I=informed29. Whether meet NCR Close ConditionNCR是否满足关闭条件a. Check NCR whether closed according to NCR Close conditions as blow:检查NCR关闭是否满足以下
15、条件1. Failure Part Relevant Machine Fixed/不良品涉及的机器已被解决2. Initial Failure Part Fixed or Handled./初始不良品被解决或处理3. Next Batch no Repeat Issue/下一批零件没有重复问题发生4. CPA Received if requested/纠正预防措施已经收到5. Relevant Stock/WIP Failure Fixed/Handled./相关库存及在制品被解决或处理6. Claim Money Recovered for supplier Resp NCR./供应商责任
16、NCR索赔金额已取得Input:a. NCR Actions follow up resultNCR行动项跟踪结果b. CPA 纠正预防措施Source:a. Actions plan Owner行动项责任人b. QS/SS Stock DataQS/SS库数据Output:a. Close or Open of NCR关闭或开启NCRb. Updated NCR Report更新NCR报告c. Updated NCR Summary List更新NCR汇总清单Customer:NCR ReceiversNCR接受人员RQCACINCR Receivers18. Disposition of
17、NCR Part不合格品处置a. Disposition of NCR Part to avoid further unintentional use of NCR parts处置不合格品以防止不合格品不小心被使用Input:a. NCR Investigation ResultNCR调查结果b. Supplier Input供应商输入 Source:a. Quality Dpt质量部b. Supplier供应商Output:a. NCR Disposition MethodCustomer: Assembling Line产线NCR ReceiversNCR接受人RQualityWithin
18、 2 days line machine NCR need to be fixed.产线NCR导致的问题需两天内解决ACINCR Receivers4.2 Handling for Physical Non-conforming Parts不良零件处理流程*备注Comments:大件不良零件直接存放于生产站点，小件不良零件放置于不良零件架。Large non-conforming parts stored in the production station, small pieces of non-conforming parts placed in non-conforming parts
19、shelf.4.2.1QUALITY ALARM LEVELS质量预警等级QUALITY CRITERIA质量标准PART CATEGORISATION/零部件分类等级“CORE” PART/核心部件MIN/MAX PARTS/最多或最小数量KANBAN(BLUE BIN) PARTS/看板零件Quantity/数量123The proposal in the first instance is to use a simple basis for the “Quality Alarms”, using the trigger quantities in the table above.上述表格
20、中的零件数量是触发质量预警所需要达到的零件数量The suggested numbers are based upon a combination of criticality, cost and time.“CORE” PART 核心部件This is defined as the main part of the assembly process being performed. For example this would be the tank, radiator, engine etc that form the basis for all work at the work stat
21、ion. Therefore, this is likely to be a critical and expensive part. It is also likely to take some time to replace so need to be identified as soon as possible. As such, the trigger level is suggested to be 1.相应装配工序的主要零部件，例如油箱，散热器，发动机等，其为整个装配工序的主题。因此其为关键并且价值高的零件，很可能出现问题，其更换时间会较长，因此其触发等级为1个MIN/MAX PA
22、RT最小或最大零件These parts are the next in line with respect to the levels of criticality, cost and time. These are the components that are procured on a min/max basis and therefore are suggested to have a trigger level of 2.这些零件位于产线旁边。其有一个最大或最小的需求量，因此建议其触发等级为2个KANBAN (BLUE BIN) PART 看板零件These parts are t
23、he lower level, component parts which are bought in larger quantities. These will be closer to commodity items with less criticality. Therefore, it is suggested that these parts have a trigger level of 3.这些零件为低等级零部件。因此建议的触发等级为3个5. Others其它5.1 不合格品的等级区分/NCR Parts severity Level：5.1.1 不合格品可分为Minor（一般）
24、、Major（主要）、Critical（关键）三个等级。其判定标准参照表1。Therere three severity level for NCR parts: Minor, Major, Critical.表1： 不合格品等级参照表/NCR Parts Severity Level Table分级Level判定标准/Judgment Standard 安全/Safety产品功能/Function产品外观/Appearance装配/Assembly一般不合格（Minor）不影响安全No safety relevant affect不影响产品主要功能，且能很快修复No main functio
25、n affect and will recover very soon有影响，但不会导致HB或客户投诉Affection, but will not cause HB/customer claim没有影响，或有影响，但不会导致生产延误或工时损失；No affection, or affection but will not cause production delay or loss time主要不合格（Major）不影响安全No safety relevant affect影响产品主要功能，但能够很快修复Main function affect and will recover very s
26、oon有影响，但不会导致HB或客户投诉Affection, but will not cause HB/customer claim有影响，会导致生产延误或工时损失，但损失在1000元以内；Affection, will cause production delay or loss time but the loss within 1000 RMB关键不合格（Critical）影响安全Safety relevant affect影响产品主要功能，且很难或无法修复Main function affect and cant recover有影响，会导致HB或客户投诉Affection and wi
27、ll cause HB/customer claim有影响，会导致生产延误或工时损失，且损失在1000元以上；Affection, will cause production delay or loss time and the loss over 1000 RMB6. Relevant Reference Procedure/Process相关参考程序/流程文件6.1 NCR Repair Process/NCR返修流程6.2 Concession Process/让步接收流程6.3 Scrap Process/报废流程6.4 Credit Note Process/Credit Note流程6.5 Return PO Process/退PO流程6.6 Part Replacement Process/换货流程7. Relevant Reference Records相关参考记录7.1 NCR7.2 Scrap Application/报废申请单7.3 PR/采购申请7.4 REC-BUY-02 退库申请单7.5 REC-WAH-05 Stock adjustment application form7.6 REC-QA-165 REWORK/REPAIR Instruction