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1、QC Training Version 2005-1.00nAbout The Silk Road Design Company.LTDn规章制度 Principlen验货注意事项 Inspection notes n各类产品特点 Attribute of variety productnQuality issue in former ordersnCustomer special requirementnEndThe Description ofnDesign&Create new products for our Blue Chip Customers,n(Including major
2、multiples e.g.M&S,Harrods,Tesco,Sainsburys),nand manage total Logistics Solutions from manufacture through to delivery.有关差旅费及相关费用报销规章制度n1.仅在以下情况下，允许搭乘计乘车：nA）从深圳去外地出差，如需要赶乘早上9：00前的飞机，或回程到达深圳的时间已晚于20：00nB）如确实因无供应商接送时，在短途本区范围内.nC）在深圳或附近地区，去程可搭乘计程车，返程如晚于18：00，离开工厂经征得负责人同 意后，方可搭乘计程车。n2.所有相关差旅费用票据，均必须能真实反
3、映所在地点事实所发生费用情况，所有发票必须是正规票据，否则，不予报销。如经查证，报销费用中有虚报、多报等不属实行为，则所发生费用不予报销，且公司将有权对此种行为做出实质性惩罚。n3.出差至深圳以外的地区给予出差津贴每天RMB50.00元。因QC工作同货物出运时间紧密相连，如遇节假日.周末，公司有工作安排，如无特殊原因，应服从公司安排。属加班时间，公司支付双倍出差津贴每天RMB100.00元。（如节假日已按劳动法规定给予加班工资的.不给予出差津贴。）n4.出差时间是在下午离开深圳的，没有当天出差津贴。返回时间是在上午到达深圳的，没有当天出差津贴。n5.公司已有手机费用补贴，故享有此待遇的员工，必
4、须保证公司能随时联络上本人，除非遇非人力不可抗拒的原因（如信号不良），公司将不追究责任。n6.绝对不允许出现收工厂红包等受贿行为。n备注：如手机费用超标，只要能提供电话清单证实其是因为公事而产生的，公司将给予报销超出部分。QC 验货注意事项一.离开办公室去验货之前要和QC经理和/或主管回顾产品的要点.n1.确认产品的材料,颜色,尺寸.n2.挑出正确的样板并随身携带.n3.带上数码相机及数据传输线、湿度计等必备工具。带上与产品相关的文件资料以及英国、供应商往来的有关产品的邮件,如有必要叫上开发部的同事一并讨论.n4.出发前与工厂确认产品的数量和生产程度是否达到我司验货要求.二.IPC&DUPRO
5、nIPC-生产刚刚开始的时候,染色产品在染色刚刚开始的时候.nDUPRO-20%-30%成品的时候 IPC&DUPROn1.检查成品的材料,颜色,尺寸是否与 contract SPEC 要求的一致；n2.验货数量:IPC:最少检验数量不少于125PCS,数量不到125PCS时必须全检.DUPRO:按CONTRACT SPEC 的要求；n3.对产品出现的问题和可能出现的问题立即与工厂或供应商协商如何解决,并出书面的解决方案(QC 和工厂代表签字),复印一份留给工厂并上报公司和供应商.如颜色,材料不能确认的要及时寄样回公司确认,并等待公司下一步指示；n4.确认内包装,并拍摄内包装图片；n5.在验货
6、过程中出现的问题要统计:验货样本数,发现的问题点,在样本数中所占的比例等等并上报公司QC部；n6.与工厂和供应商核对DUPRO或/和FRI 时间,并将结果上报QC部；n7.与工厂或供应商对工厂具体的交货期以及船期,对有可能出现的船期要及时上报公司船务部；n8.无论任何情况下都必须出正式的验货报告并向公司和/或供应商传真验货报告并电话向公司请示下一步工作安排，否则不能离开工厂。三.FRIn1.FRI 产品100%完成,80%包装好n2.验货的时候要特别注意产品的颜色。n3.如果定单是分批出的（后续还有产品出货），要给工厂写整改意见，并且要工厂或供应商签字以代表工厂或供应商接受我司的整改意见并在生
7、产中会避免此类问题再次出现。n4.向公司和/或供应商传真FRI报告，并电话向公司请示下一步工作安排。否则不能离开工厂。n5.出货后要带至少1PCS SHIPPING SAMPLE回公司。四.测试n1.防水测试 数量：（包括各类花园产品和陶瓷、玻璃产品）一般为定单数量的5-10%。时间：陶瓷类为48小时，其它为6小时。防水里布厚度必须不得小于0.04MM。（包括我司要求加双层里布的产品）。n2.摔箱测试 我司要求供应商或工厂提供的包装必须能够保证产品在运输途中不会被损坏。我司QC在工厂要做摔箱测试，摔箱具体标准如下：6 surface/3 edge/1 corner六面/三边/一角 -120 L
8、BS/30 Inch 即外箱毛重为1-9KG摔箱高度为76CM -2140 LBS/24 Inch即外箱毛重为9.1-18KG摔箱高度为61CM -4160 LBS/18 Inch即外箱毛重为18.1-25(20)KG摔箱高度为46CM 摔箱结果：产品不能损坏，外箱不得有破损、裂开等现象。五.Sample Review in Officen1.根据CONTRACT SPEC 填写SAMPLE CHECK RECORD。n 2.根据ORDER要求的数量挑选出有代表性的样品寄给英国（如果是PP SAMPLE则AO 最少应该留两个样品）。n 3.如发现颜色、形状、尺寸不对应该立即与质量经理商量。n
9、4.复印Sample check record一式三份，一份随样品寄到英国，其余两份分为A、B分别放入文件夹。n 5.填写AO27 Sample movement sheet.n 6.向工厂或供应商反馈所发现的问题并与工厂商量如何在生产中避免，如实在无法避免应该立即向质量经理汇报。六.其它注意事项 n1.对产品的颜色，材料有疑问时，一定要快递样品回公司确认，决不可以囗头或书面直接给工厂确认。绝对不能直接给工厂签板，客人确认的样板在公司允许的情况下为了方便工厂更好的核对产品颜色可以留在工厂，不过产品上必须签字（不是在挂牌上），并让工厂小心保护样品，不能有样品被污染或丢失的现象发生。n2.验货过程
10、中不可与工厂发生激烈争吵，如发生协商难以解决的问题，可以与供应商沟通，如还不能解决，可向公司汇报。由公司QC部门与供应商协商解决。n3.QC report Page 1&4 要有工厂或供应商的签名,特别是第四页有整改意见时。n4.出货时，必须是我司安排的QC或其他检测机构在做完FRI检验后，由QC或第三方检测机构出具合格的检验报告并将检验报告传真回公司，在经我司质量经理审核后电话通知供应商/工厂或我司QC，货物才能装柜。n5.若同时带着几个订单的样品，一定要封包好，最好不要把不相关的样品带到工厂去。n6.周末有验货任务时，同样需要向QC经理或主管电话报告进展。各类产品特点各类产品特点1.天然物
11、料2.陶瓷3.五金4.玻璃5.皮革6.玩具7.装饰品8.蜡烛9.印刷品10.灯具藤藤/柳柳/芒芒/草草/竹等工艺品生产流程及竹等工艺品生产流程及验货要点验货要点The Producing Procedure&Quality Checking Points-Rattan/Willow/Fern/Grass/Bamboo生产流程Producing Procedure l备料raw material incoming（防霉防虫处理/mould&insect prevention）l剪料/material cutting l编织成型woven&formedl修剪trimmed l效果处理finish（
12、染色dying/刷色等brushing etc）l返修re-inspecting&repairing l烘干baking l装配assembly l包装packingl熏蒸fumigation（溴甲烷/24小时lasting at least 24 hrs）l出货shipment备料备料raw material incoming(防霉防虫处理防霉防虫处理/mould&insect prevention)编织成型编织成型woven&formed效果处理效果处理finish(染色染色dying/刷色等刷色等brushing/抹色抹色washing etc)验货要点Quality Checking
13、Pointsl材料的质地/色泽/粗细/the nature,color,dimension of the raw material l尺寸/sizel颜色形状/color&shapel效果处理/finish&effectl湿度/humidityl平稳度/stabilityl刮手/splinters or sharp pointsl漏水/leakagel如与食品有关相关的化学药品或试剂/the relevant chemicals if be of foodl断裂/broken piece l虫眼/虫尸/生虫/worm hole/dead worm body/live worm陶瓷工艺品生产流程
14、及验货要点陶瓷工艺品生产流程及验货要点The Producing Procedure&Quality Checking Points-Porcelain-ware 生产流程 Producing Procedurel备料（陶土入厂）clay incoming l碎料clay mashing l开模（泡沫模或石膏模）molding or tooling/浇注成粗胚shaping l煅烧calcine（920-980）l效果处理finish（手绘hand-painting/喷漆spraying/釉烧decal(1000-1050等）l返修re-inspecting&repairing l烘干baki
15、ng l装配assembly l包装packing l出货shipment验货要点Quality Checking Pointsl尺寸/sizesl颜色形状/color&shapel效果处理/finishingl重量/weightl平稳度/stabilityl刮手/sharp edgel漏水/leakagel裂痕/crackingl模线/molding markl杂质/other objectsl手印/finger markl污渍/dirty markl刮伤/scratching 特别要求特别要求l漏水检测应对（窄口花瓶更应特别小心）l测试数量须是订单数量的5%，特殊情况另定。l测试时间需至少
16、连续48小时。lPPS及 PS须在SZ OFFICE做过测试后再寄 UK OFFICEl测试时产品底部须垫白纸注水高度为产品内量垂直高度的2/3。l抽箱时须做到“随机”从不同层面抽取以确保验到非连续性的生产批次。l必要时须选取工厂废品或次品砸开观察其内表面是否都有釉层及防漏油层。l必要时亦可用电子称重法对比测试前后产品本身的重量是否有较为明显的增重变化 l色差-须请客人签回至少3份可接受色差样（偏浅OK-标准OK-偏深OK）。lONE-FOR FACTORYlONE-FOR SZ OFFICElONE-FOR UK OFFICE 五金工艺品生产流程及验货要点五金工艺品生产流程及验货要点The
17、Producing Procedure&Quality Checking PointsHard-lines 生产流程 Producing Procedure（冲压类/metal sheet）l备料raw material incoming l剪料material cutting l模具成型molding&shaping l效果处理finish（抛光polishing/喷沙sand basting/印刷printing/电镀electric-plating/喷漆spraying/喷粉coating等）l返修re-inspecting repairing l装配assembly l包装packin
18、g l出货shipment生产流程Producing Procedure（铁线类/wire）l备料raw material incoming l剪料material cuttingl弯型bending/焊接welding/打磨(?grilding)/成型shapingl效果处理finishing(喷漆spraying/喷粉coating/手绘hand-painting/电镀等electric-plating etc）l返修re-inspection&repairing l装配assembly l包装packing l出货shipment 验货要点Quality Checking Pointsl
19、尺寸/sizel颜色形状/color&shapel效果处理/finish&effectl重量/weightl平稳度/stabilityl沙眼/tiny hole l刮手/sharp pointl功能等/function玻璃工艺品生产流程及验货要点玻璃工艺品生产流程及验货要点The Producing Procedure&Quality Checking Points Glassware生产流程 Producing Procedurel备料/配比 raw material incoming&ratio/l化料/熔炉material melting l吹制或机压mouth blowing or m
20、achine pressing l冷却成粗胚cooling to be semi-products l火切或水切firing cutting or watering cutting l磨平grindingl清 洗cleaning l效果处理finish&effects（酸洗/喷沙sand blasted/烧花pattern decal/马赛克mosaic/手绘hand painted/喷漆等spraying etc）l返修re-inspecting&repairing l烘干baking l装配assembly l包装packing l出货(shipment)化料化料/熔炉熔炉material
21、 melting 出货出货shipment验货要点Quality Checking Pointsl尺寸/sizel颜色形状/color&shapel效果处理/finish&effectl重量/weightl平稳度/stabilityl刮手/hand-hurtingl漏水/leakagel冰裂/crackl气泡/bubblel杂质/foreign materiall厚度/thickness on wall&bottoml模印/mold markl刮伤/scratch皮革工艺品生产流程及验货要点皮革工艺品生产流程及验货要点The Producing Procedure&Quality Checki
22、ng Points-Leather Crafts 生产流程 Producing Procedurel备料raw material in comingl纸样paper pattern/剪料cuttingl车缝/刺绣stitching or sewing or embroidery l打胶滚胶gluingl贴合成型combined&shapedl油边定型edge heating&formedl清洁cleaningl返修re-inspecting&repairing l装配assembly l包装packing l出货shipment验货要点Quality Checking Pointsl尺寸/si
23、zel颜色形状/color&shapel效果处理/finish&effectl异味/odd smellingl平稳度/stabilityl刮手/rough edgel脱胶/poor or loose gluingl涨气/air in feltl刮伤/scratchingl胶斑/glue markl车线颜色及车法/thread and stitchingl皮料（头层皮/二层皮/合成皮/pu/pvc）/material using(genuine leather/spilit leather/bonded leather/pu/pvc)玩具类工艺品生产流程及验货要点玩具类工艺品生产流程及验货要点
24、The Producing Procedure&Quality Checking Points.Toys生产流程生产流程Producing Procedure毛绒布料毛绒布料fabric or coatlines l备料选料raw material l样裁料paper pattern&cutting l车缝seam/刺绣embroidery/花边lacel填充stuffingl修剪trimming l装配assembly l包装packing l出货shipment生产流程生产流程Producing Procedure塑胶类塑胶类plastic/vinyl linesl备料raw materi
25、al l成型moldl效果处理(喷漆/喷粉/手绘/电镀等）（喷油/喷粉/喷沙/电镀/印刷等）Paint/satinfinished/electroplate/print l返修re-inspected&repair l装配Assembly l包装packing l出货shipment验货要点Quality Checking Pointsl颜色形状/color&shapel车线车缝/thread/seam&sewingl异物（针头等）/foreign objects(such as needle)l布标/sew in labell拉力测试/pulling testl（喷油/喷粉/喷沙/电镀/印刷
26、等）Paint/satin finished/electro-plate/printl5)平稳度stability:stand on the horizontal,the goods could not be incline or l刮手/批缝sharp edge/flash/burl功能等functionl安全测试/safety test装饰品验货注意事项装饰品验货注意事项 Decorationl1 PICK-材料为竹的PICK直径不得小于6MM。不能有尖头，包括插入产品内部的那端。l -材料为铁线的PICK的尾部必须加胶球。l2 类似玩具的公仔-按玩具的要求检验。l例如：必须要求过针机测试
27、。l 眼珠、针缝必须要求拉力测试。l 毛绒类产品毛绒的拉力测试等等。蜡烛验货注意事项蜡烛验货注意事项 Candlel变形 Deformed shape l尺寸 Sizel色差 Colour deviationl彩绘，丝印 Painting,Silk screen 彩绘的质量、颜色和位置 Quality、Colour&locationl烛芯长度和粗细 Wick length&thicknessl混杂在蜡中的脏物、异色、杂质 Dirty/Colour/Foreign material mixed inside waxl凹痕 Dent markl破损、裂缝、缺口、刮痕 Broken/Crack/Ch
28、ip/Scratchl香味 Fragrance印刷品验货注意事项印刷品验货注意事项 Printing&Labell1 条形码是否正确。必须用条形码扫描仪进行扫描。扫描数量每款不得少于验货样品数量的50%且要随机抽取样本。l2 价格标上的英文、单价是否有错误（critical）。l3 检查标签的粘度是否符合要求（高、低粘度）。l4 纸的材质、表面的颜色。l5 打孔的位置，离边的距离不能太近。l6 折线孔的位置与折线是否一直。l7 检查刀线位置是否正确，及标签是否容易从整版中撕出。LED灯验货注意事项灯验货注意事项 Lightl1 核对产品上的CE label是否正确，如有必要要查看工厂CE la
29、bel证书。l2 检查灯光的颜色。核对电线的颜色。l3 电池盒内部的金属件是否有生锈现象。连接是否牢固。塑料盒身是否有尖点、利边。水口的修剪情况。外表面是否有 粗糙面。l4 电线与灯座的连接是否牢固。l5 深圳办公室-必须要求工厂提供该款产品的CE认证证书。必须要求工厂提供LED灯寿命的实验报告、电线与灯座的拉力测试报告等相关工厂内部做的实验报告。Quality Issue In Former OrdersW2585nBaskets have been packed in such a way that the tops of the handles are touching the tops
30、 of the handles on the other basket.nAs a result,the handles have rubbed together in transit.The result is that this has rubbed all the stain away leaving an area about 5 cm in length of exposed natural wood.nCustomer employed a crew to repair total 2548 single baskets.nTotal Cost to be invoiced to
31、Silk Road 3100.00+vat.70%is on suppliers account.LessonnWe need to always check the method of packing and whether there is any potential risk to the product.Apparently there is nothing wrong with the quality of the basket at all-customer is really very happy but the packaging has let down the produc
32、t.nWe need to discuss with the supplier at a very early stage so that any problems will be highlighted and can be corrected before the goods arrive in the UK.R2592 Part 2nMiss Shape As customers feedback,construction issues were found in 9 out of 12 samples.Product did not conform to:-top external(n
33、arrowest face)-top internal(narrowest face)And this is a critical issue.The customer claimed for 13113 pieces.LessonnWe must be more careful about the design hazard.NPD team should cope with QC team closely in the future.nWhen we find major defect during inspection,we can try to send a range of samp
34、les or pictures to show the customer and get their confirmation.R2593 Part 1nRed Wicker The customer claimed for 3243 pieces.The reason for the claim is because they had a red band through the middle of the body of the basket&they were rejected by the customer.nTotal claim is:n3243.00-baskets unsold
35、n907.21 labour for gradingn250.00-to hire skip to dispose of basketsnTotal 4400.21nSupplier share 50%Lesson We must insist our position,do not succumb to the pressure from supplier.R26341.Sharp End InsideContract spec clearly states:Critical:Flat Ends(ends must be flat inside&outside the pick)2.Glit
36、ter Peeled OffDue to improper design and insufficient inner packingLessonnWe must be certain as a group to ensure that we do not let any product through if something is noted as a critical defect.nConduct inspection against contract spec carefully,if there is any doubt about the spec being correct,c
37、ontact office immediately.nPay attention on inner packing.R2671n50%goods got moldy.nMoisture checked in FRI was 8-14,customer checked the moisture on moldy basket was 16.nDidnt put silicon gel sachet in carton.LessonnAlthough this case is doubtful,but to place silicon gel sachet for some material wh
38、ich is prone to mould is always a good solution,for example:unpeeled willow,cattail.W2704nColour Deviation Obvious colour deviation existed in same shipment.50%goods is pale pink and another 50%is strong pink.LessonnSupplier will try their best to dissuade us but this will be for their own reasons n
39、ot for ours,dont let their words to cloud our judgment.nAlways report any issue found in inspection.R2711n2 critical,58 major&44 minor found from 200 samples in FRI.Case review:Our QC had stayed at factory for some days before Nandys visit,if Nandy didnt go to factory,he would just check 1-2 cartons
40、 goods,because he had checked many baskets when they were in production and had advised factory to improve the problem he found,he also didnt tell the factory very clear that he would check the goods again before cargos shipped out,factory had loaded the cargos on the truck when Nandy arrived factor
41、y.But after conducted a formal FRI,half of goods were rejected.LessonnA formal FRI must be conducted if the goods have not been 100%checked&packed,whatever we have stayed at factory for how long and how many goods have been checked in production.nA clear instruction should be given to factory,includ
42、ing our quality standard and inspection process.nWhen factory is not willing to cope with our QC working,supplier should be informed and involved.R2721nSharp PointnCase review:As the wire on base inside is protruding and it will damage the soft fruit packed inside,so we suggested factory to remove i
43、t;But remainder of wire at weld which is sharp was not noticed in FRI,this critical issue was found in production sample,a re-FRI was conducted thereby,and 100 baskets with this issue were scanned out.LessonnDont trust factory too much,check everything carefully.Customer Special Requirement Customer
44、#1nCarton gross weight must not be more than 20kg basketware and 25kg ceramic.Customer#9nShipping marks must be on all four sides of carton.Customer#38nHave special shipping marks and should be on 4 sides of carton.nNO SRD special tape to be used on his cartons.nThere is special sample label for#38.
45、Customer#39nWe have to provide details of the weight of materials used for our outer packing.This must include cartons used for all orders delivered to the customer#39.nFor each order we need to identify the number of cartons used,the weight of each carton and the cumulative total weight of cardboar
46、d per order.nAfter listing the total weight of cardboard for each order we then need to provide a total annual weight in tons.nEvery year customer#39 sends us a packaging materials report to fill in.nThis is a requirement by the Scottish Protection Agency to provide information about the packers use of a variety of materials.nOne of these materials is Paper/Cardboard.Thank You!Bye!