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1、1.Purposeandobjective 2.Processdefinitions 2.1Scope 2.2Processresponsibility 2.3Involvedfunctionaldivisions 2.4Definitions 2.5Measurables 3.0Procedure 3.1Controlplanforprototypes 3.2Controlplanforpre-launch 3.3Controlplanforproduction 3.4Productandprocesschanges,relocationofproduction 3.5Archiving 4
2、.Notesandremarks 5.Otherapplicabledocuments reviewfrom/从 date/signature 日期/签名 1.Purposeandobjective Duringproductandprocessdevelopment,everyindividualproductionstepforproductmanufacturemustbeplannedinsuchawaythat adherencetoallspecifiedproductcharacteristicsisguaranteedusingcontrolled,economicalsequ
3、ences.allplannedproduction,assemblyandtestingsequencesforaproductfromreceiptoftheproductionmaterialsthroughtodeliveryofthefinished changestodescribedproduction,assemblyandtestingsequencesareonlyintroducedfollowingpriorassessmentandapproval.Thecontrolplanismaintainedasacontrolleddocumentthroughoutthe
4、entireproductionperiodandcanconsequentlybepresentedtothecustomer/toap2.0Processdefinitions 2.1Scope ThedefinitionscontainedinthisCentralQualityProcedureareapplicableworldwidetoallAutomotivedivisionsandfactories.(seeIMSVolume1_1.3Org2.2Processresponsibility/fieldsofresponsibility Processresponsibilit
5、yforthecompilation,assessment,updating,releaseanddistributionofprototypecontrolplans(AandBsamples)lieswith Processresponsibilityforthecompilation,assessment,updating,releaseanddistributionofproductioncontrolplansforpre-launch(Csample2.3Involvedfunctionaldivisions Developmentdivisionswhichproduceands
6、upplysamplesorprototypesforcustomers(e.g.EEV,EEG,ELT)ProductionPlanning Logistics QualityManagement SupplierQualityAssurance 2.4Definitions Controlplan:seeISO/TS16949chap.7.5.1.1andAnnexA Productionmaterial:Materialwhichisusedinthemanufactureofproducts.Prototypes:Prototypesareproductsmanufacturedund
7、ertheresponsibilityofDevelopmentandsuppliedtothecustomer.Parts,componen Pre-launchproducts:Pre-launchproductsareproductsmanufacturedundertheresponsibilityofProductionPlanningfrompartsandcompo Seriesproducts:SeriesproductsareproductsmanufacturedundertheresponsibilityofProductionmadefromreleasedpartsa
8、ndcomponen Partgroups:Thisdescribespartsofasimilarnaturewhicharemanufacturedusingidenticalprocesssteps,e.g.Duroplastreflectorproduction Productfamilies:Thisdescribesdifferentvehiclemodel-relatedheadlamptypessuchasHalogen,right-handdriveversionorhalogenleft-ha Producthistory:Thisisaproduct-specificdo
9、cumentationinwhichallmajorproductandprocesschangesarelistedinchronologicalorderwith Submissionlevel PPAP,VDAVolume2PPRprocess 2.5Measurables Nonedefined.3.0Processsequence InaccordancewiththeQMplan(CP531),controlplansmustbeproducedduringtheproductdevelopmentprocess.Adistinctionmustbemadebetween:Cont
10、rolplanforprototypes Controlplanforpre-launchproducts Controlplanforseriesproducts Thesedifferentcontrolplanstakeintoconsiderationdifferentproduction,assemblyandteststepsdependingontheproductdevelopmentphase.Acontrolplancanreferto:Partgroups(e.g.Duroplastreflectorproduction)Productfamilies(e.g.left-
11、handdriveandright-handdriveheadlampsofthesametype)TheconditionforthisisthattheseareproducedwithintheframeworkofidenticalprocessesatthesamelocationandthattheyeachtakeintoconsiderationRemark1:Inthecaseofcontrolplansforpartgroups,caremustbetakentoensurethatifacontrolplanalreadyexists,therequirementsfor
12、newlyaddedproductsaretaSchematicstructureofthecontrolplan:A)Productidentificationinformationsuchas Productname,vehicletype ALitemnumberandrevisionstatusandifrequiredcustomeritemnumberandreleasestatus.ALproductionplant,(plantidentificationDUNSNo.)Authorandinvolvedteam Release(byinvolvedorganization,c
13、ustomerifrequested)Processdesignation(e.g.assembly)Typeofcontrolplan(prototype,pre-launchorproduction)B)Processstepsmustbelistedandindicated:Allproductcharacteristicsinfluencedbytheprocessandspecialproductcharacteristics Allprocesscharacteristicstobemonitoredandspecialprocesscharacteristics C)Forall
14、characteristics,themethodsandactionsforproductandprocesscontrolmustbedefined.Thisrelatesto:Targetvalueswithtolerance Testmethods Testfrequencieswithrandomsamplesize Controlmethod Recordingofresults Actionsincaseofnon-conformance,i.e.reactionplanandcorrectiveactionplan Remark1:Inthecontrolplan,specia
15、lcharacteristicsmustbemarkedwiththesymbolrequestedbythecustomer(ISOTS169497.3,2.3).IfnocustomerrequestexisRemark2:Ifrequestedbythecustomer,thecustomersformsmustbeusedfordrawingupthecontrolplan.Remark3:Onprocessacceptance/releaseofaproduct,asarulecustomersrequestsubmissionlevel3.Anagreementmustbereac
16、hedwiththecustomerregardinRemark4:Thecontrolplandoesnotreplacetheworkandinspectioninstructionsforeachindividualprocessstep.However,theircontentsformthebasisforthecontTheinspectioninstructionsdescribetheindividualtestandinspectionmethods.3.1Controlplanforprototypes Ifthecustomerrequestsaprototypecont
17、rolplan,thenthecustomersstipulationsmustbetakenintoaccountforthis.TheALstandardforprototypecontrolplanscomprisesorder-specificdocumentationwith:Sampleorder(requirementcatalogue,partslist,productionstepsinprototyping)Testsheetfortheproductsample Documentationofresults Ifapplicableindicationofthedevel
18、opmentstatus/softwarestatusforelectronics.Ifapplicableconcessionwheresampleshavetobedelivereddespitenon-conformance.Theprototypecontrolplaniscompiledandreleasedbythedeliveringdevelopmentdepartment,e.g.lightprototypebyELT,electronicprototypebyEEG,3.2Controlplanforpre-launch Thestructureofthepre-launc
19、hcontrolplanmustbedrawnupinaccordancewiththeISO/TS16949stipulations(seeAnnex1)andsubsequentproduction Thepre-launchcontrolplanmustcontaincontrolactionsandreactionplansfortemporaryproductionandteststeps.(seeAnnex1and2)Itisadmissibletoproducedifferentcontrolplansforpre-launchproductionprocessesandasse
20、mblyprocesses.Theproductandprocesscontrolmethodswhichdeviatefromproductionmustbespecified.Thepre-launchcontrolplanmustbecontinuouslyadjustedinaccordancewithadvancingproductandprocessmaturityandassignedtothesupThebasisforcompilationofthecontrolplanarefindingsfromtheFMEAs,QRCs,informationfromthedrawin
21、g,testspecifications,IMSprocedures,thetaRemark:Temporaryproductionandteststepsaredefinedasproductionandteststepsdeviatingfromproduction.(e.g.productionandtestfacilitiesnotyetreleased).ProductionPlanningisresponsibleforcompilationofthecontrolplan.Itcoordinatestherelevantcontributionstothecontrolplanf
22、romotherdivisions,suc Maintenance,e.g.preventivemaintenance,repairsofmachines,fixturesandtools Logistics,e.g.transportandstorage,incominggoods SupplierQualityAssurancee.g.inspectionplansforreceivinginspections QualityManagemente.g.productaudit,pre-launchtesting,ReleaseisperformedbytheresponsibleHead
23、ofQualityManagementfornewproducts/theQualityManagerofaplant.3.3Controlplanforproduction Onceprocessvalidationiscomplete,allproductionandteststepsfromincominggoodstogoodsdispatchmustbedrawnupanddocumentedinchronologReleaseisissuedbytheresponsible:HeadofQualityManagementintheplantand HeadofProductionP
24、lanning,Assembly/Pre-launchProduction 3.4Productandprocesschanges,relocationofproduction Thecontrolplansmustdocumentthecurrentproductandproductionstatus.Thisencompassesupdatingofthecontrolplanincaseof:Allprocesschangesand Productchangeswithrepercussionsonthecontrolplan Remark:Relocationofproductiont
25、oanewlocationalwaysconstitutesaprocesschange.3.5Archiving Allprototypecontrolplansmustberetainedforatleast3?yearsintheresponsibledepartment.Pre-launchandproductioncontrolplansmustberetainedforatleast15yearsfollowingproductiondiscontinuationintheresponsibledepartment.Inthecaseofrelocatedproduction,al
26、lcontrolplansmustberelocatedatthesametimeandkeptatthenewlocation.4.Notesandremarks Issue2:CompletelyrevisedandadjustedinlinewithISO/TS16949 5.Otherapplicabledocuments-Annex/Anlage1 Annex/附件 2:Examplesofcontrolmethods/控制方法的例子 Controlmethods/控制方法 Document/文件 Record/记录 Process/过程 Product/产品 Receivingin
27、spection/接受的检查 Inspectionplan/检查计划 Inspectionreport/检查报告 x Set-upspecifications/建立规范 Set-upplan/编写计划 Recordsautomatically ormanually/自动或人工记录 x Firstproducedpartrelease/首批生产的零部件的发布 Setterchecklist/首批生产者名单 Recordsautomatically ormanually/自动或人工记录 x x CalibrationwithGOandNOGOsamplesfortestingfacilities
28、e.g.100%leaktesting/测试设备能的例子，分为正常运行和不能正常运行 Calibrationinstruction/sample 类别划分或抽样 Recordsautomatically ormanually/自动或人工记录 x CalibrationwithGOandNOGOsamplesforemployeeinstruction.e.g.visualquality/员工指导的例子，分为能正常操作和不能正常操作的 Calibrationinstruction/sample/类别划分或抽样 Records/记录 x Workandinspectioninstructions?
29、/工作和检查指导 Set-upplan/编写计划 Trainingrecords/培训记录 x x PokaYokemethods/PokaYoke 方法 Setterchecklist/创建者名单 x x Processcontrol-Processparameters/工艺控制-工艺参数 Controlcharts e.g.Densityofflowcoatingpaint/控制图 如.流图涂料的密度 Recordsautomatically ormanually/自动或人工记录 x Processcontrol-Productparameters/工艺控制-产品参数 Controlcha
30、rts e.g.Coatingthickness,coverlenslacquering/控制图 如 涂层厚度，镜头盖喷漆 Recordsautomatically ormanually/自动或人工记录 x 100%inspectionautomatic/manual/visual(Controlmethodforprocesseswithnocapability)/全部自动检查或人工检查或视觉检查(没有能力控制工艺的方法)Inspectioninstruction/检查指导 Recordsautomatically ormanually/自动或人工记录 x x Productandproce
31、ssaudit/Produkt-undProzessaudit Auditinspectionplans/审核检查计划 Recordsmanually/人工记录 x x Productaudit/产品审核 Auditinspectionplans/审核检查计划 Recordsmanually/人工记录 x Shippingaudit/运输审核 Auditinspectionplans/审核检查计划 Recordsmanually/自动记录 x x Maintenance/维修 Maintenanceplan/维修计划 Recordsautomatically ormanually/自动或人工计
32、划 x Concessionaryrelease/特许发布 Formsheet,concessionaryrelease/表格形式，特许发布 Approvedconcessionaryrelease/批准特殊发布 x x Annex/附件 3:ExampleReactionplan:反馈计划的例子 01 NOKpartsblockandlabel NOK 零部件和标签 worker 02 Infotosupervisor 通知管理者 worker 03 Adjustandcheck 调整和审核 supervisor 04 Stopproduction,ifcauseisnottoeliminateimmediately 如果不能及时查明事件的起因，就停产，supervisor 05 xxx xxx Exampel:ControlPlan/例子：控制计划