【正文】 Control Plan reference manual Appendix A3 69 Special Product and Process Characteristics List特殊產(chǎn)品及過程特性表 ? Upgrade preliminary list started in Phase 1 from information gathered through review and development of design features依由審查及設(shè)計(jì)活動(dòng)獲取的資訊更新初期特性表 ? Additional sources其他來源 : DFMEA, SFMEA if applicable, PFMEA, Previous history ? Must be on control plans for prototype, prelaunch and production 必須出現(xiàn)在各階段的 CP ? Listing should be a team consensus 小組共識(shí) 70 Gage and Testing Equipment Requirements 量具及測(cè)試設(shè)備的要求 ?Preliminary identification of inspection, test and measurement equipment鑑別檢驗(yàn)測(cè)試及量測(cè)設(shè)備的要求 ?Requirements on timing chart進(jìn)度表上的要求 : Complete in time to conduct measurement systems analysis, Equipment builder, Pilot build, Production trial run 即時(shí)完成 MSA,設(shè)備製造者 , 原型 , 試作時(shí)間 71 Team Feasibility, Commitment and Management Support 小組可行性承諾及管理者支援 ? Team feasibility mitment小組可行性承諾 ? Complete program review check list, including: Design feasibility, Can be manufactured, assembled, tested and packaged, Can be delivered in the right quantities on schedule at acceptable cost. 完成計(jì)劃查檢表 , 確保設(shè)計(jì)可行性 , 可製造 , 組立 , 測(cè)試 , 包裝 . 可以即時(shí)交貨 , 數(shù)量正確 , 可接受的成本 . Review design information check list in AIAG APQP Reference manual Appendix A2 as part of feasibility inputs ? Open issues that require resolution with assigned responsibility and ? Management Support: Report project status to management, Remend continue or drop project depending on feasibility, Cover open issues and concerns. Management support as required管理者支援 : 將進(jìn)度報(bào)告管理階層 , 根據(jù)可行性審查結(jié)果建議繼續(xù)或放棄該計(jì)劃 ,報(bào)告要包括問題點(diǎn)以獲取管理者支援 72 Subcontractor Pilot Build分包商的原型 ?Supplier participated, if appropriate組織的參與 ?Sample quantity required需求的樣品數(shù)量 ?Check that it is according to:Work instructions, Control plan根據(jù)什麼 ?作業(yè)標(biāo)準(zhǔn) ?CP? ?Where to be produced在哪裡做 ? 73 Supplier Pilot Sample Build 組織的原型樣品 ?Parts availability零件可獲性 ?Tooling and equipment availability模具及設(shè)備可獲性 ?Measurement equipment availability量測(cè)系統(tǒng)可獲性 74 APQP Phase 3: Process Design and Development 製程設(shè)計(jì)及開發(fā) 75 Packaging Standards 包裝標(biāo)準(zhǔn) ?From customer由客戶端來 ?Developed during prototype or prelaunch runs 在原形或量試階段就要發(fā)展 76 Product and Process Quality System Review 產(chǎn)品及過程品質(zhì)系統(tǒng)審查 ? Team must review existing quality systems manual to ensure that changes resulting from APQP (if any) are reflected小組審查現(xiàn)有品質(zhì)系統(tǒng)以確保任何更改都以更新 ? Must ply with QS 9000要符合 QS9000品質(zhì)系統(tǒng) ? Changes must be reflected in control plan將變更反映在 CP中 ? Reference AIAG APQP Reference manual Appendix A4 check list 77 Process Flow Chart 製程流程圖 ? Update process flow chart 更新製程流程圖 ? Describes current or proposed process flow描述現(xiàn)有或已提出的製程流程圖 ? Used to analyze sources of variation用以分析變異的來源 ? Helps analyze total process有助於分析整個(gè)製程流程 ? Needed for process FMEA, characteristics matrix and control plan製程流程圖製程 FMEA, 特性矩陣及 CP 的基礎(chǔ) ? Reference AIAG APQP Reference manual Appendix A6 check list 78 Floor Plan Layout廠房佈置圖 ? Determine acceptability of inspection and test points決定檢驗(yàn)及測(cè)試點(diǎn)的可接受性 ? Control chart location(s)管制圖的位置 ? Visual aides目視輔具 ? Interim repair stations (rework)中間維修站 ? Nonconforming material storage不符合品放置區(qū) ? Keyed to material flow and control plan納入物流及管制計(jì)劃 ? Reference AIAG APQP Reference manual Appendix A5 79 Characteristics Matrix 特性矩陣 ?Displays relationship between: Process parameter and Manufacturing stations顯示製程參數(shù)及製造站的關(guān)係 ?Reference AIAG APQP Reference manual Appendix B, page 82 80 製程失效模式與效應(yīng)分析 ?分析時(shí)機(jī)－在產(chǎn)品品質(zhì)規(guī)劃期間及開始生產(chǎn) ? PFMEA是分析及審查新 /變更之製程 ? PFMEA是解決、監(jiān)控在製程（新 /變更）問題的方法 ? PFMEA是日常管理工作，須隨新的模式發(fā)現(xiàn)而更新 ? APQP附錄 A7中的製程 FMEA檢查清單協(xié)助進(jìn)行其評(píng)價(jià)工作 81 Process FMEA ?To the extent possible, potential failure modes have been considered and addressed盡量去考慮可能的失效模式 ?May be started after design FMEA in Phase 2可於設(shè)計(jì) FMEA後開始作 ?Must be done prior to mitting new tools and equipment要在使用新模治具及設(shè)備前完成 ?Typically started too late通常都太晚開始 82 量試前管制計(jì)畫 ? 是說明 PROTOTYPE之後至量產(chǎn)前之尺寸量測(cè)、材料和功能試驗(yàn)作業(yè) ? 外加至量產(chǎn)驗(yàn)收前之產(chǎn)品或製程管制作業(yè) ? 管制計(jì)畫目的是包含量產(chǎn)前及初期之潛在不合格事項(xiàng)均已考量： – 檢驗(yàn)數(shù)量增加 – 更多的製程中及最終之查核點(diǎn) – 統(tǒng)計(jì)評(píng)估 – 增加稽核 ? APQP附錄 A8中的管制計(jì)劃清單協(xié)助其進(jìn)行評(píng)價(jià) 83 製程作業(yè)指導(dǎo)書 ? 目的提供足夠詳細(xì)給所有直接作業(yè)人員，且均能了解 ? 作業(yè)指導(dǎo)書可參考下列文件訂定： – FMEAS －管制計(jì)畫 – 包裝標(biāo)準(zhǔn) －製程參數(shù) – 工程藍(lán)圖、性能規(guī)格、材質(zhì)規(guī)格、目視檢查標(biāo)準(zhǔn)及工業(yè)標(biāo)準(zhǔn) – 製造 / 組裝流程圖 – 製程場(chǎng)地怖置 (LAYOUT) – 特性矩陣 – 生產(chǎn)人員對(duì)製程及產(chǎn)品之經(jīng)驗(yàn) – 製程之作業(yè) 84 量測(cè)系統(tǒng)分析計(jì)畫 ?必須完成必要儀器之量測(cè)系統(tǒng)分析 ?至少包括： – 量具之線性、精確、再現(xiàn)性、再生性及比對(duì)儀器之相關(guān)性 ?參考量測(cè)系統(tǒng)分析手冊(cè) 85 Measurement Precision 量測(cè)精度 Indicates Poor Precision 精度不夠 86 初期製程能力分析 ?針對(duì)管制計(jì)畫所定義之特性，做初期製程能力分析 ?參考生產(chǎn)性零組件核準(zhǔn)及基本統(tǒng)計(jì)技術(shù)手冊(cè) 87 包裝規(guī)範(fàn) ?確保個(gè)別產(chǎn)品之包裝（含內(nèi)層隔板）均已設(shè)計(jì)及發(fā)展出來 ?須將客戶或法規(guī)要求之包裝需求列入考慮 ?以確保產(chǎn)品經(jīng)歷打包、運(yùn)送及開包之過程，還能保持原有之性能及特性 ?所有包裝作業(yè)、物能保護(hù)所有材質(zhì)之運(yùn)搬機(jī)器，包括機(jī)器手臂 88 管理階層支持 ?必須舉行正式的審查，以提供通知高階管理者之支持與承諾 89 APQP Phase 4: Product and Process Validation 產(chǎn)品及製程驗(yàn)收 90 ? 必須用生產(chǎn)的工具、設(shè)備、環(huán)境（含作業(yè)）及時(shí)間 ? 製程驗(yàn)收是從生產(chǎn)量試才開始 ? Minimum quantity set by customer (Can be increased by team)由客戶決定數(shù)量 ? Generally 300 parts ? 生產(chǎn)量試之目的是要做： – 初期製程能力分析 – 量測(cè)系統(tǒng)評(píng)估 – 最終可行性評(píng)估 – 製程檢討 – 生產(chǎn)驗(yàn)收試驗(yàn) 生產(chǎn)量試 － 生產(chǎn)零件之承認(rèn) －包裝之分析評(píng)估 －品質(zhì)計(jì)畫確認(rèn) －試生產(chǎn)能力 91 Measurement Systems Analysis (MSA) 量測(cè)系統(tǒng)評(píng)估 ?Complete studies as defined in the MSA plan 依 MSA plan 執(zhí)行 ?Minimum are those identified in the control plan 在 CP中提及的量具都要 , 此為 minimum ?Subjected to evaluation prior to or during production trial 要在量試時(shí)或之前來做 92 Preliminary Process Capability Studies 初期製程能力分析 ? Characteristics identified in the control plan 管制計(jì)劃內(nèi)的項(xiàng)目 ? Usually 100 pieces minimum, May be 30 if run is less 最少 100 pieces, 若批量小 , 30 pieces 也可 ? Ppk = is acceptable unless otherwise specified 可接受 ? Ppk requires action plan unless otherwise specified 除非另有規(guī)定否則要有矯正計(jì)劃 ? Reference AIAG Fundamental SPC Reference Manual 93 PPAP Scope ? Production parts generally