試制零件質(zhì)量控制流程SGM版100201.doc

TS-090-0051.0008/10/2010試制零件質(zhì)量控制流程Pre-production Part Quality Procedure1. 目的規(guī)范試制零件質(zhì)量控制過程，確保試制零件質(zhì)量滿足工程樣車試制活動要求。2. 適用范圍適用于樣車試制科進(jìn)行的各階段(包括IV/IVR/IV2/OTS等)工程樣車試制活動中所涉及的試制零件。3. 權(quán)責(zé)3.1 試制質(zhì)量工程師：負(fù)責(zé)整個PPQP活動、跟蹤并審核試制關(guān)鍵零件、抽檢試制非關(guān)鍵零件、負(fù)責(zé)交樣文件的歸檔工作。3.2 試制物料管理員：審核交樣文件并接收物料。3.3 試制計劃工程師：接受并批準(zhǔn)試制零件清單更改申請。3.4 設(shè)計發(fā)布工程師：支持并參與整個PPQP活動、跟蹤并審核試制零件狀態(tài)。3.5 子系統(tǒng)認(rèn)證工程師：跟蹤試制零件的試驗進(jìn)度并審核零件試驗認(rèn)證狀態(tài)。3.6 材料工程師：確認(rèn)試制零件的材料符合設(shè)計要求。3.7 供應(yīng)商質(zhì)量工程師：確認(rèn)分供方/材料信息的真實性，及尺寸檢驗的真實性（PT零件除外）。3.8 SMT高級經(jīng)理：幫助設(shè)計發(fā)布工程師對存在偏差的零件進(jìn)行偏差認(rèn)可。3.9 項目尺寸經(jīng)理：負(fù)責(zé)制定試制關(guān)鍵零件清單及過程控制計劃。4. 定義 4.1 PPQP: 試制零件質(zhì)量控制流程4.2 PDT: 產(chǎn)品開發(fā)小組4.3 ADVP&R: 認(rèn)證計劃及報告4.4 SVE: 子系統(tǒng)認(rèn)證工程師 5. 相關(guān)文件5.1 T&V-ISO-WI-37 試制物料控制流程5.2 T&V-ISO-WI-38試制BOM生成及維護(hù)流程6. 記錄6.1 試制零件清單6.2 試制零件清單更改申請表7. 程序內(nèi)容7.1 流程圖試制零件質(zhì)量控制流程（詳見附件1）。7.2 流程描述7.2.1 試制計劃工程師負(fù)責(zé)維護(hù)試制零件清單，接收并審核試制零件清單更改申請表。7.2.2 設(shè)計發(fā)布工程師在釋放零件時需明確每個零件來源的信息，包括借用件、采購件等以及該零件在工程認(rèn)可流程中的狀態(tài)。7.2.3 生成需要PPQP認(rèn)證的試制零件清單。7.2.3.1 試制質(zhì)量工程師根據(jù)需要PPQP認(rèn)證零件的識別原則，結(jié)合零件來源、狀態(tài)等信息生成需要PPQP認(rèn)證的零件清單。7.2.3.2 需要PPQP認(rèn)證零件的識別原則: 未通過工程認(rèn)可的零件 開發(fā)過程中的緊固件（包括螺栓、螺母、螺釘?shù)龋?PT PPO自行采購的其他類零件7.2.4 生成PPQP試制關(guān)鍵零件清單7.2.4.1 項目尺寸經(jīng)理組織試制質(zhì)量工程師及各SMT代表等在BOM凍結(jié)前根據(jù)項目關(guān)鍵零件清單（附件4）討論確定試制關(guān)鍵零件清單。7.2.4.2 試制關(guān)鍵零件的識別原則： 由于質(zhì)量問題可能造成PPO停線的零件 由于質(zhì)量問題可能造成試驗延誤的零件 由于質(zhì)量問題可能造成GCA較大分值(分值10)的零件 供應(yīng)商能力或口碑較差的零件7.2.5 制定試制關(guān)鍵零件的過程控制計劃7.2.5.1 關(guān)鍵零件評審小組包括：設(shè)計發(fā)布工程師、試制質(zhì)量工程師、供應(yīng)商質(zhì)量工程師、材料工程師、尺寸工程師、子系統(tǒng)認(rèn)證工程師等。7.2.5.2 評審小組制定關(guān)鍵零件過程控制計劃： 前期過程控制采用定期開會形式,評審小組定期組織供應(yīng)商開會討論模具、檢測設(shè)備、檢測方法、生產(chǎn)進(jìn)度等進(jìn)展情況。 后期過程控制采用現(xiàn)場零件驗收形式，評審小組走訪供應(yīng)商，現(xiàn)場審核零件狀態(tài)、檢測結(jié)果、文件準(zhǔn)備情況等。7.2.6 試制質(zhì)量工程師根據(jù)零件的特性及供應(yīng)商的能力等因素在試制非關(guān)鍵零件清單中以一定的比例抽取零件，形成試制非關(guān)鍵零件的抽檢清單。7.2.7 評審小組確定零件檢測方法及內(nèi)容： IVER階段: 測量方法（以模代檢、三坐標(biāo)、檢具、白光等），測點圖，認(rèn)證計劃等由供應(yīng)商負(fù)責(zé)編寫，由PATAC審批。 OTS階段:測量方法、測點圖，認(rèn)證計劃等由SGM輸入給供應(yīng)商7.2.8 供應(yīng)商生產(chǎn)零件7.2.8.1供應(yīng)商嚴(yán)格按照SOR中的要求按時、高質(zhì)量地生產(chǎn)出零件。7.2.8.2 供應(yīng)商在生產(chǎn)過程中遇到問題，應(yīng)及時與評審小組有效溝通。7.2.8.3評審小組成員積極幫助供應(yīng)商解決問題，克服困難。7.2.9 供應(yīng)商檢驗零件 7.2.9.1 供應(yīng)商按照評審小組既定的檢測方法進(jìn)行檢驗工作，檢驗工作包括以下3方面： 零件尺寸檢測： 供應(yīng)商按照評審小組確定的測量方法及測點圖進(jìn)行檢測。 材料性能檢測：a 提供材料質(zhì)保書b 供應(yīng)商在不能夠提供材料質(zhì)保書的情況下，需要進(jìn)行材料性能試驗，并提供性能試驗報告。 零件性能試驗： 供應(yīng)商按照子系統(tǒng)認(rèn)證工程師確認(rèn)的認(rèn)證計劃進(jìn)行零件性能試驗。7.2.9.2 供應(yīng)商在檢驗過程中遇到問題，應(yīng)及時與評審小組有效溝通。7.2.10 供應(yīng)商制作交樣文件7.2.10.1 供應(yīng)商按照泛亞提供的交樣文件模板制作交樣文件，交樣文件模板見附件7-13。7.2.10.2 供應(yīng)商將零件生產(chǎn)、檢驗等相關(guān)數(shù)據(jù)真實、準(zhǔn)確、完整的填入交樣文件模板中。7.2.10.3 供應(yīng)商將相關(guān)的原始檢驗報告（包括測量報告、材料報告和試驗報告等）附在交樣文件中一并提交。7.2.11 零件首次交樣7.2.11.1 試制關(guān)鍵零件，評審小組去供應(yīng)商現(xiàn)場驗收零件，驗收內(nèi)容包括: 零件狀態(tài): 確保零件狀態(tài)符合數(shù)模要求。 檢測方法及檢測結(jié)果:確保供應(yīng)商采用的檢測方法與評審小組制定的檢測方法一致,并分析檢測結(jié)果。 交樣文件的準(zhǔn)備情況:確保所有必需的信息都在交樣文件中體現(xiàn)。7.2.11.2 試制非關(guān)鍵零件, 供應(yīng)商按照SOR自行評審零件狀態(tài)。7.2.12 零件非首次交樣7.2.12.1 交貨理由有: a. 追加數(shù)量 b. 差錯糾正c. 工程更改7.2.12.2 對于差錯糾正和工程更改兩類零件，需要重新評審該批零件的狀態(tài)。7.2.12.3 根據(jù)不同的交貨理由，準(zhǔn)備不同類型的交樣文件。a. 交貨理由為追加數(shù)量，需要提交供應(yīng)商產(chǎn)品質(zhì)量保證書并更新認(rèn)證計劃及報告。b. 交貨理由為差錯糾正，需要提交供應(yīng)商產(chǎn)品質(zhì)量保證書以及與 差錯糾正相關(guān)的文件，并更新整改計劃及認(rèn)證計劃及報告。c. 交貨理由為工程更改，需要提交供應(yīng)商產(chǎn)品質(zhì)量保證書以及與 工程更改相關(guān)的文件，并更新整 改計劃及認(rèn)證計劃及報告。7.2.13 評審小組根據(jù)附件2中合格件的標(biāo)準(zhǔn)，判斷該零件是否為合格件。7.2.14 對于不符合合格件標(biāo)準(zhǔn)的試制零件，評審小組幫助供應(yīng)商查找不符合項的根本原因，制定整改計劃。7.2.15 評審小組根據(jù)附件2中臨時認(rèn)可件的標(biāo)準(zhǔn)，判斷該零件是否可以臨時認(rèn)可。7.2.15.1 評審小組有條件接受存在缺陷的零件將視為“臨時認(rèn)可件”用于試制造車活動。評審小組需督促供應(yīng)商按照整改計劃要求進(jìn)行后期整改，并在時間節(jié)點前提供新狀態(tài)的樣件。7.2.15.2 評審小組不可接受存在缺陷的零件，供應(yīng)商需重新安排生產(chǎn)、檢驗工作。待零件完成后,評審小組需再次評審零件，直至評審小組能接受該零件。7.2.16 交樣文件的簽署7.2.16.1 評審小組接受零件狀態(tài)后（包括合格件與臨時認(rèn)可件），對交樣文件進(jìn)行簽字確認(rèn)（簽署要求詳見附2）。7.2.16.2 高級經(jīng)理對不符合附件2中最低尺寸要求及試驗失效的零件進(jìn)行缺陷認(rèn)可。7.2.17 供應(yīng)商在交樣零件上掛上泛亞規(guī)定的標(biāo)牌，將交樣零件與交樣文件一同按照采購訂單上規(guī)定的貨地點發(fā)運。7.2.18 PPO物料管理員審閱交樣文件是否完整且已被簽署。7.2.18.1 交樣文件完整且全部簽署完畢, PPO倉庫管理員清點交樣零件數(shù)量，辦理入庫手續(xù)。7.2.18.2 交樣文件不完整或未全部簽署完畢，PPO倉庫管理員將拒絕接受物料，供應(yīng)商負(fù)責(zé)將零件運回，待交樣文件完整且全部簽署完畢，再重新交樣。7.2.19 試制質(zhì)量工程師根據(jù)試制非關(guān)鍵零件抽檢清單，辦理相關(guān)零件的出庫手續(xù)，進(jìn)行抽檢工作。7.2.20 試制質(zhì)量工程師將抽檢結(jié)果與交樣文件進(jìn)行對比。7.2.20.1 抽檢結(jié)果與交樣文件上相關(guān)數(shù)據(jù)一致，零件可進(jìn)入制造現(xiàn)場并辦理交樣文件的存檔手續(xù)。7.2.20.2 抽檢結(jié)果與交樣文件上相關(guān)數(shù)據(jù)不一致: 首先，隔離已交樣的零件； 其次，供應(yīng)商查明原因且填寫整改計劃； 然后，相關(guān)工程師對零件進(jìn)行認(rèn)可，認(rèn)可通過后，零件方可進(jìn)入制造 現(xiàn)場； 最后，PPO試制質(zhì)量工程師將相關(guān)問題反饋給SQE,SQE協(xié)助推動供應(yīng)商進(jìn)行整改。7.2.21 試制質(zhì)量工程師負(fù)責(zé)PPQP文件的歸檔工作。 8. 附件附件1：試制零件質(zhì)量控制流程附件2：合格件/臨時認(rèn)可件的標(biāo)準(zhǔn)附件3：文件簽署要求附件4：項目關(guān)鍵零件清單附件5：試制零件清單更改申請表附件6：交樣零件標(biāo)簽?zāi)０甯郊?：檢查清單附件8：供應(yīng)商產(chǎn)品質(zhì)量保證書附件9：零件尺寸檢驗報告附件10：材料審核報告附件11：材料及分供方清單附件12：整改計劃附件13：認(rèn)證計劃及報告1. PurposeThe procedure is documented to standardized pre-production part control process, to ensure pre-production part adequately meet pre-production operation requirement.2. ApplicabilityIt is applicable to the parts which are being used in pre-production operation (including IV/IVR/IV2/OTS phase).3. Activity and Personnel Responsible3.1 PPO Quality Engineer: Responsible for PPQP activity, track and check pre-production critical parts, Pre-production Non-critical parts spot check, responsible for archiving PPQP documents.3.2 PPO Material Operator: Check PPQP document and accept material.3.3 PPO Planning Engineer: Receive and approve BOM Change Request.3.4 Design Release Engineer: Support and participate in the PPQP activity, track and validate pre-production parts.3.5 Sub-system Validation Engineer: Track pre-production part ADV process and check the ADV result.3.6 Material Engineer: Confirm part material meet design request.3.7 Supplier Quality Engineer: Ensure the authenticity of subcontractor , material and dimension information (except PT parts)3.8 SMT Senior Manager: Help DRE to confirm the defect part.3.9 Dimension Program Manager: Responsible to make the critical parts list and critical parts process controlling plan. 4. Definitions 4.1 Pre-production Part Quality Process4.2 Production Development Team4.3 Analysis/Development/Validation Plan & Report4.4 Sub-system Validation Engineer5. Related Documents5.1 T&V-ISO-WI-37PPO Material Control Process5.2 T&V-ISO-WI-38PPO BOM Development Process6. Records6.1 PPO Bill of Material 6.2 BOM Change Request7. Contents7.1 FlowchartPre-production Part Quality Process (See Appendix 1).7.2 Process Description7.2.1 PPO plan engineer is responsible to maintain BOM, receive, check and approve BCR.7.2.2 DRE need to confirm part sourcing information when releasing the part including Carry Over part, Purchasing part, etc. And also the part status during the process of engineering approval.7.2.3 Make the part list that needs to be validated by PPQP process.7.2.3.1 PPO quality engineer make the part list that needs to be validated by PPQP process according to PPQP recognition principle and the part sourcing, status information from DRE.7.2.3.2 PPQP recognition principle: The parts have not been approved by Engineering Approval The fastener in development (including bolt, nut and screw, etc.) Other parts bought by PT PPO7.2.4 Make the PPQP critical part list.7.2.4.1 DPM leads PPO quality engineer and SMT representative to make critical part list according to “Program critical part list (See Appendix 4)” before BOM frozen.7.2.4.2 Critical part recognition principle: Part quality issue may cause that PPO will shut down. Part quality issue may cause that vehicle test will delay. Part quality issue may cause great factor in GCA（GCA factor 10）. Bad responsibility of supplier.7.2.5 Make critical part process controlling plan.7.2.5.1 PDT including: DRE, PPO quality engineer, SQE, material engineer, dimension engineer, SVE and so on.7.2.5.2 PDT make critical parts process controlling plan: In advanced process control phase, PDT organize regular meeting with suppliers for discussing molding, checking fixture, checking method, product progress, etc. In post-process control phase, PDT visit to supplier to check the part status, inspection result and document preparation on site.7.2.6 PPO quality engineer make non-critical parts spot checking plan as a certain proportion from non-critical parts list according to the part feature and suppliers ability.7.2.7 PDT confirm part checking method and content: IVER phase: supplier prepare for checking method (inspect on molding instead of check fixture, CMM, checking fixture, white-light and so on), measurement point drawing, ADV plan and PATAC approve them. OTS phase: SGM input checking method, measurement point drawing and ADV plan and so on to supplier.7.2.8 Supplier produce part7.2.8.1 Supplier produces part on time and with high quality strictly according to SOR.7.2.8.2 Supplier effectively communicates issues with PDT in time in product process.7.2.8.3 PDT support supplier to solve issues and overcome difficulties actively.7.2.9 Supplier check part 7.2.9.1 Supplier checks the part strictly according to the checking method approved by PDT. Checking content including 3 points: Part Dimension Inspection: supplier check part strictly according to checking method and measurement point drawing approved by PDT. Material performance test :a Provide warrant of material.b Supplier implement material performance test without warrant of material. Part functional test: supplier implement part functional test according to ADV plan approved by SVE.7.2.9.2 Supplier effectively communicates issues with PDT in time in inspection process.7.2.10 Supplier prepare for PPQP document7.2.10.1 Supplier prepare for PPQP document according to PATAC PPQP document template, refer to Appendix 7-13 for PPQP document template.7.2.10.2 Supplier fills the data of product and inspection process in PPQP document template truly, exactly and completely.7.2.10.3 Supplier attaches related original inspection reports (including measurement report, material report and ADV report) to PPQP documents.7.2.11 Part initial submission7.2.11.1 For critical parts, PDT check and accept parts on site, including: Part status: confirm that part status accord with its math data. Checking method and result: confirm that checking method implemented by supplier accord with it approved by PDT, and analyze checking result. PPQP document preparation status: confirm that all the required information has been filled in PPQP document.7.2.11.2 For non-critical part, Suppliers check the part by themselves according to SOR.7.2.12 Part non-initial submission7.2.12.1 Reason for submission: a. Additional Quantities b. Correction of Discrepancyc. Engineering Change7.2.12.2 For the part that Correction of Discrepancy or Engineering Change checks part status again.7.2.12.3 Prepare various PPQP documents according to various submission reasons.a. When reason for submission is Additional Quantities, supplier submit”SUPPLIER PARTS QUALITY WARRANT”, and update “ANALYSIS/DEVELOPMENT/VALIDATION PLAN &REPORT”.b. When reason for submission is Correction of Discrepancy, supplier submit “SUPPLIER PARTS QUALITY WARRANT” and related documents about Correction of Discrepancy, and update the “CORRECTIVE ACTION PLAN” and ”ANALYSIS/DEVELOPMENT/VALIDATION PLAN &REPORT”.c. When reason for submission is Engineering Change, supplier submit “SUPPLIER PARTS QUALITY WARRANT” and related documents about Engineering Change, and update “CORRECTIVE ACTION PLAN” and ”ANALYSIS/DEVELOPMENT/VALIDATION PLAN &REPORT”.7.2.13 PDT judge whether part is OK or not according to criterion of Appendix 2.7.2.14 For the part can not meet OK part standard, PDT help supplier to find out the root cause, make long term and short term solution and their break points, and fill these information in “CORRECTIVE ACTION PLAN”.7.2.15 PDT judge whether part is useable or not according to criterion of Appendix 2.7.2.15.1 Part with defect that is accepted by PDT as “useable part” for pre-production operation. PDT push supplier to correct part according to “CORRECTIVE ACTION PLAN” and provide new status part before break point.7.2.15.2 Part rejected by PDT must be reproduced and inspected. PDT checks the reproduction until PDT can accept the part.7.2.16 Sign off PPQP document7.2.16.1 PDT sign off PPQP document when accepting the part (including OK part and useable part), see attachment 2 for sign off requirement.7.2.16.2 SMT senior manager evaluate and approve the part that all measurement points pass rate cannot meet Appendix 2 or ADV test failed.7.2.17 Supplier attach the label specified by PATAC to every part that is to part, and ship the part and PPQP document to the place appointed by PR.7.2.18 PPO material operators check whether PPQP documents are completed and signed-off or not.7.2.18.1 When PPQP documents are completed and signed-off, PPO material coordinator check and count the parts, and then stock in part.7.2.18.2 When PPQP documents are not completed or signed-off PPO material coordinator rejects the parts. Supplier is responsible to ship the parts back, and submit the parts again until PPQP documents are completed and signed-off.7.2.19 PPO quality engineer stock out parts accordingnon-critical parts list and do spot check for non-Critical parts.7.2.20 PPO qu