喷漆品质管理培训课件.pptx

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1、本资料来源试漆试产渐进生产计划试产渐进生产计划（SLR ）PPAP,SIP,SOP ready送承认量产渐进生产计划量产渐进生产计划（SLM)RTS量产喷漆量产前管制流程稳定量产直通率目标量产点检直通率目标量产点检漆厂线上稽核漆厂线上稽核量产SL-制程不良制程不良P-chartSQRC Review试漆报告CPK report调漆及喷漆参数标准调漆及喷漆参数标准PMP，SIP and SOP试产前SL喷漆稽核点检喷漆周月报喷漆周月报-直通率目标直通率目标-周月品质改善周月品质改善(3up chart and painting monthly reportISSUE异常处理异常处理-DELL 5

2、C report-TFC SCAR-LESSON LEARN喷漆品质系统管理Paint storePaint storeIQCIQCPrePre- -mixmixPrePre- -treatmenttreatmentPainting boothLine ovenOven boxLot reworkLot reworkinspectionPaperfilterPaperfilterBag filterAir pressuredryerOilwaterDe-ionize to dustAir outputAir inputAir inputTestingTestingASTMASTMpacking

3、packing1.Time speed up2.FAI IPQ FQCOQCPMPQC SIPOn going reliability1.sandpaper2.cleaning3 rework procedure4.rework SOP/Mark5.off line rework*cosmeticinspection*cleaning control*bake temp. and time controlfilter Air gunseniorjunior*cleaningcontrol*pot life control*pre-mixing parameter control*TH cont

4、rol*cleaning control*TH control*FIFO*expired datePilot painting(Painting supplier PDS)CosmeticQC*positive pressurecontrol*TH control*dust free control*program revisionControl*painting parameter controlPM planSOPrecordOperatorsafetymaskglassesapronglove*trainingLine QCDell Painting Critical Control F

5、low Chart Revision 3.0 2003.04.24Prepared by: Rick MiaoFlash timeFlash timeSupply roomSupply room*TH control*cleaning control*key parameter controlEquipment/fixturefilterovencontainerCleaningbakebakedegreaseESD dust(ESD tester)dryHeater systemShower systemDouble doorDry time control before packing(t

6、he malyer Assy)1.Pre-mix person2.painting room person3.fixture cleaning areaSPC 1.CPK Delta L/a/b/gloss/thickness/texture2.safety launch喷漆制程管理流程Thickness CPKbuildingColor match CPKbuildingSafety launch building-co-work with paints suppliers try thickness Spec and CPK in.-Trial run units min. 30pcs-F

7、ix the painting parameter. -Painting applicators take care.-Trail run min. 100pcs for yield rate- Yield rate meet target.-Top 5 issue with FA and CA.-co-work with paints suppliers try Painting color with tints adjustment to in Spec.-Trial run units min. 30pcs.-Fix the painting tints ratio.-Painting

8、suppliers take care.-co-work with paints suppliers try color and Thickness CPK 1.33.-Trial run min. 3 lots(each lots 30pcs)-QSMC SQE involve each CPK reportReview. -All reliability should be passed.Painting Applicators Trail run process flowchartYield ratebuildingCPK Continues Trial Run building-.co

9、lor and thickness Spec and CPK. in-.reliability testing passed.-.yield rate can support RTS.Trail run ok-Before RTS 3K trial run safety launch - After RTS 5K MP safety launch.- Safety launch with issue highlight. with FA and CA per day.试漆PROCSS流程Spec. PMP creationSafety launch building-Color chip-PD

10、S and Cosmetic & testing Spec.-Painting ratio viscosity Spec.-Trail run min. 100pcs for yield rate- Yield rate meet target.-Top 5 issue with FA and CA.-Based on trail run result create PMP.-Painting ratio and viscosity parameter.-FAI and IPQC check items.-Flash time & oven temp. and time.-Painting p

11、arameter.-Reliability testing and color & film building.-Co-work with TFC IQC to create SOP and SIP-Customer Spec. and QC and process key point. Painting Applicators Trail run system flowchartYield ratebuildingSIP and SOP creation-.color and thickness Spec and CPK. in-.reliability testing passed.-.y

12、ield rate can support RTS.Trail run ok-Before RTS 3K trial run safety launch - After RTS 5K MP safety launch.- Safety launch with issue highlight. with FA and CA per day.试漆SYSTEM流程Supplier Paint Safe Launch StatusExample of Reporting format Product X Painting Safe Launch PlanLine numberLocation Prod

13、uct NameUnitsCumm TotalUnitsCumm Totaldaily deltaCumm deltaGateActualGateActualGateActualGateActualGateActualGate80.0%90.3%85.0%90.0%92.0%92.0%94.0%80.0%93.6%85.0%90.0%92.0%92.0%94.0%80.0%85.7%85.0%90.0%92.0%92.0%94.0%51.2%72.4%61.4%0.0%72.9%0.0%77.9%0.0%77.9%0.0%83.1%1.330.221.331.331.331.331.331.3

14、38.711.331.331.331.331.331.332.421.331.331.331.331.331.331.371.331.331.331.331.331.331.371.331.331.331.331.331.332.221.331.331.331.331.33 Pilot Build Qty= 3730Phase 3 (date)Phase 4 (date)Phase 5 (date)Phase 6 (date)Gloss CpKRoughness CpKPhase 1 (date)Phase 2 (date)Color L CpKColor A CpKColor B CpKTh

15、ickness CpKIPQC 1(Process 1)IPQC 2(Process 2)Process 3Test Point 3 (FPY)Critical Processess-25417645622012202820Delta-25443028022010001600055455400000010102201220282028022010001600Plan 300430300730Actual5540554Phase1(10/21)Phase 2(11/25)Phase 3(12/4)Phase 4(1/6)Phase 5 (1/13)Phase 6 (1/20)Pilot Buil

16、d Qty= 3730Supplier XIssueStatusOwnerEstimated Completion DateCause/ActionSome where didnt have paintCompal - SQE11/15/2002The gloves of the operators were made by cotton.Operators didnt follow the process that been definedCompal - SQE11/16/2002In SOP, mainly define the method of operation. Training

17、 the operator by the line leader about how to prevent scratch.Total- New Yield after implementationCorrective Action Tracking LogExample of Reporting format Customer/客 戶客 戶制造流程制造流程Process FlowCharacteristics方法方法MethodsNo.Phase of ProductionProcess ParametersMeasurement Method抽樣方法SampleAnalysis Metho

18、ds產品狀況制程參數測量方法大小Size頻率Frequency分析方法(記錄表單)Cpk9涂裝調漆涂裝調漆 碼表量杯黏度杯N/AA.涂料 B.硬化劑 C.稀釋劑 D.濃度比A.一色XPM-60360S二色XPM-21332涂料B.GXH60266硬化劑C.M850-59572稀釋劑D.4:1:1.5目測電子秤+量杯1逐桶涂料用量對照表(TS-PR-65 A1N/A退貨重工報廢10前處理前處理噴風槍(編號0110-0203或0204-0209)N/AA.外觀B.結構依 SOP(AQ-QUA-JM2007)目測樣品整批全檢作業標准書(AQ-QUA-JM2007)N/A停線報廢重工11涂裝涂裝(面漆

19、面漆) ABB機器人(R-01)A;霧化壓力:52barB.噴幅壓力:52barC:滑台時間:3.50.5SD:直立式烤箱溫度60+/-5E:直立式烘烤時間:20minF:流水線烘箱溫度:第一段關閉,第A.涂料B:涂裝條件C:信賴性測試 (硬度測試, 附著性,膜厚測試, 酒精測試 耐磨耗測試)A.第一色XPM -60360S 第二色XPM - 21332B:涂裝條件C:依信賴性測試辦法 硬度測試: H附著性: 1OO%不可脫漆膜厚測試: 25+/-5 u酒精測試: 來回50次.不可掉漆耐磨耗測試: 重量目視鉛筆硬度計百格刮刀3M610膠帶模厚計酒精+砝碼(500g)11 pcs /500 pc

20、s作業標准書,涂裝條件表,信賴性測試記錄表(TS-QR-50 A1),信賴性測試結果記錄表(TS-QR-70 A1)N/A停線調機重工報廢12首件檢查首件檢查N/AA;霧化壓力:52barB.噴幅壓力:52barC:滑台時間:3.50.5SD:直立式烤箱溫度60+/-5E:直立式烘烤時A.檢驗比對樣品.B.SIP C:色差值D:涂裝條件E:尺寸A.樣品檢驗比對檢查結構B.SIPC.L=0.8a=0.4b=0.4D:涂裝條件表E: 依SIP色差機黑點表目視游標卡尺3P/X1X/S首件檢查記錄表(TS-QR-72 A60異常處理單(TS-QR-14 A5)N/A停線調機報廢 XXX- PROCES

21、S MANAGEMENT PLAN-PLASTIC異常處理 Reaction If Out ofControl達丰Jig,Tools ForManufacturing制造機器,設備,夾治具Char No.流程圖產品特性位置.管制方案Product Char.Loc./Desig.產品具體特性Product CriticalCharacteristicsPainting PMP -The FPY targets are defined for each process and stages: -SLR (Safe Launch Ramp) since system pilot build Mas

22、s production Build stageSLR(Qty:3K)Mass production(Qty:5K)Forming process Injection 95.00%96 .00%Pressing 85.50%90.00%Die-casting Al/Zn/Mg90%/90%/79%95%/95%/87%Painting process Painting-plastic86.00% for one pass88.00%for one passPainting-Metal/Mg 78.90%/75% for one pass83.00%/83% for one passSub-as

23、sy process Sub-assy(incl. Heat staking, gluing, etc.)96.00%98.00% 2nd Tier Supplier Quality Gate of New ToolingSafety launch quality goalPlastic portion:NoItems SpecASTMOperationASTMChineserevisionEquipmentor method1 1 colorDeltaL +/-0.8a,b +/-0.4D17292 2 gloss.+/-3D523-893 3 adhesionAbove 4B(2mm) D

24、33594 4 film hardnessHD33635 5 curerating of 4D47526 6 solvent resitanceD47527 7 film thickness2030uMetal portion:NoItems SpecASTMOperationASTMChineserevisionEquipmentor method1 1 colorDeltaL +/-0.8a,b +/-0.4D17292 2 gloss.+/-3D523-893 3 adhesionAbove 4B(2mm) D33594 4 film hardness2HD33635 5 curerat

25、ing of 4D47526 6 solvent resitanceD47527 7 film thickness30-70uDell 85FMA Paints Performance Specification Reviewing Items喷漆测试项目SPCEXXXXXX PAINTING PARTS RAMP PLAN REVIEW STATUSPart NamePart NamePart NumberPart Number序号序号/ NOReadyReadyReadyReady1 12 23 34 45 56 67 78 89 91010111112121313141415151616

26、1717181819192020喷漆色板及色差机光泽机校正/painting colorchip and colormeterand gloss meter carlibration.印刷色板/printing color chipXXX XXXXXX PAINTING PARTS LIST调漆SOP和参数标准/pre-mixed and parameter standard.厂商名称-厂商名称-填写日期： 填写日期： 制程直通率品质目标/process FPY quality target炉温测试/curing profile testing.喷漆厂的TSSR/Painting suppli

27、ers. 漆及产品外观特性检查培训/painting&parts/cosmetic and technical training.材质证明/Material Certification 喷漆的程式/painting program 漆及油墨的产品特性技术资料/Painting PDS标准检验规范/SIP-Standard Inspection Procedure功能测试治具或Go No-Go治具FunctionTest Fixture / Go No-Go Fixture印刷检验治具/Print Inspection Fixture标准作业规范/SOP-Standard Operation P

28、rocedure喷涂及印刷可靠性测试报告/Paint&Print Reliability Test制程管制计划/PMP-Process Management Plan非自动管理制程及产品参敉/parameter not under automatic control.喷漆遮盖图面/Quanta-TFC painting masking Drawing5pcs样品/5pcs SamplesRemark喷涂治具/painting fixture通用审核项目通用审核项目/ COMMON REVIEW ITEMSRemarkRemarkRemark1234喷漆量产前点检表data36規格：25.00正

29、公差:5.00 上限規格：30.00客 戶：單位： 。負公差:5.00 下限規格：20.00NO.DataNO.DataNO.Data NO. Data1 127.00212125.0041612 225.00222224.004262-0.034-0.0343 323.00232325.0043631.411.414 425.00242425.0044641.361.361.361.365 525.00252523.0045651.461.466 625.00262625.0046667 726.00272725.004767Max =27.0027.00。Min =23.0023.00。R

30、ange =4.004.00。8 827.00282825.0048689 923.00292924.004969101024.00303024.0050507070111124.00313125.005171121227.00323224.005272131326.00333326.005373141425.00343424.005474151523.00353525.005575161626.00363623.005676171726.00375777181827.00385878191924.00395979202024.004040606080800 0pcsSum：Sum：89489

31、4Avg.：Avg.： 24.8324.83LSL : 規格下限。Xbar : 平均數。Sc : 規格中心。 U SL : 規格上限。操作說明操作說明Measuring Data AnalysisMeasuring Data AnalysisD & J TONY 90.12.21 REV.B料號：EAJM3003018總 樣 本 數：檢驗者：Dd.Huang 品名：JM3 TOPQUANTA日 期：2003-1-11 * Process Capability Index - Cp , Ca & Cpk * * Process Capability Index - Cp , Ca & Cpk *

32、 Ca =Ca =Cp = Cp = OKOKCpl =Cpl =Cpk = Cpk = Cpu =Cpu =Out of Spec: Std Dev.：Std Dev.： #圖例說明:Histogram000000000000LSLLSLUSLUSLXbarScSc00.10.20.30.40.50.60.70.80.9103.336.669.9913.3216.6519.9823.3126.6429.9733.3QTYQTY0%20%40%60%80%100%120%Histogram0059540000013LSLLSLUSLUSLXbarScSc024681012142021.1122

33、.2223.3324.4425.5526.6627.7728.8829.9931.1QTYQTY0%20%40%60%80%100%120%Painting CPK report品名品名料號料號涂料涂料進料批號進料批號調合調合比例比例粘度粘度paintingboothtemphumidity.液溫液溫過濾過濾网目网目程式程式號號噴槍噴槍口徑口徑霧化霧化噴幅噴幅涂料涂料開關槍開關槍枪距枪距1 layerfilmbuildingbaketime andtemp.cycletime干燥时间干燥时间立式烘烤箱立式烘烤箱溫度溫度XPN-21332MC-001899-004GXH60266MC-09190

34、2-0002M850-59572MC-001956-028XPM-60360S MC-001954GXH60266MC-091902-0002M850-59572MC-001956-028XPM-60360S MC-001954GXH60266MC-091902-0002M850-59572MC-001956-028XPM-60360S MC-001954GXH60266MC-091902-0002M850-59572MC-001956-028BASE CASEEBJM1004017TOP CASWEBJM1005013LCD BEZELEAJM1007016EAJM100610LCD COV

35、ER涂裝涂裝試作參數一覽表試作參數一覽表涂装试作参数记录applicators: ABBtrail run summary reportkey-in date:issued by:date partscolor name Qty testing itemMax Min RanAvg out paint temp. CPK resultchange record.FA result12/2702 BASEmoonlight silver30 Thickness302025.1223.123.580 20231.33 偏下限在保証外觀OK情況下調整噴漆程序。L63.73 62.1363.8863.

36、10.7863.4700.62 偏上限調整噴漆程序。A0.990.190.580.420.160.5102.81 OKB1.831.031.841.590.251.7201.35 OKGloss201418.8162.817.1301.27 偏上限調整噴漆程序。Roughness11.271.277.123.683.445.7101.96 OK12/2802HINGECOVERiron silver30 Thickness302025.822.73.124.120 20231.39 偏下限在保証外觀OK情況下調整噴漆程序。L84.48 82.8884 83.030.9783.4300.77 偏

37、下限涂料中添加銀漿。A-0.16 -0.96-0.61 -0.850.24-0.7301.35 OKB1.931.131.581.310.271.4601.39 OKSpec.试漆报告Dell 2K Monocoat with two applicationsOperation Guide PlasticPretreatment2k MonocoatDFT 10-15umBaking(30 mins60C)Baking(30 mins60C)PackingflashFlash All information is given in good faith but users must satis

38、fy themselves that there are no circumstances requiring additional information or precautions or the verification of details given EH10/022k MonocoatDFT 10-15umInspectDefectYesNoYes#No2000grit sandingInspectDefect1.#This step is only allowed one time. If part is still defective after passing through

39、 the second application station twice, the part must be scrapped.2.Total DFT will range from 20-45 microns.Paints process flowchartDell 2K Monocoat with one ApplicationOperation Guide PlasticPretreatmentWith Mineral Spirits2K MonocoatDFT 20-30umBaking(30mins60C) Substrate Temp. flash All information

40、 is given in good faith but users must satisfy themselves that there are no circumstances requiring additional information or precautions or the verification of details given EH10/02Scuff SandingWith 2000gritCleanNOYesInspectDefectPackage1.No more than 1 time rework;2.Total DFT 20-60 microns; 3.Dell

41、 need to confirm total DFT. 4. The process will be modified based on line condition.3-5minsAmbientCool Down2 Hrs later4-48hrs laterXPM60360S:XPH80002:M850-59572=4:1:1Viscosity: 1218 Seconds NK2#Issue #: Issue Title: Date: Description: Champion: Containment: Root Cause: Corrective Action: Preventive

42、Action: Verification: described sheet- CharacterizeContainCauseCorrective ActionClosureBlank form example- Green = Completed- Yellow = Currently Working- Red = Future Work 5C reportBlank form example3-up ChartPRODUCTION QUALITY REPORTPROCESS QUALITY STATUSCHECK POINTGOALWeek 1Week 2Week 3Week 4Week

43、5TESTEDPASSEDYIELDTESTEDPASSEDYIELDTESTEDPASSEDYIELDTESTEDPASSEDYIELDTESTEDPASSEDYIELDIijection100.0%30903090100.0%7951791799.6%22802280100.0%38503850100.0%Painting100.0%11101110100.0%1403138498.6%51595159100.0%12311231100.0%Printing99.0%11101110100.0%2476245599.2%51595159100.0%10721072100.0%Insert1

44、00.0%5877584599.5%59865986100.0%24752475100.0%Assembly100.0%6481626496.7%5987597099.7%7214720299.8%Outgoing100.0%56973464339898.1%26552655100.0%First Pass Yield99.0%100.0%91.8%99.7%99.8%FAILURESYMPTOMAssembly:1.依 顆 粒 之 限 度 樣 品 執 行依 顆 粒 之 限 度 樣 品 執 行噴漆顆粒毛屑檢 驗檢 驗 .印刷顆粒2.顆 粒 毛 屑 不 良 居 多顆 粒 毛 屑 不 良 居 多

45、,雖 目 前 未 能 有 效 排 除雖 目 前 未 能 有 效 排 除 ,但 仍 再 接 再 勵 共 同 堅 守但 仍 再 接 再 勵 共 同 堅 守品 質品 質 ,把 現 場 品 質 做 好把 現 場 品 質 做 好 ,將 不 良 率 降 至 最 低將 不 良 率 降 至 最 低 .Date: APRIL 2Submitter: ShyCustomer Location: ChinaPROCESS QUALITY INDEXProject Name: Supplier Name: ShySupplier Location: TaipeiCustomer Name: DellPart Numb

46、er: 39JM1BAWI03Part Description: Bottom教育訓練. 成 型 廠 成 型 廠 -協 宜協 宜持 續 追 蹤持 續 追 蹤 依 顆 粒 之 限 度 樣 品 執 行 依 顆 粒 之 限 度 樣 品 執 行且將不良品攜回以便做將不良品隔離挑除 依 檢 驗 規 範 執 行 依 檢 驗 規 範 執 行 .2003/3/103/15TEST STATION 噴 漆 廠 噴 漆 廠 -三 立三 立REMARKSREPAIR ACTIONFAILURE ANALYSISCORRECTIVE ACTIONSCLOSURE DATEProcess Quality Index90

47、.0%92.0%94.0%96.0%98.0%100.0%IijectionPaintingPrintingInsertAssemblyOutgoingWeek 1Week 2Week 3Week 4Week 5Quality Bridge ChartActions to Increase Yield98.0%99.0%99.8%80%84%88%92%96%100%LastMonthsYieldYieldGoalFinalWeekBlank form examplePart Number: 39JM1BAWI03Part Description: BottomPROCESS QUALITY

48、INDEXCHECKPOINTGOALMondayTuesdayWednesdayThursdayFridaySaturdaySummaryTESTED PASSEDYIELDTESTEDPASSED YIELD TESTED PASSEDYIELDTESTED PASSEDYIELDTESTEDPASSEDYIELDTESTEDPASSEDYIELDTESTEDPASSEDIijection99.0%2480245098.8%960960100.0%570570100.0%11401140100.0%1425142399.9%1376137499.9%79517917Painting97.0

49、%54052396.9%86386199.8%14031384Printing97.0%1710170099.4%76675598.6%24762455Insert99.0%1710170399.6%65565299.5%1793178099.3%56255498.6%1157115699.9%58775845Assembly99.0%1710156091.2%65562595.4%1793176998.7%60560099.2%56255598.8%1156115599.9%64816264Outgoing99.0%2880281797.8%58458199.5%34643398FAILUR

50、ESYMPTOMinjection:冷料冷料Assembly:噴漆顆粒毛屑噴漆顆粒毛屑印刷顆粒毛屑印刷顆粒毛屑(2)檢驗人員檢驗人員,未能將不良品挑出未能將不良品挑出,造成異常造成異常REPAIR ACTIONFAILURE ANALYSISCORRECTIVE ACTIONSCLOSUREProject Name: Submitter: APRIL 2DATETEST STATIONREMARKSSubmitter: ShySupplier Name: ShySupplier Location: TaipeiCustomer Name: DellCustomer Location: Chin