模具制作过程控制程序

1、质量管理文件模具制作过程控制程序文件编号：版 本 号：1.0 目的Objective确保模具制作过程在受控状态下进行，使模具品质、交期和成本满足预期要求。Ensure the mold s production process is under control ;. And the mold s quality, delivery date and cost meet the expectation 。2.0 范围Scope本文件只适用於 XX 有限公司之模具制作过程。不包括修模、执模、改模。3.0 定义Definition物料清单工程更改通知BOMECNBill of materialEng

2、ineering change notification4.0 职责Responsibility采购文员制定物料计划，确保物料按期到位。PurchasingSet the material plan, ensure the material is ready。clerk加工部 /组按图加工，确保工件按质按期完成。ProcessingProcessingaccordingto the graph , ensurethe parts qualityanddepartment/finish it on time 。Team组织制定和调整生产计划，确保按计划加工。制作部Set andadjust th

3、e production plan,ensure toprocessingaccording精密模具部the plan 。Production统筹模具的整体进度、模具制作工艺，确保模具按期试模，监控加工department部 /组加工工件的质量。PrecisionOrganize the whole schedule of the mold, the production technique,productionand ensure to carry out mold trial on time, monitor the items or partsdepartmentquality 。负责工

4、件的品质检验、记录和状态标识，反馈品质信息，推动品质改进。品质部QualityResponsible tothe parts qualityexamine,record,andlabeling,feedback thequality information,andencouragethequalitydepartmentimprovement技术部提供技术支援，协助解决制作过程中的工程技术问题。technicalResponsible to handle the failure during the production process第1页共15页质量管理文件模具制作过程控制程序文件编号：版

5、 本 号：department注！以上未尽之处详见5.0 所述。以下对于精密模具部，制作部经理则为精密模具部经理。Remark:Detailsrefer to 5.0. In the following,the productiondepartmentmanageralsoinclude the precision production department manager.5.0 内容Content5.1 物料计划material Planning5.1.1 模胚大肉、 BOM 物料：Mold core, BOM material制 模图初稿评审后，制采购文员查询采购员采购库存造 填写 和

6、，确认可以定经编码员师 料后连同模胚图交理5.1.2 直接常备物料：Direct and regular material常备物料低于采购订购点文员5.1.3 间接常备物料：Indirect regular material开采购采购员流程常备物料低于仓务员 开组长员流程5.2 生产计划Production plan步骤行动负 责ProcedureActionIC接到模图 A 版，对除标准件外的所有工件 (除铜公外 )编排加工工初步的工作 艺，估计工时，要求完成时间，编制 (初稿 ) 。制作组长编排After received the mold graph version A, set the

7、 processingProductioninitial worktechnique requirement, estimate time required, dead line forteam leaderarrangementall the parts beside standard items., andthe (draft) 。第2页共15页质量管理文件文件编号：版本 号：模具制作过程控制程序根据产品图、模图A 版、 ( 初稿 ) 完成以下工作：According to the product graph, mold graph version A,(draft) to complet

8、e the following works：详细讲解模具制作要求、模具结构、产品要求；Describe the mold req uirement, mold s structure, and制作部经理product requirement in details.Production强调制作过程可能引起的失效，落实预防措施；departmentEmphasis the potential failure in the production process,managerrealize the prevention measures.确认 各工件之加工工艺和完成时间。Conform the pr

9、ocess techniqueand time of completion ofthe parts in the , sign the final version 。产前将输入电脑系统；打印后交制作部经理签核后分准备发制作部、品质部等相关人员。制作编排员及Input the into the computer system ；PrintProduction生产it, pass to the production department manager sign toscheduler编排approve, then distribute to the production department,P

10、re-producquality department, and related staff；tion and根据已有 未完成部分、新的 及修production模/改模计划，制订排机计划；arrangementAccording to the unfinished , new and mold modify/repair plan, to set加工 /制作the machine arrangement编排员制订 分发各加工组。Processing/Set the and distribute to theproductionprocessing teamscheduler统计分析，发现超负

11、荷现象，提前向上级反馈。Statistic and analysis, if discover any over loading, report tothe superior.根据实际情况决定工件可否提前或延后， 可否改变加工工艺以制作部经理缓解负荷。PorductionAccording to the actual situation, to decide whether the part sschedule have to be changed or not, and whether to changedepartmentmanagerthe technique 。第3页共15页质量管理文

12、件模具制作过程控制程序文件编号：版本 号：对于调整排期后，仍然无法加工的工件， 申请外发加工，见外发加工控制程序 (工模厂 )For those parts, which cannot be finished even by changed the machine arrangement, could apply contract out processing, details refer to contract out processing controlprocedure (Mold factory)5.3 工艺和进度控制Technique and progress control行动负

13、责NOICAction依，安排各机台之加工任务，并对操作者明确加工要加工组长求及注意事项 (特别是以往曾出现的失效 )，采取预防措施。Processing01 According ，arrange the machineteamprocessing arrangement, and clarify the processing requirement, ,leaderand take preventive measures。加工前应提前准备好辅助用具 (如夹具、刀具等 )，检查监测装置处于完好状态。Prepare all the assistant tools before processin

14、g, examine the操作者02monitoring devices to ensure they all in good condition。Operator看清图纸和工艺流程，并按其要求加工。Carefully read the graph and technique procedure, and processing according to the requirement 。加工过程中，需调整或更改加工工艺时，与制作组长协商，并将结果知加工组长会制作编排员。Processing03During the processing，when need to adjust or chang

15、e the processingteamtechnique, communicate with the production team leader, and notifythe result to the scheduler 。leader加工完成后，填写 /（锣床 /磨床 /钻床）经上级审核后交编排员。After the processing is finished, fill the / and pass to the scheduler after appraised by操作者04operatorsuperior 。 省模、制作组以人为单位记录工时；Mold polish er, p

16、roduction team record the staff s working hour 除此之外的组别则以机台为单位记录工时。第4页共15页质量管理文件模具制作过程控制程序文件编号：版 本 号：Other team record the machine s working hour。将所有 /（锣床 /磨床 /钻床）中的工时输入电脑：Input all the working hour of / into the computer ：Warehouse 对各员工或机台加工工时进行统计，定期生成报表交指定人员。clerk05Calculate each staff ors machine

17、sprocessinghour, formreportregularly and provide to specialize staff 。加工 /制作根据完成情况调整排机计划，未按期完成的工件，向加工组长汇报。编排员Arrange the machine according to the finishing time, report to theProcessing/.processing team leader about the parts which have to be postponed。 Productionscheduler促使各加工负责人检讨违规原因 ,采取相应对策 , 并知

18、会制作部经理。加工组长06Encourage the processing PIC to evaluate the reason of broken law,Processingand take correspondent measures, and notify the productionteamdepartment manager 。leader跟进模具各工件的加工进度，将跟进结果记录於上。制作部编排员07 Follow up the progress of mold s parts, and record the result on the.Productionscheduler在调整

19、生产计划仍无法确保货期时，应提前申请。If the pats cannot finished before dead line even by changing the制造工程师working schedule, should apply ahead 。Production 填写 ，由制作部经理确认后交项目工程师；engineer08Write ， pass to the projectengineer after approved by production department manager 与客户沟通并即时回复制作部经理。项目工程师Communicate with the custom

20、er and reply to the productionProjectdepartment manager immediately。engineer5.4 制程发现来料问题The material problem arise during production第5页共15页质量管理文件模具制作过程控制程序文件编号：版 本 号：流程：品质加工/IQ采供I部主C购最终制作属实应Q管/组员标识、跟进处理人员工程商C长师不属实流程说明：Procedure description流程行动和要求负责ProceAction and requirementICdure发现来料问题，影响正常生产时，及时知会

21、品质主管或品质工程师。01 When problem raised ， affect the normalproduction ， notify操作人员thequality manager or quality engineer immediately。Operator接到生产制作部门反馈来的信息，及时确认问题是否属实：When received theproblem informationformtheproductiondepartment, investigate whether the problem is exist：属实不属 实品质部existRejected主管/工程-则应知会

22、IQC 组长，及时发出 ，确定处理方法并交采购员 ；问题。师Quality02IQC teamleader ， issue totheissuer,departmentandascertain the handle measures and pass to thereachhead/agreementpurchaseron the problemengineer-安排 IQC 作好不合格标识。ArrangementtheIQC to preparethe failurelabel ；若为退货或需对供应商进行处罚，则按来料控制程序处理。03If need to rejected the good

23、s or penalty the supplier, treat accordingthe Material control procedure按要求对制程发现的不良来料进行标识，并跟进其处理。04Labelthe failurematerialdiscoverduringtheproductionprocessIQCaccording to the requirement, and follow up the treatment第6页共15页质量管理文件模具制作过程控制程序文件编号：版本 号：5.5 品质检验与控制Quality examining and control检验方式：Metho

24、d of examine ：检验标准： 操作者自检；examining criteria ：The operator self-examine； 受控图纸 (模图、散件图、加工图 )；制作组的监督检查；Controlled graph(moldgraph 、itemsMonitoringexaminebytheproduction team；graph 、processing graph) ； 检验指导书。IPQC 对规定工序进行检验。 Examining instruction 。IPQC examine the regulate workingprocedure 。操作者合格不合 格Pas

25、sFailure自检 返工； 于图纸对应流程处签名，然后将工件、Operatorredo图纸一起流入下工序。self- 重检合格方可放行。Sign for the correspondent procedureexamingraph, thenpassthe parts, graphdeliveryonlyafterof theere-examine 。to next procedure 。制作组 每个工件所有工序完成后，制作组收到工件后应作监督检查，发现有问题及监督检时将其反馈给 IPQC ；查After finish all procedure of each parts, the pro

26、duction team should carryMonitoriparts, if discoverany problem,out monitoring examine after received thengnotify the IPQC immediately ；examin”要求处理。 IPQC 发出 交品质部主管确认后， 按“e of thefeedbackform and passto the qualityIPQC issue failure informationproductidepartment head, handle according to “ ”。on tam加工完

27、成的工件，自检合格后以下情形必须送IPQC 检验：IPQCThe parts finished processing, under the following conditions after examine,检验must send to IPQC to examine ：IPQC1 、外发加工前； 2、工件加工完送制作前； 3、工件在加工过程中转移加工组别Examin时。e； 2 、 before send to the productionBefore contract out processing第7页共15页质量管理文件模具制作过程控制程序文件编号：版本 号：department af

28、ter finished the processing ；3、when the parts transfer to otherteam during processing 。IPQC 组长与制作组长沟通，确定工件之重要尺寸，在参考图上做出标识。IPQC team leader should communicate with the production team leader，conform the important dimension of the parts ，and indicate on the referencegraph 。IPQC 组长根据实际情况，将工件检测工作分配给指定人员

29、。IPQC team leader depends on the situation, distribute the part s examinjob to specialize staff 。检测工件之重要尺寸， 填写 ，尺寸检测结果记录在参考图上。Examine the important dimension, writethe ,record the examine result on the reference graph。於图纸反面盖 “ QC PASSED ”，於对应流程处签字做实， 检验记录与图纸经 IPQC 组长审核后，与工件一起置於“合格区” ；IPQC 检Seal “ QC

30、 PASSED ” on the back of the graph ， sign on theIPQCcorrespondent procedure, examine the record and the graph, then验合格IPQCappraised by the quality department supervisor or IPQC teamexamineleader, put the parts on the“ pass； ” areapassed 注：需多次检查的工件及多工件之图纸，检验记录和标识应予适当区分。Remark ：the graph of parts whic

31、h need multiple examine, the examine recordand the label should be separated 。於图纸反面盖红色“ QC REJ ”，於对应流程处签字作实；并在对应流程下记录 号码。seal red “ QCREJ ” onthegraph sback ， signon thecorrespondentprocedure, and record the number of on the correspondent procedure。检验记录与图纸交品质部主管或IPQC 组长审核后，於工件上标识IPQC 检“QC REJ ”字样，置“

32、不合格区” ；验 不 合Pass the examining resultand the graph to thequality格department to appraise, seal “QC REJ ” on the parts and put itin the “failure ” area ；IPQC 组对于不合格工件，则填写 交品质部主管，跟长进不合格品的处理。IPQCFor those failure parts, fill the failure information feedback sheet.teamAnd pass to thequality departmenthea

33、d, to follow up the failure第8页共15页质量管理文件模具制作过程控制程序文件编号：版 本 号：leadergoods treatment.组织制作组长、制造工程师等相关人员评审以决定处理方式，并将处理结果填写在 上。若有分歧，则由制造工程师品质部主决定最终处理方式。但烧焊必须获得项目工程师的同意。管Organizethe productionteamleader 、 productionengineerandQualityrelatedstafftodecidetakewhichmeasures,andrecordthedepartmentdecisionon th

34、e .If cannotHeadreach agreement, the production engineer should make final decision.不合格品处理Failure goods treatment处理方式行动负 责TreatmentActionIC烧 焊按烧焊工作指导书进行BurningCarry out according to the Burning work instruction 镶 件发出 ECN ，修改图纸并通知相关人员制造工程师ProductionMountingIssue ECN ，amend the graph and notify the re

35、lated staffengineer按图纸重新加工；原加工者OriginalReprocess according to the graph；原件再加工processorReprocess若涉及更改设计，发出ECN 和修改图纸。制造工程师If change of designis needed,issue ECN and amend theProductiongraph 。engineer在不合格工件上作报废标识， 依 将报废工件退废品仓，并将 抄送一份给原加工部门。Label write off on the failure items, send to the wasteIPQC报 废w

36、arehouse according to the and send a copy to the original processingdepartment提出补料申请 (即以旧换新 )，注明 编号。原加工者Make material refill application, indicate the code of processor第9页共15页质量管理文件模具制作过程控制程序文件编号：版 本 号：注！决定处理方式后， 除报废直接由 IPQC 将工件退仓外，其余均由IPQC 将随工件一起退回原加工者。After decide the measures taken, Beside the wr

37、ite off parts send directly to thewarehouse by the IPQC, the IPQC should send back the remains parts withthe failure information feedback sheet to the original processor。以上不合格工件烧焊、镶件和原件再加工处理后， IPQC 须作重新检验，并记录於上。The parts above after burning, mounting or reprocessing, should be examined by the IPQC,

38、and record the result on the 。品质部主管决定是否发出CAR( 纠正措施报告 )。The quality department supervisor decide whether to issue CAR (correction actions report) or not 。5.6 现场管理On site management5.6.1标识、可追溯性：所有模具和工件均以模号进行追溯。Label 、tractability ： All the mold and parts are trace by the mold no 。NO行动和要求负 责Action and

39、requirementIC物料从货仓领出时，标注零件编号 (标准件除外 )。仓务组01 When get the materials form the warehouse, label the item no.Warehouse(except the standard items) 。team在加工或打字唛前， 以仓务组标注的零件编号为标识； 经粗加工后， 必须补上加工前原有标识。操作者02Before processing ，use the items no given by the warehouse team asOperatorthe indicator ；after rough pr

40、ocessing ， must add back the originallabel 。工件加工时， 按散件图之零件编号及要求， 在工件指定位置打上字唛后，再进行加工；铜公应按照加工图之铜公编号及要求进行标识。when the parts processing ，according to the code and requirement03of the item graph. The brass parts should indicate according to the操作者processing graph s code and requirement。Operator加工完成的工件应与其它

41、未加工工件分区放置并标识清楚。The parts which finished processing should separate storage and label form the unfinished parts 。第10页共15页质量管理文件模具制作过程控制程序文件编号：版 本 号：模胚或模具上拆下来的零件，按字唛统一要求标识，并将其统一摆制作放在箱 /架内，然后再在箱 /架上标注模号。技工04 The items remove form the mold or mold embryo, should labelProductionaccording to the Wording u

42、nify requirement， and put in theworkerbox/rack ，then label the mold no on the box/rack 。注：铜公、工件之编号方法详见字唛统一要求 。Brass work 、 work pieces coding details refer towording unify requirement 。5.6.2 物料管理material management项目行动和要求负 责ProjectAction and requirementIC申请：填写 ，注明补料原因补料者Application: write the , indicate the补料ApplicantreasonMaterial部门经理refill审批DepartmentApprovalmanager每半年列印呆料清单交总经理、加工、制作部经理。Print the idle material list to the GM, production manager and呆料processing manager half an year仓务组长组织相关人员讨论处理方案，提交总经理审批，并检讨呆/料产WarehouseIdle生的原因，制订纠正和预防措施。teammaterialOrganize related staff to