封闭型电热塞过程流程图及控制计划

1、 PROCESS FLOW DIAGRAM 过过程程流流程程图图DaimlerChrysler Ford General Motors 戴姆勒克莱斯勒、福特、通用汽车Number文件编号版本号:QP024/F-001 APart Number零件号:CP-73Establish Date创建日期:2009/5/6Part Description零件描述:封闭型电热塞Revamp Date修改日期:Rev工程图样更改等级:APREPARED BY:责任人Li Ying ZhongSymbol InstructionsOp-Seq.工序号FABRICATION制造MOVE 搬运STORE 贮存IN

2、SPECT 检验Rework返工Scrap/ Contain报废/控制Changeover工序特性OPERATIONDESCRIPTION过程描述Class(KPC, QCI)产品特性序号Significant ProductCharacteristics(Outputs)关键产品特性IClass(KCC, QCC)过程特性编号Significant ProcessCharacteristics(Inputs)关键过程特性CONTROLMETHODS控制方法 10材料采购采购控制程序20临时存放30进料检验调节丝规格：2.6X27X16总电阻：0.280+0.1发热丝规格：2.6X10X5.5

3、总电阻：0.280+0.1有效圈数符合要求及其它零部件符合相关技术要求40入库50领料60焊接焊点间距4mm11V电阻1.070铆接同心度0.15mm长度间隙1mm80氩弧焊焊点高度0.5mm焊点光滑，无裂纹，无虚焊，焊点平整，均匀90振粉总高度830.2同心度0.15mm螺杆与固定螺母持平,氧化镁不能溢出100上胶胶平面与护套面持平,不得溢出110干燥自然干燥12小时恒温温度50C,4h120第一次缩管(小头)长度38+0.30直径5+0.20130第二次缩管(外径)直径50.1长度42140第三次缩管(头部)长度440-0.02直径50.1150第四次缩管(小头)锥度直径4总高度881.5

4、160检验(柱件总成)短路,断路检查5A检查时间3S170压配圆角高度201总高度881.5180试压按封闭型电热塞技术条件JB5783-91执行电动工具旋进力径2N.m190装定心环各部位旋紧200发红发红质量210装螺母拧紧力矩1N.mX-R图表单编号：QP024/F-001版 本 号：APart Submission WarrantP art N am eP art N um berSaf ety and/orGovernm ent R egulationE ngineering D raw ing C hange LevelD atedAdditional E ngineering C

5、 hangesD atedShow n on D raw ing N o.P urchase Order N o.Weight (kg)C hecking Aid N o.E ngineering C hange LevelD atedSU PPLIE R MAN U FACTU R IN G IN FOR MATIONSU B MISSION IN FOR MATIONSupplier Nam e & Supplier CodeC ustom er N am e/D ivisionBuyer/Buyer C odeSt reet A ddressApplicationCit ySt

6、at eZipN ote:D oes this part contain any restricted or reportable substancesAre plastic parts identified w ith appropriate ISO m arking codesR E ASON FOR SU B MISSIONR E QU E STE D SU B MISSION LE VE L (Check one)SU B MISSION R E SU LTSThe results fo r dimensio nal measurements material and functio

7、nal tests appearance criteria statistical pro cess packageThese results meet all drawing and specificatio n requirements: (I f N O - E xplanation R equired)M old / C avity / P roduction P rocessD E CLAR ATIONI hereby affirm that the samples represented by this warrant are representative o f o ur par

8、ts, have been made to the applicableP ro ductio n P art A ppro val P ro cess M anual 3rd Editio n Requirements. I further warrant these samples werepro duced at the pro ductio n rate o f / 8 ho urs. I have no ted any deviatio ns fro m this declaratio n belo w.E XP LAN ATI ON /C OM M E N TS: Dim ensi

9、onalMaterials/FunctionalAppearanceInitial Subm issionEngineering Change(s)Tooling: Transfer,Replacem ent, Refurbishm ent or additionalCorrection of DiscrepancyTooling Inactive 1 yearChange to Optional Construction or MaterialSub-Supplier or Material Source ChangeChange in Part ProcessingPart Produce

10、d at Additional LocationOther - Please specifyLevel 1 - Warrant only (and for designated appearance item s, an Appearance Approval Report) subm itted to custom er.Level 2 - Warrant with product sam ples and lim ited supporting data subm itted to custom er.Level 3 - Warrant with product sam ples and

11、com plete supporting data subm itted to custom er.Level 4 - Warrant and other requirem ents as defined by custom er.Level 5 - Warrant with product sam ples and com plete supporting data reviewed at suppliers m anufacturing location. Yes NO No YES YES YES NO NO PROCESS FLOW DIAGRAM 过过程程流流程程图图DaimlerC

12、hrysler Ford General Motors 戴姆勒克莱斯勒、福特、通用汽车Number文件编号版本号:QP024/F-001 APart Number零件号:CP-73Establish Date创建日期:2009/5/6Part Description零件描述:封闭型电热塞Revamp Date修改日期:Rev工程图样更改等级:APREPARED BY:责任人Li Ying ZhongSymbol InstructionsOp-Seq.工序号FABRICATION制造MOVE 搬运STORE 贮存INSPECT 检验Rework返工Scrap/ Contain报废/控制Chang

13、eover工序特性OPERATIONDESCRIPTION过程描述Class(KPC, QCI)产品特性序号Significant ProductCharacteristics(Outputs)关键产品特性IClass(KCC, QCC)过程特性编号Significant ProcessCharacteristics(Inputs)关键过程特性CONTROLMETHODS控制方法表单编号：QP024/F-001版 本 号：APart Submission WarrantP art N am eP art N um berSaf ety and/orGovernm ent R egulation

14、E ngineering D raw ing C hange LevelD atedAdditional E ngineering C hangesD atedShow n on D raw ing N o.P urchase Order N o.Weight (kg)C hecking Aid N o.E ngineering C hange LevelD atedSU PPLIE R MAN U FACTU R IN G IN FOR MATIONSU B MISSION IN FOR MATIONSupplier Nam e & Supplier CodeC ustom er N

15、 am e/D ivisionBuyer/Buyer C odeSt reet A ddressApplicationCit ySt at eZipN ote:D oes this part contain any restricted or reportable substancesAre plastic parts identified w ith appropriate ISO m arking codesR E ASON FOR SU B MISSIONR E QU E STE D SU B MISSION LE VE L (Check one)SU B MISSION R E SU

16、LTSThe results fo r dimensio nal measurements material and functio nal tests appearance criteria statistical pro cess packageThese results meet all drawing and specificatio n requirements: (I f N O - E xplanation R equired)M old / C avity / P roduction P rocessD E CLAR ATIONI hereby affirm that the

17、samples represented by this warrant are representative o f o ur parts, have been made to the applicableP ro ductio n P art A ppro val P ro cess M anual 3rd Editio n Requirements. I further warrant these samples werepro duced at the pro ductio n rate o f / 8 ho urs. I have no ted any deviatio ns fro

18、m this declaratio n belo w.E XP LAN ATI ON /C OM M E N TS: Dim ensionalMaterials/FunctionalAppearanceInitial Subm issionEngineering Change(s)Tooling: Transfer,Replacem ent, Refurbishm ent or additionalCorrection of DiscrepancyTooling Inactive 1 yearChange to Optional Construction or MaterialSub-Supp

19、lier or Material Source ChangeChange in Part ProcessingPart Produced at Additional LocationOther - Please specifyLevel 1 - Warrant only (and for designated appearance item s, an Appearance Approval Report) subm itted to custom er.Level 2 - Warrant with product sam ples and lim ited supporting data s

20、ubm itted to custom er.Level 3 - Warrant with product sam ples and com plete supporting data subm itted to custom er.Level 4 - Warrant and other requirem ents as defined by custom er.Level 5 - Warrant with product sam ples and com plete supporting data reviewed at suppliers m anufacturing location.

21、Yes NO No YES YES YES NO NO220成品检验零件外观无缺陷按图纸要求检验产品额定电压：DC11V电流值：施加额定电压在25S时,电流8.00.5A温升特性：施加额定电压在800时小于10S,距电热塞端部5-10mm间过电压试验：电流为0,产品短路,断路,电流大于5A均为不合格品扭力力距：1N.m气密性试验：15S内电热塞头部不得有漏气现象检具，量具检测产品，保证合格样件230 packaging包装240moving to warehouse搬运入库250发货Deliver the goods260annaul audition年度质量审核编制： 李应忠/2009.06

22、.12 校对： 批准：第 3 页，共 16 页 CONTROLCONTROL PLANPLAN 控控制制计计划划DaimlerChrysler Ford General Motors 戴姆勒克莱斯勒、福特、通用汽车Control Plan Number控制计划编号版本号Key Contact/Phone主要联系/电话：-63288732Date (Orig.)创建日期：2009.06.29QP04/CP-006 ADate (Rev.)修改日期：Part Number/Latest Change Level零件号/更改等级Core Team核心小组成员：孙增华（ 常务副总）曹福树（生产经理）

23、Customer Engineering Approval/Date (If Reqd.)CP-73/封闭型电热塞朱思之（项目工程师）胡青权（装配车间主任 等项目开发小组客户工程批准日期（如果有要求）Part Name/Description零件名称/描述Supplier/Plant Approval/Date供应商/工厂批准日期Customer Quality Approval/Date (If Reqd.)电热塞总成客户质量批准日期（如果有要求）Supplier/Plant供应商/工厂Supplier Code供应商代码Other Approval/Date (If Reqd.)其它批准日

24、期（如果有要求）Other Approval/Date (If Reqd.)宁波兴慈热动电器有限公司Ningbo Xingci Thermal electhricappliances CO.,Ltd其它批准日期（如果有要求）MACHINE,CHARACTERISTICS 特性METHODS 方法PART/PROCESS NAME/DEVICE,SPECIALPROCESSOPERATIONJIG,TOOLS,CHAR.PRODUCT/PROCESSEVALUATION/SAMPLE 样本CONTROLRespREACTIONNUMBERDESCRIPTIONFOR MFG.NO.PRODUCT

25、PROCESSCLASSSPECIFICATION/MEASUREMENTSIZEFREQMETHODPLAN零件/过程编号过程名称/操作描述机器，装置，夹具，工装编号产品特性过程特性特殊特性TOLERANCE产品/过程/规范/公差TECHNIQUE评价/测量技术数量频率控制方法责任人反应计划10材料采购1采购资料资料齐全，正确采购控制程序次每批采购申请单采购员采购评审20临时存放1来料待检各零部件所需材料目测次每批Visual and labelling目视检查和标签Inspector检验员1.Quarantine隔离2.nameplate标示30进料检验1MaterialTypeSpeci

26、fication材料类型特性 进料检验零部件材料Material Cerificate材料证明ones1次Per batch每批Materialcertificate log材料保证书来料检验单和委外1.Quarantine隔离2.nameplate标示3.Notify supplier toreturn the material ifrequired通知供应商退回材料2Material component材料成分Spectrometer光谱仪1 bar1块Per batch每批MaterialtestInstruction材料成份检测指导书3力学性能零部件材料万能拉力试验机all power

27、ful pullingforce test machine一次once每年per year国家标准2、测试报告（委外）来料检验单和中国兵器工业金属材料理化检测中心4数量目测次每批来料检验单检验员5外观目测6尺寸相关量具检具7调节丝电阻0.280+0.1电桥表单编号：QP024/CP-006版 本 号：AProtype样件Pre-launch试生产Production量产Part Submission WarrantP art Nam eP art Num berSafety and/orGovernm ent RegulationE ngineering Draw ing Change Lev

28、elDatedAdditional E ngineering ChangesDatedShow n on Draw ing No.P urchase Order No.Weight (kg)Checking Aid No.E ngineering Change LevelDatedSUPPLIE R MANUFACTURING INFORMATIONSUBMISSION INFORMATIONSupplier Name & Supplier CodeCustom er Nam e/DivisionBuyer/Buyer CodeSt reet AddressApplicationCit

29、 ySt at eZipNote:Does this part contain any restricted or reportable substancesAre plastic parts identified w ith appropriate ISO m arking codesRE ASON FOR SUBMISSIONRE QUE STE D SUBMISSION LE VE L (Check one)SUBMISSION RE SULTSThe results fo r dimensio nal measurements material and functio nal test

30、s appearance criteria statistical pro cess packageThese results meet all drawing and specificatio n requirements: (I f NO - E xplanation Required)M old / Cavity / P roduction P rocessDE CLARATIONI hereby affirm that the samples represented by this warrant are representative o f o ur parts, have been

31、 made to the applicableP ro ductio n P art A ppro val P ro cess M anual 3rd Editio n Requirements. I further warrant these samples werepro duced at the pro ductio n rate o f / 8 ho urs. I have no ted any deviatio ns fro m this declaratio n belo w.E XP LANATI ON/COM M E NTS: Dim ensionalMaterials/Fun

32、ctionalAppearanceInitial Subm issionEngineering Change(s)Tooling: Transfer,Replacem ent, Refurbishm ent or additionalCorrection of DiscrepancyTooling Inactive 1 yearChange to Optional Construction or MaterialSub-Supplier or Material Source ChangeChange in Part ProcessingPart Produced at Additional L

33、ocationOther - Please specifyLevel 1 - Warrant only (and for designated appearance item s, an Appearance Approval Report) subm itted to custom er.Level 2 - Warrant with product sam ples and lim ited supporting data subm itted to custom er.Level 3 - Warrant with product sam ples and com plete support

34、ing data subm itted to custom er.Level 4 - Warrant and other requirem ents as defined by custom er.Level 5 - Warrant with product sam ples and com plete supporting data reviewed at suppliers m anufacturing location. Yes NO No YES YES YES NO NO第 4 页，共 16 页 CONTROLCONTROL PLANPLAN 控控制制计计划划DaimlerChrys

35、ler Ford General Motors 戴姆勒克莱斯勒、福特、通用汽车Control Plan Number控制计划编号版本号Key Contact/Phone主要联系/电话：-63288732Date (Orig.)创建日期：2009.06.29QP04/CP-006 ADate (Rev.)修改日期：Part Number/Latest Change Level零件号/更改等级Core Team核心小组成员：孙增华（ 常务副总）曹福树（生产经理） Customer Engineering Approval/Date (If Reqd.)CP-73/封闭型电热塞朱思之（项目工程师）胡

36、青权（装配车间主任 等项目开发小组客户工程批准日期（如果有要求）Part Name/Description零件名称/描述Supplier/Plant Approval/Date供应商/工厂批准日期Customer Quality Approval/Date (If Reqd.)电热塞总成客户质量批准日期（如果有要求）Supplier/Plant供应商/工厂Supplier Code供应商代码Other Approval/Date (If Reqd.)其它批准日期（如果有要求）Other Approval/Date (If Reqd.)宁波兴慈热动电器有限公司Ningbo Xingci Ther

37、mal electhricappliances CO.,Ltd其它批准日期（如果有要求）MACHINE,CHARACTERISTICS 特性METHODS 方法PART/PROCESS NAME/DEVICE,SPECIALPROCESSOPERATIONJIG,TOOLS,CHAR.PRODUCT/PROCESSEVALUATION/SAMPLE 样本CONTROLRespREACTIONNUMBERDESCRIPTIONFOR MFG.NO.PRODUCTPROCESSCLASSSPECIFICATION/MEASUREMENTSIZEFREQMETHODPLAN零件/过程编号过程名称/操

38、作描述机器，装置，夹具，工装编号产品特性过程特性特殊特性TOLERANCE产品/过程/规范/公差TECHNIQUE评价/测量技术数量频率控制方法责任人反应计划表单编号：QP024/CP-006版 本 号：AProtype样件Pre-launch试生产Production量产Part Submission WarrantP art Nam eP art Num berSafety and/orGovernm ent RegulationE ngineering Draw ing Change LevelDatedAdditional E ngineering ChangesDatedShow n

39、 on Draw ing No.P urchase Order No.Weight (kg)Checking Aid No.E ngineering Change LevelDatedSUPPLIE R MANUFACTURING INFORMATIONSUBMISSION INFORMATIONSupplier Name & Supplier CodeCustom er Nam e/DivisionBuyer/Buyer CodeSt reet AddressApplicationCit ySt at eZipNote:Does this part contain any restr

40、icted or reportable substancesAre plastic parts identified w ith appropriate ISO m arking codesRE ASON FOR SUBMISSIONRE QUE STE D SUBMISSION LE VE L (Check one)SUBMISSION RE SULTSThe results fo r dimensio nal measurements material and functio nal tests appearance criteria statistical pro cess packag

41、eThese results meet all drawing and specificatio n requirements: (I f NO - E xplanation Required)M old / Cavity / P roduction P rocessDE CLARATIONI hereby affirm that the samples represented by this warrant are representative o f o ur parts, have been made to the applicableP ro ductio n P art A ppro

42、 val P ro cess M anual 3rd Editio n Requirements. I further warrant these samples werepro duced at the pro ductio n rate o f / 8 ho urs. I have no ted any deviatio ns fro m this declaratio n belo w.E XP LANATI ON/COM M E NTS: Dim ensionalMaterials/FunctionalAppearanceInitial Subm issionEngineering C

43、hange(s)Tooling: Transfer,Replacem ent, Refurbishm ent or additionalCorrection of DiscrepancyTooling Inactive 1 yearChange to Optional Construction or MaterialSub-Supplier or Material Source ChangeChange in Part ProcessingPart Produced at Additional LocationOther - Please specifyLevel 1 - Warrant on

44、ly (and for designated appearance item s, an Appearance Approval Report) subm itted to custom er.Level 2 - Warrant with product sam ples and lim ited supporting data subm itted to custom er.Level 3 - Warrant with product sam ples and com plete supporting data subm itted to custom er.Level 4 - Warran

45、t and other requirem ents as defined by custom er.Level 5 - Warrant with product sam ples and com plete supporting data reviewed at suppliers m anufacturing location. Yes NO No YES YES YES NO NO8发热丝电阻0.750+0.05电桥9发热丝有效圈数9圈目测10调节丝有效圈数27圈目测11调节丝、发热丝直径0.4游标卡尺0-200/0.0212标识零部件材料目测40入库1Material Storage原材

46、料储存零部件材料colour mark标识材料领用卡100%Continueh连续仓库管理规定WarehouoseManagementRegulationWarehouseman仓管员1.Quarantine隔离2.nameplate标示3.Validate验证50领料拖车1领料待生产领用材料符合生产订单和客户要求batch每班每次核对生产通知单领料员1.隔离2.通知仓库退回材料60(C1)焊接微电脑电阻焊接机KD3-200-4S点焊工装1设备点检点检记录点检记录2输出电压电压220-230V5KVA高精度全自动交流稳压器batch每班1次/每班Once/batch1.检验记录2.作业指导书操

47、作工检验员1.停止生产2.通知主管;3.执行改正措施4.必要时更改指导书5.通知工艺员3焊头压力71Kg设备显示屏30进料检验1.Quarantine隔离2.nameplate标示3.Notify supplier toreturn the material ifrequired通知供应商退回材料次每批来料检验单检验员第 5 页，共 16 页 CONTROLCONTROL PLANPLAN 控控制制计计划划DaimlerChrysler Ford General Motors 戴姆勒克莱斯勒、福特、通用汽车Control Plan Number控制计划编号版本号Key Contact/Phon

48、e主要联系/电话：-63288732Date (Orig.)创建日期：2009.06.29QP04/CP-006 ADate (Rev.)修改日期：Part Number/Latest Change Level零件号/更改等级Core Team核心小组成员：孙增华（ 常务副总）曹福树（生产经理） Customer Engineering Approval/Date (If Reqd.)CP-73/封闭型电热塞朱思之（项目工程师）胡青权（装配车间主任 等项目开发小组客户工程批准日期（如果有要求）Part Name/Description零件名称/描述Supplier/Plant Approval

49、/Date供应商/工厂批准日期Customer Quality Approval/Date (If Reqd.)电热塞总成客户质量批准日期（如果有要求）Supplier/Plant供应商/工厂Supplier Code供应商代码Other Approval/Date (If Reqd.)其它批准日期（如果有要求）Other Approval/Date (If Reqd.)宁波兴慈热动电器有限公司Ningbo Xingci Thermal electhricappliances CO.,Ltd其它批准日期（如果有要求）MACHINE,CHARACTERISTICS 特性METHODS 方法PAR

50、T/PROCESS NAME/DEVICE,SPECIALPROCESSOPERATIONJIG,TOOLS,CHAR.PRODUCT/PROCESSEVALUATION/SAMPLE 样本CONTROLRespREACTIONNUMBERDESCRIPTIONFOR MFG.NO.PRODUCTPROCESSCLASSSPECIFICATION/MEASUREMENTSIZEFREQMETHODPLAN零件/过程编号过程名称/操作描述机器，装置，夹具，工装编号产品特性过程特性特殊特性TOLERANCE产品/过程/规范/公差TECHNIQUE评价/测量技术数量频率控制方法责任人反应计划表单编号

51、：QP024/CP-006版 本 号：AProtype样件Pre-launch试生产Production量产Part Submission WarrantP art Nam eP art Num berSafety and/orGovernm ent RegulationE ngineering Draw ing Change LevelDatedAdditional E ngineering ChangesDatedShow n on Draw ing No.P urchase Order No.Weight (kg)Checking Aid No.E ngineering Change L

52、evelDatedSUPPLIE R MANUFACTURING INFORMATIONSUBMISSION INFORMATIONSupplier Name & Supplier CodeCustom er Nam e/DivisionBuyer/Buyer CodeSt reet AddressApplicationCit ySt at eZipNote:Does this part contain any restricted or reportable substancesAre plastic parts identified w ith appropriate ISO m

53、arking codesRE ASON FOR SUBMISSIONRE QUE STE D SUBMISSION LE VE L (Check one)SUBMISSION RE SULTSThe results fo r dimensio nal measurements material and functio nal tests appearance criteria statistical pro cess packageThese results meet all drawing and specificatio n requirements: (I f NO - E xplana

54、tion Required)M old / Cavity / P roduction P rocessDE CLARATIONI hereby affirm that the samples represented by this warrant are representative o f o ur parts, have been made to the applicableP ro ductio n P art A ppro val P ro cess M anual 3rd Editio n Requirements. I further warrant these samples w

55、erepro duced at the pro ductio n rate o f / 8 ho urs. I have no ted any deviatio ns fro m this declaratio n belo w.E XP LANATI ON/COM M E NTS: Dim ensionalMaterials/FunctionalAppearanceInitial Subm issionEngineering Change(s)Tooling: Transfer,Replacem ent, Refurbishm ent or additionalCorrection of D

56、iscrepancyTooling Inactive 1 yearChange to Optional Construction or MaterialSub-Supplier or Material Source ChangeChange in Part ProcessingPart Produced at Additional LocationOther - Please specifyLevel 1 - Warrant only (and for designated appearance item s, an Appearance Approval Report) subm itted

57、 to custom er.Level 2 - Warrant with product sam ples and lim ited supporting data subm itted to custom er.Level 3 - Warrant with product sam ples and com plete supporting data subm itted to custom er.Level 4 - Warrant and other requirem ents as defined by custom er.Level 5 - Warrant with product sa

58、m ples and com plete supporting data reviewed at suppliers m anufacturing location. Yes NO No YES YES YES NO NO4预压1周波5加压时间1周波6焊接时间4周波7焊接扭量20周波8维持时间1周波9休止时间2周波1焊点间距焊点间距4mm游标卡尺0-200/0.023件/次1次/3小时once/3hoursWorkinstruction作业指导书、封样件 Operator操作工1.停止生产2.执行改正措施3.隔离2.标示3.报废2冷态电阻11V电阻1.0电桥batch每班1次/每班Once/b

59、atch3焊接质量焊接牢固，无虚焊，两管同心目测100%Continueh连续70(C2)铆接手工1同心度同心度0.15mm目测1件/次1次/每班Once/batchWorkinstruction作业指导书、封样件 Operator操作工1.停止生产2.通知主管;3.执行改正措施4.隔离，报废2长度间隙长度间隙1mm游标卡尺/0-200/0.023件/次1次/3小时once/3hours1.隔离2.报废60(C1)焊接微电脑电阻焊接机KD3-200-4S点焊工装batch每班1次/每班Once/batch1.检验记录2.作业指导书操作工检验员1.停止生产2.通知主管;3.执行改正措施4.必要时

60、更改指导书5.通知工艺员设备显示屏第 6 页，共 16 页 CONTROLCONTROL PLANPLAN 控控制制计计划划DaimlerChrysler Ford General Motors 戴姆勒克莱斯勒、福特、通用汽车Control Plan Number控制计划编号版本号Key Contact/Phone主要联系/电话：-63288732Date (Orig.)创建日期：2009.06.29QP04/CP-006 ADate (Rev.)修改日期：Part Number/Latest Change Level零件号/更改等级Core Team核心小组成员：孙增华（ 常务副总）曹福树（生产经理） Customer Enginee