富士康驗廠制程能力評估

2 制程能力 / Process Control   
2.1 General                    
 2.1.1     機器設(shè)備的日常保養(yǎng)記錄掛在機器處而且都是最新的嗎? Are Daily Maintenance logs kept at the machine and are they up to date?
 2.1.2     量測儀器如卡尺、色差計、三次元設(shè)備、分光儀…(可讀取數(shù)值)是否有保養(yǎng)與維修記錄? 是否有校驗標示, 有否過期? 免校儀器是否有明確標示? Are there maintain and repair record of test equipments such as caliper, chromatic aberration meter, 3D equipment, spectrometer (numerical value available)? Is there calibration mark and if outdate.
 2.1.3     "生產(chǎn)前是否對所有設(shè)備與夾治具實施檢查? 檢查結(jié)果是否記錄?
Whether all equipments and fixtures are checked and recorded before production? "
 2.1.4     對于儀器設(shè)備和治具上的耗材(如cable, connector等)是否符合使用要求? 是否有汰舊換新計劃? Does the consumable (consumable material, expendable) such as cable, connector using in the equipment and fixture meet the use requirement? Is there a change plan for them?
 2.1.5     是否作業(yè)員身邊都有機器設(shè)備操作的SOP? Does the Operator have the Standard Operating Procedure (SOP) for the machine available to them at all times?
 2.1.6     是否有證據(jù)顯示對操作員進行過SOP的訓(xùn)練和鑒定? Is there evidence that the Operator has been trained and certified against the Standard Operating Procedure for the Machine?
 2.1.7     操作員知道機器SOP的內(nèi)容?他們遵守了嗎? Does the Operator know the content of the Standard Operating Procedure for the Machine and do they and follow it?
 2.1.8     "生產(chǎn)前是否對所有材料進行確認，外觀及P/N是否對應(yīng)?
Are all materials checked, such as appearance and P/N before production?"
 2.1.9     "生產(chǎn)線之質(zhì)量報告，是否作歸納分析，如材料、人員或設(shè)計不良? 質(zhì)量報告是否作追蹤對策報告并反饋給相關(guān)單位?
Whether the quality report of product line perform the conformity analysis (such as materials, stuff and mis-design) and make the tracking report of improvement to feedback related department?"
 2.1.10 停線標準是否清楚說明質(zhì)量和緩沖的限制要求? Are line shutdown criteria clearly specified for both quality and buffer limiting requirements?
 2.1.11 是否有証據(jù)顯示質(zhì)檢員經(jīng)過培訓(xùn)認証并且具有基本的品保和統(tǒng)計知識? Is there evidence that quality inspector has been trained/certified in basic quality practices and statistics/SQC?

2.2    富士康驗廠進料管控   
 2.2.1      是否將物料按其編號、名稱、規(guī)格、消耗量、供應(yīng)商進行分類編號，建立物料清單？Do you divide the parts and creat the BOM by the PN, name, Spec., quantity the parts will be used and vendors of the parts?
 2.2.2      物料的儲存環(huán)境是否嚴格按要求控制溫、濕度? Do you require storage environment's temp. and the humidity as it is prescribed?
 2.2.3      是否有檢驗規(guī)范介定物料的常規(guī)檢查項目以及檢查方法? Whether inspection rule includes normal inspection items and methods?
 2.2.4     待檢材料和已檢驗的材料是否被適當(dāng)?shù)母綦x并標識? Do you devide and label the materials which are to be inspected and the materials which have been inspected properly?
 2.2.5     合格材料和不合格材料是否被適當(dāng)?shù)母綦x并標識? Do you devide and label the qualified material and disqualified material properly?
 2.2.6     是否有做進料檢驗記錄及歷史記錄以備查?Do you take records of import inspection and store them for review?
 2.2.7     不良物料訊息是否以書面形式及時反饋供應(yīng)商并要求其改善?whether the message of bad materials feedback to the supplier in time,and demand the supplier improve?
   
2.3 富士康驗廠倉庫管理 Ware House
 2.3.1     對工序中使用的化學(xué)品保存條件是否有標準指導(dǎo)書，并有相應(yīng)記錄? Is there a SOP and related record for the chemical storage condition?
 2.3.2     對油墨，粘膠等重要物品如何進行保存?是否妥當(dāng)? How to storage the ink and glue? Is it correct?
 2.3.3     是否對倉庫的溫濕度進行管制并記錄? Is the temperature and humidity of the warehouse controlled and recorded?
 2.3.4     在材料的外箱上對材料的保存期限是否有適當(dāng)?shù)亩x及鑒別?Do you define and discriminate the materials' limited storage periode on the material box properly?
 2.3.5     是否有書面程序文件根據(jù)材料的保存期限規(guī)定先進先出原則? Is there a written process document which prescribed the FIFO rule according to the materials' storage period?
 2.3.6     是否有定期實施庫存呆料及過期材料處理及標示.Whether the stocks and overdue materials were dealt with and marked?
 2.3.7     是否有規(guī)定原材料及成品擺放高度? Do you crescribe the limited height the raw material and finished products stack?
 2.3.8     對生產(chǎn)線退還部件是否有管制? 是否有相應(yīng)標準? Are the components back from the product line controlled with the related standards?
 2.3.9     是否清楚的劃分區(qū)域擺放部件及標記? Is the area plotted and marked clearly for different components?
 2.3.10 如何確保發(fā)料不會產(chǎn)生混料問題﹖是否有做混料防止措施? Is there a effective measure to avoid material mixing?
 2.3.11 成品擺放是否明確區(qū)隔，不會造成出貨錯誤? Are the final products plotted distinctly to avoid shipment mistakes?
 2.3.12 成品堆棧擺放是否適宜，不會造成產(chǎn)品損毀? Are the final products stacked correctly to avoid damage?

2.4 "原紙-輥軋-粘合-縱切-橫切-紙板堆碼-印刷-分紙-壓線-開槽-釘箱-粘箱
Raw material-Wheel press-Paste-Cut-Storehouse-Print-Die cut-Rail-Paste"                           
    "瓦楞加工：原紙-輥軋-粘合-縱切-橫切-紙板堆碼 Raw material-Wheel press-Paste-Cut-Storehouse"           

 2.4.1     "是否有相應(yīng)的設(shè)備操作說明書及緊急異常處理說明書懸掛于操作者可視位置.作業(yè)員是否有經(jīng)充分的培訓(xùn)上崗并佩戴相應(yīng)標識.
If have SOP to instruct operate and issue deal with? If abundant train for operator before work on the station?"
 2.4.2     是否有辦法或應(yīng)急機制確保加熱系統(tǒng),空壓系統(tǒng),電氣系統(tǒng)的穩(wěn)定 ，以滿足生產(chǎn)制造的順利進行？If the SOP defined  and implemented for heating system, air pressure system,electric system stable and ensure the smoothly production?
 2.4.3     "作業(yè)現(xiàn)場是否有相應(yīng)的流程卡及SOP指導(dǎo)如何作業(yè).流程卡是否有對原物料,日期,定單號,客戶,進料批次,規(guī)格,機臺,治具等信息做定義.SOP中是否有詳細定義如何確認這些信息？
If hang some flow chart and SOP on site? If record raw material,date code,PO,customer,lot no,spec,equipment,fixture information in flow chart,if SOP instruct how to double check."
 2.4.4     "生產(chǎn)前是否有做首件檢查,首件是否有檢查產(chǎn)品的關(guān)鍵尺寸(長,寬,厚度)及材料,外觀等重點項目.
If FAI execution before production, if FAI define how to check the dimension,raw material and cosmetic information?"
 2.4.5     "是否定義原紙支架的進給速率？
If defined the feed speed for the paper brack?"
 2.4.6     "是否有文件定義原紙預(yù)熱器的溫度及預(yù)熱時間？
If defined the equipment temparature and heating time for paper pre-heating ?"
 2.4.7     "是否有文件定義瓦楞輥的配合壓力(間隙)、平行度、中高等重要技術(shù)指標.
If defined the gap,parallel and high etc imprtant parameter for reel?"
 2.4.8     "是否有文件定義單面紙板的固化時間?
If defined the time of solidify for corrugated paper？"
 2.4.9     "是否有文件定義單面紙板預(yù)熱器的溫度及預(yù)熱時間?
If defined the equipment temparature and heating time for corrugated paper?"
 2.4.10 "是否有文件定義瓦楞涂膠膠量及如何確保涂膠均勻？
If defined the glue dosage for corrugated paper? How to ensure the glue self?"
 2.4.11 "是否有文件定義上膠后紙板固化環(huán)境(溫度,壓力,時間)
If defined the environment(temparature,pressure,time etc...) of glue solidify after corrugated paper coated glue?"
 2.4.12 "是否有文件定義涂膠的原物料成分及比例?涂膠的特性如何管制？
If defined the ingredient of glue and dosage? How to control the sticky character for glue?"
    印刷制程-Print
 2.4.13 是否有文件規(guī)定印刷材料規(guī)格,產(chǎn)品承認,ECN之標準作業(yè)程序并實施？If the procedure about process and material Qualification , ECN control prepared and implemented ?
 2.4.14 素材表面是否清潔干凈,拿取/轉(zhuǎn)移方式是否合適?SOP 是否明確定義  Make sure that part suface is clean and  methord of hold/transferproduct   is good and it can protect products not bring defect. Whether SOP has been defined?
 2.4.15 環(huán)境是否清潔,是否有定期監(jiān)測？是否采用水簾、風(fēng)淋、靜電除塵等方式?
      If the  environment is clean and tested  regularly? If the methond  of suface clean is suitable?
 2.4.16 網(wǎng)板,刮刀或膠頭,鋼板規(guī)格型號是否符合SOP要求？是否對網(wǎng)板或膠頭,鋼板使用壽命進行管控？履歷卡是否制做并管理?保管狀態(tài)是否良好?是否有檢查、維修、保養(yǎng),報廢和更換作業(yè)記錄？Is the tooling type apply with sop requment? Is there tool  history card for management? Is the molding state good or not?  Any record for tool inspection,repair,maintain,change and abolition?
 2.4.17 "油墨粘度,刮刀角度,速度和壓力是否合適?(絲印)                                                   
If the parameter Ink stickness,blade angle/speed/pressure is suitable?"
 2.4.18 "操作員是否能及時調(diào)節(jié)絲印網(wǎng)板與承印物之間的距離?(絲印)                                  
Could the operation  adjust the height of screen and part according to the status?"
 2.4.19 油墨粘度, 膠頭壓力,取墨速度和上升速度是否合適?操作員是否經(jīng)過相關(guān)培訓(xùn),考核?(移印) If the parameter Ink tickness, pin pressure/speed/ is suitable?
 2.4.20 工件/膠頭定位是否精確,絲網(wǎng)/鋼板是否鎖緊?  Location of part and pin is correct,the screen is fixed
 2.4.21 產(chǎn)品涂層檢查如何管控？檢測項目（膜厚、硬度、附著性、耐磨性等）是否按要求進行檢測？測量結(jié)果是否記錄并符合產(chǎn)品要求？                            How to control the coating? The test of thickness/hardess/adhesive etc.  are done, and record the result
 2.4.22 無塵室是否有定期監(jiān)測?有無檢測記錄？If the clean room is tested regularly and record the result.
 2.4.23 膜厚計是否有校正,并定期更換歸零片? If the thickness jig is regulated,and modify the part?
 2.4.24 "在制品是否依lot no.是否識別管理 以方便異常追溯處理?                                  
         If the mold WIPs are managed following lot no. or not for abnormal traceability management?"
 2.4.25 作業(yè)現(xiàn)場 產(chǎn)品外觀檢驗條件如照度值是否標準？是否有標準如限度樣品方便作 檢查比對？作業(yè)人員對外觀檢查標準是否了解？如果零件外觀超出限度樣品管控，如何處理？If the surrunding conditions are suitable ,  SIP and limited samples are avaliable for operators and QC implementing  cosmetic inspection? How to hadle if any cosmetic issue found?
    "分紙-壓線-開槽-釘箱-粘箱
Die cut-Nail-Paste"
 2.4.26 "是否有文件定義圓模模切的轉(zhuǎn)速?  If defined the roll speed for die cut?"
 2.4.27 "SOP是否詳細定義紙板的定位？
If SOP defined the location of paper board?"
 2.4.28 "是否有文件定義平模模切的上下形程？
If defined the route of the cutter?"
 2.4.29 是否有文件定義箱釘?shù)亩ㄎ唬?br /> If defined the location of nail for fix the paper board?"

2.5 包裝出貨 Packing and Shipment                   
 2.5.1     是否有包裝規(guī)范? Is there packing specification?
 2.5.2     包裝前是否對外觀進行檢查? 是否制定檢查標準? Is there appearance inspection before packing? Is there inspection standard?
 2.5.3     是否有方法預(yù)防短料的現(xiàn)象? Is there method to prevent less or more prodcuts for shipment?
 2.5.4     是否有產(chǎn)品出貨檢驗相關(guān)標準?是否規(guī)定重點檢查項目? Is there a shipment inspection standard? Are there key items defined to check?
 2.5.5     檢查站別是否有適當(dāng)?shù)臋z查工具?檢查時燈光是否足夠? Are there proper inspection tools in the inspection station? Is the light enough when inspect?
 2.5.6     以前的質(zhì)量問題和客戶抱怨點是否被寫在相關(guān)料號的檢查記錄上? Do you take relative records for former quality issues and customers' compliants?
 2.5.7     是否執(zhí)行檢查的追蹤和控制?如果檢查人員的能力不夠，是否進行再培訓(xùn)或工作的轉(zhuǎn)換? Do you control inspection and tracing? Do you retrain or shift the inspectors if the inspectors are not competent?
 2.5.8     對出貨中的不良品, 是否有專門的處理程序? 是否會發(fā)出不良報告? Is there special procedure to deal with the failure product in the shipment? Is there failure report to be released?
 2.5.9     是否建立Hold Shipment作業(yè)程序? Is there procedure of Hold Shipment?
 2.5.10 當(dāng)產(chǎn)品為特采品時，產(chǎn)品是否完成特采流程并留下記錄? Is there special-adopted procedure and record when the product is  special-adopted?

2.6 富士康驗廠可靠性管控  Reliability Managerment                   
 2.6.1     是否有測試設(shè)備及治具管理之一覽表? Is there a management list of the test equipment and fixture ?
 2.6.2     是否對測試設(shè)備進行定期校正? Is there periodic calibration for the test equipment?
 2.6.3     新產(chǎn)品開發(fā)流程中是否有進行可靠性測試? 是否有依照開發(fā)流程進行可靠度測試? Is the reliability test done during the new product development process?  Whether it follow the development process?
 2.6.4     有無環(huán)境、運輸?shù)鹊目煽慷葴y試計劃并進行測試, 比如溫度、濕度、振動、沖擊、跌落等? Is there the reliability test plan about environment and transportation, as temperature, humidity, shock, vibration, drop, etc?
 2.6.5     檢測異常發(fā)生時，是否有可靠度測試異常處理程序，是否嚴格按照程序處理? Is there the reliability test abnormal disposal program when the abnormal happen, and whether deal with the abnormal according to the program strictly?