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en/business/equipment-warehouse.md
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# Equipment and Warehouse Management
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## 1. Function Overview
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This section covers two major modules: Equipment Management and Warehouse Logistics. It implements full lifecycle management of equipment and warehouse logistics management of materials to ensure smooth production processes.
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**Main Contents:**
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| Chapter | Main Content |
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|---------|-------------|
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| Equipment Management | Equipment ledger, inspection & maintenance, fault repair, OEE analysis |
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| Warehouse Logistics | Receiving management, issuing management, inventory management |
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## 2. Equipment Management
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### 2.1 Equipment Ledger
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**Equipment Information Management:**
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| Function | Description |
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|----------|-------------|
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| Equipment Registration | Basic equipment information entry |
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| Equipment Query | Query equipment information by conditions |
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| Equipment Change | Equipment information change management |
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| Equipment Scrap | Equipment scrap process handling |
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| Equipment Documents | Equipment document management |
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**Equipment Lifecycle:**
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```
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Equipment Procurement → Equipment Installation → Equipment Acceptance → Equipment Operation → Equipment Maintenance → Equipment Scrap
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```
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### 2.2 Equipment Inspection
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**Inspection Types:**
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| Inspection Type | Execution Cycle | Executor | Main Content |
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|-----------------|----------------|----------|--------------|
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| Daily Inspection | Daily | Operator | Equipment running status check |
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| Periodic Inspection | Weekly/Monthly | Maintenance Technician | Equipment performance check |
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| Precision Inspection | Quarterly/Yearly | Engineer | Equipment accuracy check |
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**Inspection Process:**
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```
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Inspection Plan Generation → Inspection Task Assignment → Execute Inspection → Inspection Record → Abnormal Handling
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```
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**Inspection Execution Steps:**
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1. Receive inspection task
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2. Arrive at equipment location
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3. Perform inspection item by item according to standards
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4. Record inspection results
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5. Submit inspection record
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6. Trigger abnormal handling process if any abnormality found
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**Inspection Record Information:**
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| Record Item | Description |
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|-------------|-------------|
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| Inspection Order No. | Unique identifier for inspection order |
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| Equipment No. | Equipment being inspected |
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| Inspection Type | Daily/Periodic/Precision |
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| Inspector | Person performing inspection |
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| Inspection Time | Inspection time |
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| Inspection Items | Items being inspected |
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| Inspection Result | Normal/Abnormal |
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| Abnormal Description | Description of abnormality |
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### 2.3 Equipment Maintenance
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**Maintenance Types:**
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| Maintenance Type | Cycle | Content | Man-hours |
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|------------------|-------|---------|-----------|
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| Daily Maintenance | Daily | Cleaning, lubrication, tightening | 15-30min |
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| Level 1 Maintenance | Weekly | Cleaning, lubrication, adjustment | 2-4h |
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| Level 2 Maintenance | Monthly | Cleaning, lubrication, tightening, replace wear parts | 8h |
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| Level 3 Maintenance | Quarterly | Comprehensive inspection, adjustment, replacement | 1-2 days |
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| Major Overhaul | Yearly | Complete disassembly and inspection | 3-7 days |
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**Maintenance Process:**
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```
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Maintenance Plan → Maintenance Preparation → Maintenance Execution → Maintenance Record → Acceptance Confirmation
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```
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**Maintenance Content:**
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| Maintenance Item | Content | Required Materials |
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|-----------------|---------|-------------------|
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| Cleaning | Equipment surface and internal cleaning | Cleaning agent, rags |
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| Lubrication | Lubrication of moving parts | Lubricating oil |
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| Tightening | Check and tighten loose parts | Wrenches and tools |
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| Adjustment | Adjust equipment parameters | Adjustment tools |
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| Replacement | Replace wear parts | Spare parts |
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### 2.4 Equipment Fault Management
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**Fault Classification:**
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| Fault Category | Description | Repair Requirement |
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|----------------|-------------|-------------------|
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| Minor Fault | No impact on production | Repair within 2 hours |
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| General Fault | Partial function affected | Repair within 4 hours |
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| Serious Fault | Equipment down | Repair within 8 hours |
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| Emergency Fault | Equipment damaged | Immediate response |
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**Fault Handling Process:**
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```
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Fault Discovery → Fault Report → Fault Diagnosis → Repair Processing → Repair Acceptance → Fault Record
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```
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**Fault Reporting Steps:**
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1. Discover equipment fault
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2. Assess fault impact
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3. Emergency shutdown (if needed)
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4. Submit fault report
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5. Maintenance technician receives work order
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6. Fault diagnosis
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7. Execute repair
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8. Repair acceptance
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9. Archive fault record
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**Fault Report Information:**
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| Field | Description |
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|-------|-------------|
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| Report No. | Unique identifier for fault report |
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| Equipment No. | Faulty equipment |
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| Fault Type | Type of fault |
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| Fault Description | Description of fault |
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| Fault Time | Time fault discovered |
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| Reporter | Person reporting fault |
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| Urgency Level | Emergency/General/Minor |
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| Impact Scope | Impact on production |
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**Maintenance Record Information:**
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| Record Item | Description |
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|-------------|-------------|
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| Repair No. | Unique identifier for repair order |
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| Repair Technician | Person performing repair |
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| Repair Start Time | Start time of repair |
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| Repair End Time | Completion time of repair |
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| Fault Cause | Cause of fault |
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| Repair Measures | Repair methods taken |
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| Spare Parts Replaced | List of replaced parts |
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| Repair Result | Repair effectiveness |
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### 2.5 Equipment OEE Analysis
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**OEE Concept:**
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OEE (Overall Equipment Effectiveness) is a ratio measuring the actual production capacity versus the theoretical production capacity of equipment.
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**OEE Calculation Formula:**
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```
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OEE = Availability × Performance × Quality
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Where:
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- Availability = Actual Operating Time / Planned Operating Time × 100%
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- Performance = Actual Output / Theoretical Output × 100%
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- Quality = Qualified Product Quantity / Total Output Quantity × 100%
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```
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**OEE Standards:**
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| OEE Value | Level | Description |
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|-----------|-------|-------------|
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| ≥85% | World Class | Excellent |
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| 70%-85% | Good | Meeting standard |
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| 60%-70% | Average | Needs improvement |
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| <60% | Poor | Requires focused improvement |
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**OEE Analysis Dimensions:**
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| Analysis Dimension | Loss Type | Description |
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|-------------------|-----------|-------------|
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| Availability | Fault Downtime | Downtime due to equipment failure |
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| Availability | Changeover & Setup | Product changeover and setup time |
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| Performance | Idle & Minor Stops | Short stops |
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| Performance | Speed Loss | Running speed below theoretical speed |
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| Quality | Scrap | Defective products |
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| Quality | Rework | Products requiring rework |
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**OEE Improvement Measures:**
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| Loss Type | Improvement Measures |
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|-----------|---------------------|
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| Fault Downtime | Strengthen preventive maintenance |
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| Changeover & Setup | Optimize changeover process |
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| Idle & Minor Stops | Optimize operation process |
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| Speed Loss | Equipment upgrade and modification |
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| Scrap & Rework | Strengthen quality control |
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## 3. Warehouse Logistics
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### 3.1 Warehouse Layout
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**Warehouse Zone Planning:**
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| Zone Type | Purpose | Characteristics |
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|-----------|---------|----------------|
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| Inspection Zone | Pending inspection materials | Isolated storage |
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| Raw Material Zone | Raw material storage | Zoned by category |
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| Semi-finished Zone | Semi-finished product storage | Batch management |
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| Finished Goods Zone | Finished product storage | FIFO |
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| Return Zone | Returned materials | Separate management |
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| Scrap Zone | Scrap storage | Safety isolation |
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| Defective Zone | Defective product storage | Clear identification |
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**Location Coding Rules:**
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| Code Example | Meaning |
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|--------------|---------|
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| A-01-001 | Zone A, Row 01, Position 001 |
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| B-02-005 | Zone B, Row 02, Position 005 |
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| C-03-010 | Zone C, Row 03, Position 010 |
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### 3.2 Receiving Management
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**Receiving Types:**
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| Receiving Type | Description | Document Type |
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|----------------|-------------|---------------|
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| Purchase Receiving | Purchased materials arrival | Purchase Receipt |
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| Production Receiving | Production finished goods | Production Receipt |
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| Return Receiving | Sales return | Return Receipt |
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| Transfer Receiving | Transfer from other warehouse | Transfer Order |
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| Other Receiving | Other reasons | Other Receipt |
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**Receiving Process:**
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```
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┌──────────┐ ┌──────────┐ ┌──────────┐ ┌──────────┐
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│ Arrival │───▶│ Document │───▶│ IQC │───▶│ Inspection│
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│ Receive │ │ Create │ │ Trigger │ │ Execute │
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└──────────┘ └──────────┘ └──────────┘ └──────────┘
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│
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▼
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┌──────────┐ ┌──────────┐ ┌──────────┐ ┌──────────┐
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│Confirm │◀───│Allocate │◀───│Location │◀───│ Qualified│
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│Receiving │ │ Location │ │ Select │ │ Decision│
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└──────────┘ └──────────┘ └──────────┘ └──────────┘
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```
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**Receiving Operation Steps:**
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1. Materials arrive, receive delivery note
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2. Create receiving document
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3. System automatically pushes IQC inspection task
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4. Execute incoming inspection
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5. After passing inspection, allocate location
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6. Put materials onto designated location
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7. Scan location to confirm
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8. Complete receiving
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**Receiving Document Information:**
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| Field | Description |
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|-------|-------------|
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| Receipt No. | Unique identifier for receipt |
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| Receiving Type | Purchase/Production/Return etc. |
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| Supplier | Material supplier (for purchase) |
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| Related Document | Purchase order/work order etc. |
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| Receiving Date | Receiving date |
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| Material Details | List of received materials |
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| Warehouse | Receiving warehouse |
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| Status | Pending inspection/Received etc. |
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### 3.3 Issuing Management
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**Issuing Types:**
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| Issuing Type | Description | Document Type |
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|--------------|-------------|---------------|
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| Production Issue | Materials for production | Issue Order |
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| Sales Issue | Sales delivery | Sales Issue Order |
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| Return Issue | Return to supplier | Return Order |
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| Transfer Issue | Transfer to other warehouse | Transfer Order |
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| Other Issue | Other reasons | Other Issue Order |
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**Issuing Process:**
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```
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┌──────────┐ ┌──────────┐ ┌──────────┐ ┌──────────┐
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│ Material │───▶│ Document │───▶│ Picking │───▶│ Approval │
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│ Request │ │ Create │ │ Prepare │ │ Pass │
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└──────────┘ └──────────┘ └──────────┘ └──────────┘
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│
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▼
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┌──────────┐ ┌──────────┐
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│Confirm │◀───│ Scan │
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│ Issuing │ │ Issue │
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└──────────┘ └──────────┘
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```
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**Issuing Operation Steps:**
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1. Create issue order based on work order or manually
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2. Select required materials
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3. System checks inventory status
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4. Approve issue order
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5. Warehouse personnel prepare and pick materials
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6. Scan materials and locations
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7. Confirm issuing
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8. Deliver materials to using department
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**Issue Order Information:**
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| Field | Description |
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|-------|-------------|
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| Issue No. | Unique identifier for issue order |
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| Issue Type | Production issue/Other |
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| Related Work Order | Work order related to issue |
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| Issue Department | Department requesting materials |
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| Issuer | Person issuing materials |
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| Issue Date | Issue date |
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| Material Details | List of issued materials |
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| Warehouse | Issuing warehouse |
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| Status | Pending approval/Issued etc. |
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### 3.4 Inventory Management
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**Inventory Query:**
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| Query Dimension | Query Content |
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|-----------------|---------------|
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| By Material | Inventory status of a material |
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| By Warehouse | Inventory status of a warehouse |
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| By Location | Inventory status of a location |
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| By Batch | Inventory status of a batch |
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| By Status | Inventory quantity distribution |
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**Inventory Data:**
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| Data Item | Description |
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|-----------|-------------|
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| Material Code | Material number |
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| Material Name | Material name |
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| Warehouse | Warehouse location |
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| Location | Storage location |
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| Batch | Material batch |
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| Quantity | Inventory quantity |
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| Unit | Unit of measurement |
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| Inventory Status | Normal/Frozen/Pending inspection |
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**Inventory Accounting:**
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| Account Type | Description |
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|--------------|-------------|
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| Opening Inventory | Inventory at period start |
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| Current Receipt | Quantity added this period |
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| Current Issue | Quantity removed this period |
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| Closing Inventory | Inventory at period end |
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**Inventory Calculation Formula:**
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```
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Closing Inventory = Opening Inventory + Current Receipt - Current Issue
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```
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### 3.5 Batch Management
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**Batch Traceability:**
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| Traceability Dimension | Traceability Content |
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|------------------------|---------------------|
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| Forward Traceability | Raw Material → Finished Product |
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| Reverse Traceability | Finished Product → Raw Material |
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**Batch Information:**
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| Information Item | Description |
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|------------------|-------------|
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| Batch No. | Unique batch identifier |
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| Material Batch | Material batch |
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| Supplier Batch | Supplier provided batch |
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| Production Batch | Production batch |
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| Receiving Date | Receiving time |
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| Expiry Date | Shelf life |
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| Inspection Status | Qualified/Unqualified |
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**First In First Out (FIFO):**
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| Principle | Description |
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|-----------|-------------|
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| First in, first out | Earlier received materials issued first |
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| Shelf life management | Near expiry materials issued first |
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| Clear batch identification | Clear traceable batch identification |
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### 3.6 Inventory Alert
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**Alert Types:**
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| Alert Type | Trigger Condition | Alert Content |
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|------------|------------------|---------------|
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| Safety Stock Alert | Inventory ≤ Safety Stock | Low inventory alert |
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| Expiry Alert | Near expiry date | Expiry approaching alert |
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| Slow-moving Alert | Long-term unused | Material slow-moving alert |
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| Maximum Stock Alert | Inventory ≥ Maximum Stock | High inventory alert |
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**Inventory Control Strategies:**
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| Strategy | Description | Application Scenario |
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|----------|-------------|---------------------|
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| Safety Stock | Minimum inventory guarantee | Regular materials |
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| Maximum Stock | Inventory upper limit control | Avoid overstock |
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| Reorder Point | Replenish when inventory reaches reorder point | Fixed quantity procurement |
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| Periodic Order | Regular inventory check and replenishment | Periodic procurement |
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### 3.7 Inventory Count
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**Count Types:**
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| Count Type | Description | Frequency |
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|------------|-------------|-----------|
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| Full Count | Count all materials | Year-end |
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| Partial Count | Count selected materials | Monthly/Weekly |
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| Cycle Count | Planned cyclic counting | Daily |
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| Dynamic Count | Real-time counting | Continuous |
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**Count Process:**
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```
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Count Plan → Count Preparation → Initial Count → Recount → Variance Review → Accounting Adjustment
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```
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**Count Steps:**
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1. Create count document
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2. Select warehouse and materials
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3. Execute initial count (first count)
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4. Execute recount (verification)
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5. Reconcile with system records
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6. Analyze count variances
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7. Approve variances
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8. Execute accounting adjustment
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**Count Records:**
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| Record Item | Description |
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|-------------|-------------|
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| Count No. | Unique count document identifier |
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| Count Type | Full/Partial/Cycle |
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| Count Warehouse | Warehouse being counted |
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| Count Date | Count date |
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| Book Quantity | System recorded quantity |
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| Actual Quantity | Physically counted quantity |
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| Variance Quantity | Quantity difference |
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| Variance Reason | Reason for variance |
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| Approval Status | Pending approval/Approved |
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---
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**End of Equipment and Warehouse Management**
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en/business/production.md
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en/business/production.md
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# Production Management
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## 1. Function Overview
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The Production Management module is the core module of the MES system, covering the entire process from production planning to production execution. It achieves digitalization, transparency, and intelligence of the production process.
|
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|
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**Core Functions:**
|
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| Function | Description |
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|----------|-------------|
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| Production Planning | Production plan formulation and breakdown |
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| Work Order Management | Work order creation, approval, release, and change |
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| Reporting Management | Production reporting and completion confirmation |
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| Production Monitoring | Real-time production progress monitoring |
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| Material Flow | Material release, picking, and semi-finished product flow |
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| Production Reports | Production data statistics and analysis |
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## 2. Production Planning Management
|
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### 2.1 Production Plan Types
|
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|
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| Plan Type | Description | Time Range |
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|-----------|-------------|------------|
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| Annual Plan | Annual production outline | 1 year |
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| Monthly Plan | Monthly production plan | 1 month |
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| Weekly Plan | Weekly production schedule | 1 week |
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| Daily Plan | Daily production dispatch | 1 day |
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| Emergency Plan | Rush order, change plan | Immediate |
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### 2.2 Production Plan Sources
|
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**Plan Generation Methods:**
|
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| Source | Description | Automation Level |
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|--------|-------------|------------------|
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| Sales Order | Generated from sales orders | Semi-automatic |
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| Forecast Order | Generated from forecast data | Semi-automatic |
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| Inventory Replenishment | Generated when inventory below safety level | Automatic |
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||||
| Manual Creation | Manually created plan | Manual |
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||||
### 2.3 Plan Balance and Breakdown
|
||||
|
||||
**Plan Balance Process:**
|
||||
|
||||
```
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||||
┌─────────────┐ ┌─────────────┐ ┌─────────────┐ ┌─────────────┐
|
||||
│Demand Plan │───▶│Capacity Check│───▶│Plan Adjustment│───▶│Plan Confirmation│
|
||||
└─────────────┘ └─────────────┘ └─────────────┘ └─────────────┘
|
||||
```
|
||||
|
||||
**Capacity Assessment Factors:**
|
||||
|
||||
| Assessment Item | Assessment Content |
|
||||
|-----------------|-------------------|
|
||||
| Equipment Capacity | Whether equipment capacity meets requirements |
|
||||
| Material Capacity | Whether materials are available |
|
||||
| Personnel Capacity | Whether personnel are sufficient |
|
||||
| Tooling Capacity | Whether tooling fixtures are ready |
|
||||
| Environmental Capacity | Whether production environment meets requirements |
|
||||
|
||||
## 3. Work Order Management
|
||||
|
||||
### 3.1 Work Order Types
|
||||
|
||||
| Work Order Type | Description | Trigger Method |
|
||||
|-----------------|-------------|----------------|
|
||||
| Production Order | Normal production order | Plan triggered |
|
||||
| Rework Order | Rework production order | Quality issue triggered |
|
||||
| Material Supplement Order | Material supplement order | Scrap triggered |
|
||||
| Trial Order | Trial production order | R&D triggered |
|
||||
| Emergency Order | Emergency rush order | Ad-hoc triggered |
|
||||
|
||||
### 3.2 Work Order Status Flow
|
||||
|
||||
**Status Flow Diagram:**
|
||||
|
||||
```
|
||||
┌────────┐ ┌────────┐ ┌────────┐ ┌────────┐ ┌────────┐
|
||||
│Pending │───▶│Created │───▶│Approved│───▶│Released│───▶│In │
|
||||
│Draft │ │ │ │ │ │ │ │Production│
|
||||
└────────┘ └────────┘ └────────┘ └────────┘ └────────┘
|
||||
│ │
|
||||
│ ▼
|
||||
│ ┌────────┐
|
||||
│ │Completed│
|
||||
└────────────────────────────────────────────────────▶│ │
|
||||
└────────┘
|
||||
```
|
||||
|
||||
**Status Description:**
|
||||
|
||||
| Status | Description | Available Operations |
|
||||
|--------|-------------|---------------------|
|
||||
| Pending Draft | Plan being formulated | Edit, Delete |
|
||||
| Created | Plan completed | Submit for approval, Edit |
|
||||
| Approved | Approved | Release |
|
||||
| Released | Released to production line | Start production |
|
||||
| In Production | Production in progress | Reporting, Pause |
|
||||
| Completed | Production completed | Receiving, Close |
|
||||
| Closed | Work order closed | View |
|
||||
| Cancelled | Work order cancelled | View |
|
||||
|
||||
### 3.3 Work Order Creation
|
||||
|
||||
**Creation Steps:**
|
||||
|
||||
1. Go to [Production Management] → [Work Order Management]
|
||||
2. Click [New Work Order]
|
||||
3. Select product
|
||||
4. Fill in work order information:
|
||||
- Production quantity
|
||||
- Planned start/end date
|
||||
- Planned production line
|
||||
- Priority
|
||||
5. System automatically calculates material requirements
|
||||
6. Save work order
|
||||
|
||||
**[Note]** Ensure product BOM and routing are maintained before creating work order.
|
||||
|
||||
### 3.4 Work Order Information
|
||||
|
||||
**Work Order Basic Information:**
|
||||
|
||||
| Field | Description | Required |
|
||||
|-------|-------------|----------|
|
||||
| Work Order No. | Unique work order identifier | ✓ |
|
||||
| Product Code | Product to produce | ✓ |
|
||||
| Product Name | Product name | ✓ |
|
||||
| Production Quantity | Planned production quantity | ✓ |
|
||||
| Qualified Quantity | Qualified product quantity | - |
|
||||
| Defective Quantity | Defective product quantity | - |
|
||||
| Planned Start Date | Planned start date | ✓ |
|
||||
| Planned End Date | Planned end date | ✓ |
|
||||
| Actual Start Date | Actual start date | - |
|
||||
| Actual End Date | Actual end date | - |
|
||||
| Priority | Work order priority | ✓ |
|
||||
| Work Order Status | Current status | System auto |
|
||||
|
||||
**Work Order Related Information:**
|
||||
|
||||
| Related Item | Description |
|
||||
|--------------|-------------|
|
||||
| Sales Order | Related sales order |
|
||||
| Customer Info | Customer information |
|
||||
| BOM Version | BOM version used |
|
||||
| Process Version | Process version used |
|
||||
|
||||
### 3.5 Work Order Approval
|
||||
|
||||
**Approval Process:**
|
||||
|
||||
1. Work order creator submits for approval
|
||||
2. Approver receives approval task
|
||||
3. Review work order information
|
||||
4. Check material availability
|
||||
5. Check capacity status
|
||||
6. Approve or reject
|
||||
|
||||
**[Tip]** Work order quantity and planned dates can be adjusted during approval.
|
||||
|
||||
### 3.6 Work Order Release
|
||||
|
||||
**Release Conditions:**
|
||||
|
||||
| Condition | Check Item | Description |
|
||||
|-----------|------------|-------------|
|
||||
| Complete Information | All required fields filled | ✓ |
|
||||
| Approved | Work order status is approved | ✓ |
|
||||
| Valid BOM | BOM is approved and effective | ✓ |
|
||||
| Valid Process | Routing is approved and effective | ✓ |
|
||||
| Materials Available | Required materials in stock | ✓ |
|
||||
| Line Available | Production line is available | ✓ |
|
||||
|
||||
**Release Steps:**
|
||||
|
||||
1. Select approved work order
|
||||
2. Click [Release] button
|
||||
3. System performs availability check
|
||||
4. Availability check passed
|
||||
5. Confirm release information
|
||||
6. Work order status changes to "Released"
|
||||
|
||||
**[Note]** If availability check fails, materials need to be replenished or work order adjusted first.
|
||||
|
||||
### 3.7 Work Order Change
|
||||
|
||||
**Change Types:**
|
||||
|
||||
| Change Type | Description | Impact |
|
||||
|-------------|-------------|--------|
|
||||
| Quantity Adjustment | Increase/decrease production quantity | Affects material requirements |
|
||||
| Plan Adjustment | Adjust planned dates | Affects scheduling |
|
||||
| Line Change | Change production line | Affects scheduling |
|
||||
| Process Adjustment | Adjust process sequence | Affects routing |
|
||||
| Emergency Rush | Adjust work order priority | Affects scheduling |
|
||||
|
||||
**Change Process:**
|
||||
|
||||
```
|
||||
Change Request → Change Approval → Change Execution → Change Confirmation
|
||||
```
|
||||
|
||||
**[Tip]** Work order changes during production need to be handled carefully as they may affect ongoing production operations.
|
||||
|
||||
## 4. Reporting Management
|
||||
|
||||
### 4.1 Reporting Types
|
||||
|
||||
| Reporting Type | Description | Timing |
|
||||
|----------------|-------------|--------|
|
||||
| Start Reporting | Process starts operation | At process start |
|
||||
| Completion Reporting | Process completes operation | At process completion |
|
||||
| Exception Reporting | Process abnormally paused | When exception occurs |
|
||||
| Shift Reporting | Shift handover record | At shift handover |
|
||||
|
||||
### 4.2 Reporting Process
|
||||
|
||||
**Process Reporting Flow:**
|
||||
|
||||
```
|
||||
Start Reporting → Process Operation → Completion Reporting → Next Process
|
||||
```
|
||||
|
||||
**Detailed Flow:**
|
||||
|
||||
```
|
||||
┌──────────┐ ┌──────────┐ ┌──────────┐ ┌──────────┐
|
||||
│Start │───▶│Operation │───▶│Completion│───▶│Quality │
|
||||
│Reporting │ │In Progress│ │Reporting │ │Inspection│
|
||||
└──────────┘ └──────────┘ └──────────┘ └──────────┘
|
||||
│
|
||||
┌──────────────────────────────────────┘
|
||||
│
|
||||
▼
|
||||
┌──────────┐
|
||||
│Process │
|
||||
│Transfer │
|
||||
└──────────┘
|
||||
```
|
||||
|
||||
### 4.3 Start Reporting
|
||||
|
||||
**Operation Steps:**
|
||||
|
||||
1. Go to [Production Management] → [Reporting Management]
|
||||
2. Select work order ready to start
|
||||
3. Select process
|
||||
4. Fill in start information:
|
||||
- Start time
|
||||
- Operator
|
||||
- Equipment selection
|
||||
5. Submit start report
|
||||
6. System records start time
|
||||
|
||||
**[Tip]** After start reporting, the system locks the process to prevent duplicate starts.
|
||||
|
||||
### 4.4 Completion Reporting
|
||||
|
||||
**Operation Steps:**
|
||||
|
||||
1. Select started work order
|
||||
2. Select process
|
||||
3. Fill in completion information:
|
||||
- Completed quantity
|
||||
- Qualified quantity
|
||||
- Defective quantity
|
||||
- Defect reason (if any)
|
||||
- Operation time
|
||||
- Material consumption (if needed)
|
||||
4. Submit completion report
|
||||
5. System automatically triggers quality inspection (if inspection point configured)
|
||||
|
||||
**Completion Reporting Information:**
|
||||
|
||||
| Field | Description | Required |
|
||||
|-------|-------------|----------|
|
||||
| Completed Quantity | Quantity completed this time | ✓ |
|
||||
| Qualified Quantity | Qualified product quantity | ✓ |
|
||||
| Defective Quantity | Defective product quantity | - |
|
||||
| Defect Reason | Description of defect reason | - |
|
||||
| Operation Time | Actual operation time | ✓ |
|
||||
| Material Consumption | Quantity of materials consumed | - |
|
||||
|
||||
### 4.5 Reporting Data
|
||||
|
||||
**Reporting Record Information:**
|
||||
|
||||
| Data Item | Description |
|
||||
|-----------|-------------|
|
||||
| Reporting Time | Reporting operation time |
|
||||
| Reporting Type | Start/Completion/Exception |
|
||||
| Work Order No. | Related work order |
|
||||
| Process No. | Related process |
|
||||
| Operator | Person performing operation |
|
||||
| Equipment No. | Equipment used |
|
||||
| Reporting Quantity | Reported quantity |
|
||||
| Qualification Rate | Qualified quantity/Reported quantity |
|
||||
| Operation Time | Actual operation time |
|
||||
|
||||
## 5. Production Monitoring
|
||||
|
||||
### 5.1 Monitoring Content
|
||||
|
||||
**Real-time Monitoring Data:**
|
||||
|
||||
| Monitoring Item | Description | Update Frequency |
|
||||
|-----------------|-------------|------------------|
|
||||
| Work Order Progress | Completion status of each work order | Real-time |
|
||||
| Process Progress | Completion status of each process | Real-time |
|
||||
| Production Statistics | Daily/Shift production volume | Real-time |
|
||||
| Defective Rate | Defective product ratio | Real-time |
|
||||
| Equipment Status | Equipment running status | Real-time |
|
||||
| Personnel Status | Operator status | Real-time |
|
||||
|
||||
### 5.2 Monitoring Dashboard
|
||||
|
||||
**Production Dashboard Display:**
|
||||
|
||||
```
|
||||
┌─────────────────────────────────────────────────────────────┐
|
||||
│ Production Monitoring Dashboard │
|
||||
├─────────────────────────────────────────────────────────────┤
|
||||
│ │
|
||||
│ Today's Production Overview: │
|
||||
│ ┌──────────────┐ ┌──────────────┐ ┌──────────────┐ │
|
||||
│ │ Plan Output │ │ Actual Output│ │ Achievement │ │
|
||||
│ │ 10000 │ │ 9520 │ │ 95.2% │ │
|
||||
│ └──────────────┘ └──────────────┘ └──────────────┘ │
|
||||
│ │
|
||||
│ Production Line Status: │
|
||||
│ ┌─────────────────────────────────────────────────────┐ │
|
||||
│ │ SMT-A Line ████████████░░░░ 80% Running │ │
|
||||
│ │ SMT-B Line ██████████████░░ 85% Running │ │
|
||||
│ │ Assembly-A ██████████░░░░░░ 60% Running │ │
|
||||
│ └─────────────────────────────────────────────────────┘ │
|
||||
│ │
|
||||
└─────────────────────────────────────────────────────────────┘
|
||||
```
|
||||
|
||||
### 5.3 Process Flow Control
|
||||
|
||||
**Flow Rules:**
|
||||
|
||||
| Flow Type | Description | Configuration Requirement |
|
||||
|-----------|-------------|--------------------------|
|
||||
| Sequential Flow | Operations in defined sequence | Routing definition |
|
||||
| Parallel Flow | Multiple processes simultaneously | Routing definition |
|
||||
| Conditional Flow | Process selection based on conditions | Flow condition configuration |
|
||||
|
||||
**Process Start Conditions:**
|
||||
|
||||
| Condition Item | Check Content |
|
||||
|----------------|---------------|
|
||||
| Previous Process Complete | Whether previous process completed |
|
||||
| Materials Available | Whether materials ready |
|
||||
| Equipment Ready | Whether equipment idle |
|
||||
| Personnel Ready | Whether operators ready |
|
||||
|
||||
## 6. Material Flow
|
||||
|
||||
### 6.1 Material Release Management
|
||||
|
||||
**Release Process:**
|
||||
|
||||
```
|
||||
Material Request → Warehouse Preparation → Scan Release → System Confirmation
|
||||
```
|
||||
|
||||
**Release Methods:**
|
||||
|
||||
| Method | Description | Application Scenario |
|
||||
|--------|-------------|---------------------|
|
||||
| By Work Order | Release based on work order BOM | Batch production |
|
||||
| By Process | Release based on process requirements | Multi-process production |
|
||||
| By Line | Batch release to production line | Continuous production |
|
||||
| Auto Release | System automatically controls release | Automated production line |
|
||||
|
||||
### 6.2 Material Consumption Record
|
||||
|
||||
**Consumption Data:**
|
||||
|
||||
| Data Item | Description |
|
||||
|-----------|-------------|
|
||||
| Material Code | Material consumed |
|
||||
| Material Batch | Material batch number |
|
||||
| Consumption Quantity | Quantity consumed this time |
|
||||
| Consumption Time | Consumption time |
|
||||
| Related Work Order | Related work order |
|
||||
| Related Process | Related process |
|
||||
| Consumption Type | Actual consumption/Scrap |
|
||||
|
||||
### 6.3 Work In Process (WIP) Management
|
||||
|
||||
**WIP Monitoring:**
|
||||
|
||||
| Monitoring Item | Description |
|
||||
|-----------------|-------------|
|
||||
| WIP Work Order Count | Number of work orders in production |
|
||||
| WIP Process Count | Number of processes in progress |
|
||||
| WIP Quantity | Quantity in progress at each process |
|
||||
| Flow Time | Flow time at each process |
|
||||
| Accumulation Status | Accumulation status at each process |
|
||||
|
||||
## 7. Production Statistics and Analysis
|
||||
|
||||
### 7.1 Production Reports
|
||||
|
||||
| Report Type | Description | Target User |
|
||||
|-------------|-------------|-------------|
|
||||
| Daily Production Report | Daily production statistics | Workshop Supervisor |
|
||||
| Monthly Production Report | Monthly production statistics | Production Manager |
|
||||
| Work Order Statistics | Work order execution statistics | Planner |
|
||||
| Output Statistics | Output completion statistics | Production Supervisor |
|
||||
| Quality Statistics | Production quality statistics | Quality Supervisor |
|
||||
|
||||
### 7.2 Production Indicators
|
||||
|
||||
**Core KPI Indicators:**
|
||||
|
||||
| Indicator | Calculation Formula | Description |
|
||||
|-----------|---------------------|-------------|
|
||||
| Output Achievement Rate | Actual Output/Plan Output × 100% | Target: ≥100% |
|
||||
| Production Qualification Rate | Qualified Quantity/Total Quantity × 100% | Target: ≥98% |
|
||||
| Labor Utilization Rate | Actual Working Hours/Available Hours × 100% | Target: ≥85% |
|
||||
| Process Flow Time | Average flow time at each process | Shorter is better |
|
||||
| WIP Turnover | WIP Quantity/Daily Output | Target: 3-5 days |
|
||||
|
||||
### 7.3 Production Analysis
|
||||
|
||||
**Analysis Dimensions:**
|
||||
|
||||
| Analysis Dimension | Analysis Content |
|
||||
|-------------------|------------------|
|
||||
| Capacity Analysis | Capacity utilization, bottleneck analysis |
|
||||
| Efficiency Analysis | OEE analysis, efficiency improvement potential |
|
||||
| Quality Analysis | Defective product analysis, quality trend |
|
||||
| Material Analysis | Material consumption analysis, over-consumption analysis |
|
||||
| Labor Analysis | Working hours utilization analysis, overtime analysis |
|
||||
|
||||
---
|
||||
|
||||
**End of Production Management**
|
||||
452
en/business/quality.md
Normal file
452
en/business/quality.md
Normal file
@@ -0,0 +1,452 @@
|
||||
# Quality and Traceability
|
||||
|
||||
## 1. Function Overview
|
||||
|
||||
The Quality Management module implements full-process quality control from raw materials to finished products, including incoming inspection, in-process inspection, finished product inspection, quality exception handling, and traceability management, ensuring stable and controllable product quality.
|
||||
|
||||
**Core Functions:**
|
||||
|
||||
| Function | Description |
|
||||
|----------|-------------|
|
||||
| Inspection Standards | Inspection items and standards definition |
|
||||
| IQC Inspection | Incoming quality control |
|
||||
| IPQC Inspection | In-process quality control |
|
||||
| FQC/OQC | Finished/Outgoing inspection |
|
||||
| Quality Exception | Defective product handling, MRB management |
|
||||
| Quality Traceability | Forward/Reverse traceability |
|
||||
|
||||
## 2. Quality Management System
|
||||
|
||||
### 2.1 Quality Management Process
|
||||
|
||||
**Total Quality Management Process:**
|
||||
|
||||
```
|
||||
Raw Material Inspection → Production Process Control → Finished Product Inspection → Outgoing Inspection
|
||||
│ │ │ │
|
||||
▼ ▼ ▼ ▼
|
||||
IQC IPQC FQC OQC
|
||||
```
|
||||
|
||||
### 2.2 Quality Management Principles
|
||||
|
||||
| Principle | Description |
|
||||
|-----------|-------------|
|
||||
| Prevention First | Move quality control to design and production stages |
|
||||
| Total Participation | Quality is everyone's responsibility |
|
||||
| Process Control | Focus on every step of the production process |
|
||||
| Continuous Improvement | Continuously optimize quality management system |
|
||||
| Data Driven | Make decisions based on data analysis |
|
||||
|
||||
## 3. Inspection Standard Management
|
||||
|
||||
### 3.1 Inspection Standard Definition
|
||||
|
||||
**Inspection Standard Components:**
|
||||
|
||||
| Component | Description |
|
||||
|-----------|-------------|
|
||||
| Inspection Type | IQC/IPQC/FQC/OQC |
|
||||
| Inspection Item | Specific item to inspect |
|
||||
| Inspection Method | How to perform inspection |
|
||||
| Judgment Standard | Criteria for pass/fail determination |
|
||||
| Inspection Equipment | Required inspection equipment |
|
||||
| Sampling Plan | Sampling quantity and rules |
|
||||
|
||||
### 3.2 Inspection Item Types
|
||||
|
||||
| Item Type | Description | Example |
|
||||
|-----------|-------------|---------|
|
||||
| Visual Inspection | Visual check | Color, shape, surface quality |
|
||||
| Dimension Inspection | Dimension measurement | Length, width, height, diameter |
|
||||
| Function Inspection | Function test | Electrical performance, mechanical performance |
|
||||
| Performance Inspection | Performance test | Life, reliability |
|
||||
| Safety Inspection | Safety test | Insulation, withstand voltage |
|
||||
|
||||
### 3.3 Inspection Standard Creation
|
||||
|
||||
**Creation Steps:**
|
||||
|
||||
1. Go to [Quality Management] → [Inspection Standards]
|
||||
2. Click [New Inspection Standard]
|
||||
3. Fill in standard information:
|
||||
- Standard code
|
||||
- Standard name
|
||||
- Applicable product
|
||||
- Inspection type
|
||||
4. Add inspection items
|
||||
5. Define inspection methods
|
||||
6. Set judgment standards
|
||||
7. Save inspection standard
|
||||
|
||||
**[Tip]** Inspection standards need approval before becoming effective.
|
||||
|
||||
### 3.4 Sampling Plan
|
||||
|
||||
**Sampling Standards:**
|
||||
|
||||
| Sampling Standard | Description | Application Scenario |
|
||||
|-------------------|-------------|---------------------|
|
||||
| GB/T 2828.1 | Normal inspection single sampling plan | Regular inspection |
|
||||
| GB/T 2829 | Periodic inspection sampling plan | Periodic sampling |
|
||||
| AQL Sampling | Acceptable quality level sampling | Large batch inspection |
|
||||
| 100% Inspection | Full inspection | Critical items |
|
||||
|
||||
**AQL Standard Example:**
|
||||
|
||||
| Inspection Lot Size | AQL 1.0 | AQL 2.5 | AQL 4.0 |
|
||||
|---------------------|---------|---------|---------|
|
||||
| 26-50 | 3 | 5 | 7 |
|
||||
| 51-90 | 5 | 7 | 10 |
|
||||
| 91-150 | 8 | 12 | 18 |
|
||||
| 151-280 | 13 | 18 | 25 |
|
||||
|
||||
## 4. Incoming Quality Control (IQC)
|
||||
|
||||
### 4.1 IQC Process
|
||||
|
||||
**IQC Complete Process:**
|
||||
|
||||
```
|
||||
┌──────────┐ ┌──────────┐ ┌──────────┐ ┌──────────┐
|
||||
│ Arrival │───▶│Receiving │───▶│ IQC │───▶│ Judgment │
|
||||
│ Receive │ │Document │ │ Inspection│ │ │
|
||||
└──────────┘ └──────────┘ └──────────┘ └──────────┘
|
||||
│
|
||||
▼
|
||||
┌──────────────────────────────────┐
|
||||
│ Non-conforming Handling │
|
||||
│ ┌──────┐ ┌──────┐ ┌──────┐ │
|
||||
│ │Return │ │Concession│ │Scrap │ │
|
||||
│ │ │ │Acceptance│ │ │ │
|
||||
│ └──────┘ └──────┘ └──────┘ │
|
||||
└──────────────────────────────────┘
|
||||
```
|
||||
|
||||
### 4.2 IQC Inspection Execution
|
||||
|
||||
**Inspection Steps:**
|
||||
|
||||
1. Supplier delivery arrives
|
||||
2. Warehouse clerk creates receiving document
|
||||
3. System automatically pushes inspection task to IQC
|
||||
4. IQC inspector receives inspection task
|
||||
5. Execute incoming inspection:
|
||||
- Verify delivery note against order
|
||||
- Visual inspection
|
||||
- Quantity verification
|
||||
- Sampling inspection
|
||||
6. Record inspection data
|
||||
7. Determine inspection result
|
||||
|
||||
**Inspection Judgment:**
|
||||
|
||||
| Judgment Result | Description | Handling Method |
|
||||
|-----------------|-------------|-----------------|
|
||||
| Qualified | Accept for storage | Direct receiving |
|
||||
| Concession Acceptance | Special release | Requires approval |
|
||||
| Rejected | Return to supplier | Return to supplier |
|
||||
|
||||
### 4.3 IQC Inspection Record
|
||||
|
||||
**Inspection Record Information:**
|
||||
|
||||
| Record Item | Description |
|
||||
|-------------|-------------|
|
||||
| Inspection No. | IQC inspection document number |
|
||||
| Supplier | Material supplier |
|
||||
| Material Code | Material being inspected |
|
||||
| Material Batch | Material batch number |
|
||||
| Arrival Quantity | Arrival quantity |
|
||||
| Sampling Quantity | Sampled quantity |
|
||||
| Qualified Quantity | Qualified quantity |
|
||||
| Defective Quantity | Defective quantity |
|
||||
| Qualification Rate | Qualified quantity/Sampling quantity |
|
||||
| Inspection Conclusion | Qualified/Unqualified |
|
||||
| Inspector | Person performing inspection |
|
||||
| Inspection Time | Inspection time |
|
||||
|
||||
## 5. In-Process Quality Control (IPQC)
|
||||
|
||||
### 5.1 IPQC Types
|
||||
|
||||
| Inspection Type | Timing | Description |
|
||||
|-----------------|--------|-------------|
|
||||
| First Article Inspection | At start of each batch | Inspection of first product |
|
||||
| Patrol Inspection | During production | Regular patrol inspection |
|
||||
| Sampling Inspection | Per sampling plan | Random sampling inspection |
|
||||
| Last Article Inspection | At end of each batch | Inspection of last product |
|
||||
|
||||
### 5.2 First Article Inspection
|
||||
|
||||
**First Article Inspection Process:**
|
||||
|
||||
```
|
||||
Start Production → First Article Production → First Article Inspection → Qualified → Mass Production
|
||||
│
|
||||
▼
|
||||
Unqualified
|
||||
│
|
||||
▼
|
||||
Root Cause Analysis & Correction
|
||||
```
|
||||
|
||||
**First Article Inspection Timing:**
|
||||
|
||||
| Timing | Description |
|
||||
|--------|-------------|
|
||||
| Shift Change | First after shift handover |
|
||||
| Material Change | First after material change |
|
||||
| Process Change | First after process adjustment |
|
||||
| After Equipment Repair | First after equipment repair |
|
||||
|
||||
### 5.3 Patrol Inspection Management
|
||||
|
||||
**Patrol Inspection Points:**
|
||||
|
||||
| Inspection Item | Check Content | Check Method |
|
||||
|-----------------|---------------|--------------|
|
||||
| Process Parameters | Temperature, pressure, time | Check equipment parameters |
|
||||
| Material Usage | Correct material usage | Verify material identification |
|
||||
| Operation Method | Standard operation | Observe operation process |
|
||||
| Product Appearance | Normal appearance | Visual inspection |
|
||||
| Equipment Status | Normal equipment operation | Check equipment running status |
|
||||
|
||||
**Patrol Inspection Record:**
|
||||
|
||||
| Record Item | Description |
|
||||
|-------------|-------------|
|
||||
| Inspection Time | Inspection time |
|
||||
| Inspection Station | Station being inspected |
|
||||
| Inspector | Person performing inspection |
|
||||
| Inspection Item | Item being checked |
|
||||
| Check Result | Inspection result |
|
||||
| Abnormal Description | Issues found (if any) |
|
||||
|
||||
## 6. Finished Product Inspection (FQC/OQC)
|
||||
|
||||
### 6.1 FQC (Final Quality Control)
|
||||
|
||||
**FQC Inspection Content:**
|
||||
|
||||
| Inspection Category | Inspection Item |
|
||||
|---------------------|-----------------|
|
||||
| Visual Inspection | Color, marking, packaging |
|
||||
| Dimension Inspection | External dimensions |
|
||||
| Function Inspection | Electrical performance test |
|
||||
| Safety Inspection | Safety item test |
|
||||
| Reliability Inspection | Aging test, etc. |
|
||||
|
||||
### 6.2 OQC (Outgoing Quality Control)
|
||||
|
||||
**OQC Inspection Content:**
|
||||
|
||||
| Inspection Item | Description |
|
||||
|-----------------|-------------|
|
||||
| Quantity Verification | Verify outgoing quantity |
|
||||
| Visual Check | Check packaging appearance |
|
||||
| Marking Check | Check labels and markings |
|
||||
| Random Sampling | Sampling per sampling plan |
|
||||
| Documentation Check | Check accompanying documents |
|
||||
|
||||
### 6.3 Finished Product Receiving Process
|
||||
|
||||
**Receiving Conditions:**
|
||||
|
||||
```
|
||||
FQC Passed → OQC Passed → Packaging Complete → Finished Product Receiving
|
||||
```
|
||||
|
||||
**Receiving Requirements:**
|
||||
|
||||
| Requirement | Description |
|
||||
|-------------|-------------|
|
||||
| Inspection Complete | FQC/OQC inspection must be completed |
|
||||
| Inspection Qualified | Inspection result must be qualified |
|
||||
| Batch Identification | Must have batch identification |
|
||||
| Packaging Complete | Packaging must be intact |
|
||||
| Quantity Accurate | Quantity must be accurate |
|
||||
|
||||
## 7. Quality Exception Handling
|
||||
|
||||
### 7.1 Defective Product Classification
|
||||
|
||||
| Defect Category | Description | Handling Method |
|
||||
|-----------------|-------------|-----------------|
|
||||
| Visual Defect | Color, shape, surface defects | Rework/Scrap |
|
||||
| Dimension Defect | Dimension out of tolerance | Rework/Downgrade |
|
||||
| Function Defect | Function not meeting standard | Rework/Scrap |
|
||||
| Performance Defect | Performance not meeting standard | Rework/Downgrade |
|
||||
| Safety Defect | Safety hazard | Scrap |
|
||||
|
||||
### 7.2 MRB Handling Process
|
||||
|
||||
**MRB Process:**
|
||||
|
||||
```
|
||||
┌──────────┐ ┌──────────┐ ┌──────────┐ ┌──────────┐
|
||||
│Defective │───▶│ MRB │───▶│ Review │───▶│ Disposal │
|
||||
│Identify │ │ Initiate│ │ Judgment │ │ Execution│
|
||||
└──────────┘ └──────────┘ └──────────┘ └──────────┘
|
||||
```
|
||||
|
||||
**MRB Disposal Methods:**
|
||||
|
||||
| Disposal Method | Description | Approval Requirement |
|
||||
|-----------------|-------------|---------------------|
|
||||
| Rework | Return to process for reprocessing | Requires approval |
|
||||
| Downgrade | Use at lower grade | Requires approval |
|
||||
| Concession Acceptance | Accept under special circumstances | Senior management approval |
|
||||
| Scrap | Direct scrap | Requires approval |
|
||||
| Return | Return to supplier | Contact supplier |
|
||||
|
||||
### 7.3 Quality Exception Handling Steps
|
||||
|
||||
**Handling Steps:**
|
||||
|
||||
1. Discover quality issue
|
||||
2. Isolate non-conforming products
|
||||
3. Label non-conforming products
|
||||
4. Create MRB document
|
||||
5. Quality review
|
||||
6. Determine review result
|
||||
7. Execute disposal plan
|
||||
8. Confirm disposal
|
||||
|
||||
**[Tip]** Non-conforming products must be stored in isolation to prevent misuse.
|
||||
|
||||
## 8. Quality Traceability
|
||||
|
||||
### 8.1 Traceability Content
|
||||
|
||||
**Traceability Data Elements:**
|
||||
|
||||
| Traceability Element | Traceability Content |
|
||||
|---------------------|---------------------|
|
||||
| Material Origin | Raw material supplier, batch |
|
||||
| Production Process | Process, equipment, personnel |
|
||||
| Quality Data | Inspection records, defective products |
|
||||
| Equipment Data | Equipment parameters, status |
|
||||
| Environmental Data | Production environment conditions |
|
||||
|
||||
### 8.2 Forward Traceability
|
||||
|
||||
**Forward Traceability Process:**
|
||||
|
||||
```
|
||||
Material Batch → Semi-finished Batch → Finished Product Batch → Customer
|
||||
```
|
||||
|
||||
**Traceability Query:**
|
||||
|
||||
1. Input finished product batch number
|
||||
2. Query finished product production information:
|
||||
- Production work order
|
||||
- Production process
|
||||
- Production time
|
||||
- Operator
|
||||
- Equipment used
|
||||
3. Query materials used:
|
||||
- Material batch
|
||||
- Supplier
|
||||
- IQC inspection result
|
||||
4. Continue tracing upstream materials
|
||||
|
||||
### 8.3 Reverse Traceability
|
||||
|
||||
**Reverse Traceability Process:**
|
||||
|
||||
```
|
||||
Finished Product Batch → Semi-finished Batch → Material Batch → Supplier
|
||||
```
|
||||
|
||||
**Traceability Query:**
|
||||
|
||||
1. Input material batch number
|
||||
2. Query material usage:
|
||||
- Work orders used in
|
||||
- Processes used in
|
||||
- Finished product batches produced
|
||||
3. Query finished product destination:
|
||||
- Shipping records
|
||||
- Customer information
|
||||
|
||||
### 8.4 Traceability Query Example
|
||||
|
||||
**Query Scenario:** Customer complaint about quality issue in a product batch
|
||||
|
||||
**Traceability Steps:**
|
||||
|
||||
1. Query using batch number provided by customer
|
||||
2. Trace this batch's:
|
||||
- Production work order information
|
||||
- Production status at each process
|
||||
- Material batches used
|
||||
- Material suppliers
|
||||
- Quality inspection records
|
||||
3. Analyze quality issue root cause
|
||||
4. Determine impact scope
|
||||
5. Notify affected customers
|
||||
6. Develop improvement measures
|
||||
|
||||
**Traceability Result Example:**
|
||||
|
||||
| Item | Information |
|
||||
|------|-------------|
|
||||
| Finished Product Batch | LOT-20260410-001 |
|
||||
| Product Model | PCB-1000 |
|
||||
| Production Work Order | WO-20260410001 |
|
||||
| Production Date | 2026-04-10 |
|
||||
| Production Line | SMT-A Line |
|
||||
| Operators | Zhang San, Li Si |
|
||||
| Materials Used | Solder batch LOT-S-001 (Supplier: Company A) |
|
||||
| Inspection Records | First article qualified, patrol inspection qualified |
|
||||
| Shipping Records | Shipped to Customer B, quantity 1000PCS |
|
||||
|
||||
## 9. Quality Statistics and Analysis
|
||||
|
||||
### 9.1 Quality Indicators
|
||||
|
||||
**Core Quality KPIs:**
|
||||
|
||||
| Indicator | Calculation Formula | Target Value |
|
||||
|-----------|---------------------|--------------|
|
||||
| Incoming Qualification Rate | IQC Qualified Lots/IQC Total Lots × 100% | ≥98% |
|
||||
| Process Qualification Rate | IPQC Qualified Quantity/IPQC Total Inspected × 100% | ≥99% |
|
||||
| Finished Product Qualification Rate | FQC Qualified Quantity/FQC Total Inspected × 100% | ≥99.5% |
|
||||
| Defective Rate | Defective Quantity/Total Production × 100% | ≤1% |
|
||||
| Batch Traceability Rate | Successfully Traced Batches/Total Batches × 100% | 100% |
|
||||
|
||||
### 9.2 Quality Reports
|
||||
|
||||
| Report Type | Description | Target User |
|
||||
|-------------|-------------|-------------|
|
||||
| IQC Daily Report | Daily incoming inspection statistics | IQC Team Leader |
|
||||
| IPQC Daily Report | Daily in-process inspection statistics | IPQC Team Leader |
|
||||
| Quality Monthly Report | Monthly quality summary report | Quality Manager |
|
||||
| Defect Analysis | Defect root cause analysis | Quality Engineer |
|
||||
| Trend Analysis | Quality trend analysis | Quality Supervisor |
|
||||
|
||||
### 9.3 SPC Statistical Process Control
|
||||
|
||||
**Control Chart Monitoring:**
|
||||
|
||||
| Control Chart Type | Monitoring Content | Application Scenario |
|
||||
|--------------------|-------------------|---------------------|
|
||||
| X-bar Chart | Mean value monitoring | Measurement data |
|
||||
| R Chart | Range monitoring | Measurement data |
|
||||
| P Chart | Defective rate monitoring | Count data |
|
||||
| C Chart | Defect count monitoring | Count data |
|
||||
|
||||
**异常判定规则:**
|
||||
|
||||
| Rule | Judgment Condition | Description |
|
||||
|------|-------------------|-------------|
|
||||
| Rule 1 | 1 point outside control limits | Single point abnormality |
|
||||
| Rule 2 | 9 consecutive points on same side of center line | Shift abnormality |
|
||||
| Rule 3 | 6 consecutive points increasing or decreasing | Trend abnormality |
|
||||
| Rule 4 | 14 consecutive points alternating up and down | Periodic abnormality |
|
||||
|
||||
---
|
||||
|
||||
**End of Quality and Traceability**
|
||||
Reference in New Issue
Block a user