sales@ipcb.com
Purpose:
To inspect the production process,effectively check and control the production status of each process to fully meet the quality requirements of the products.
Responsibilities:
PCBA production line staff:responsible for the self-inspection of the products in the work station.
PCBA production foreman:Responsible for supervising and tracking the production and quality achievement status and instructing staff to work correctly.
IPQC：Responsible for the inspection of the process and supervise the handling of abnormalities.
Relevant departmentsParticipate and cooperate in the analysis and handling of abnormalities in the production process.
Production technician:responsible for the commissioning of workshop machinery and equipment.
1.IPQC work requirements
①IPQC inspection must be based on SIP, engineering blueprints,SOP,bill of materials,process standards on the appearance of the product,size, assembly, packaging, performance inspection, and make a good record of the inspection.
② Inspection frequency:the number of sampling products and inspection items according to SIP.
③When customers do SPC control on key control items,it must be carried out according to the requirements of the inspection specification.
④ When abnormalities are found,the workshop and related departments should be notified to make improvements,and PDCS should be issued to the responsible departments if necessary.
2.IPQC on-site inspection content
①Check whether the work file related to the product is complete.
②Check whether the production equipment and tools are regularly maintained, and leave a written record.
③Whether the setting of process parameters is consistent with the requirements of process parameters.
④ The production environment,including temperature, humidity, cleanliness, illumination, and static electricity protection, meets the requirements of production and inspection.
⑤Whether the material is consistent with the BOM.
⑥ Whether the quality status of each product has been uniquely labelled.
⑦ Whether the defects are traced back in a timely and thorough manner.
⑧ Whether the staff operates in strict accordance with the safety regulations.
⑨Is there any unsafe hazard on the site?
⑩Whether the staff self-inspection is carried out thoroughly and effectively.
2.1 Whether employees' work practices are in strict accordance with SOPs.
2.2 Whether employees wear relevant labour protection products in accordance with the operating instructions.
2.3 Whether the relevant execution files, samples and measuring instruments used on site are under control.
2.4 Whether other related requirements can be satisfied.
3.PCBA inspection process exception handling work
① The main types of process abnormalities: equipment abnormalities, tool abnormalities, quality abnormalities, abnormal process parameters also include IPQC inspection content.
② Operators found that the production operation is not smooth or self-inspection found abnormalities, should be notified to the site of the person responsible for its abnormalities to improve and eliminate and report to the site of the IPQC or production team leader or foreman.
③When IPQC inspects the process abnormality, it should notify the responsible person on the site to improve and eliminate the abnormality, and the responsible person should handle it within half an hour.
④The responsible person should deal with the abnormality within half an hour. ④After the abnormality is dealt with, the corresponding record should be made.
⑤ If the abnormality is serious, or the responsible person can not eliminate the problem in a short period of time, it should be reported to the corresponding director to deal with it, and at the same time, IPQC should team up with the responsible department to issue PDCS.
⑥If the production process abnormality causes more than one hour of downtime, the first piece must be reconfirmed when production is resumed before official production is allowed.
⑦The non-conforming products produced by process abnormality shall be handled in accordance with the ‘Non-conforming Products Control Procedures’.
⑧ IPQC in the inspection process found to have an impact on product quality factors, should be issued PDCS to the relevant responsible person, QE in the resolution of major quality problems should be issued to the responsible department 8D report, which is based on the ‘quality problem analysis and handling of the operating procedures’ to be carried out.
5W1H means: why (why do) who (by whom to do) what (what to do) where (where to do) when (when to do) how (how to do);
The spirit of ISO is: how to say how to do how to do how to write;
Internal audit can be classified according to the severity:serious non-conformity.Minor non-conformity.Observations;
Quality costs are divided into: prevention costs.Identification costs. Internal failure costs.External failure costs;
Why is it necessary to label products?
A: Control records uniquely identify the product so that the cause of the problem can be traced and analysed to prevent recurrence;
What is quality cost?
A: Costs incurred by an enterprise in carrying out quality activities;
What are the eight management principles in ISO9001?
1.Customer focus
2.Leadership
3.Full participation
4.Process approach
5.Systematic approach to management
6.Continuous Improvement
7.Fact-based decision-making approach
8.Mutually beneficial supplier relationships
Nonconformity means: failure to meet requirements
Three attributes of quality control: adequacy, suitability, and effectiveness
What should be done to prevent nonconforming products from being used?
A: labelling, isolation
What is the definition of quality in ISO?
A: The degree to which a set of intrinsic characteristics meets requirements.
When is 8D used to solve problems?
A: For recurring, more significant problems that have not been resolved or for customer complaints that require a response.
What are the 4 common shapes of bar graphs?
A: Normal, Jagged, Partial, Absolute, Double Peak, and Island Plateau;
What are the 9 steps to solve a problem?
1.Discover the problem
2.Select the problem
3.Trace the problem
4.Analyse the information
5.Suggest Methods
6.Select Countermeasures
7.Drafting Actions
8.Compare results
9.Standardise
The old seven techniques of quality control:
1.Layer method: classified by layer, statistical analysis of the role: from different levels to find problems.
2.Characteristic key factor diagram: to find the causal relationship role: to find the cause of the results. Also known as fishbone diagram
3.Checklist: Investigating and recording data for analysis: collecting and organising information.
4.Walking Chart: Find the relationship between the two Role: show the linear relationship between the variables
5.Bar chart: analyse the distribution of data status role: show the distribution of the process
6.Control charts: understand the process capability and its variability which is the role of identifying the source of fluctuations.
7.Plato: find out the important minority role: to determine the leading factors (the so-called principle of two or eight)
New QC seven techniques:
1.Connection diagram method:the role of clarifying the relationship between complex factors
2.System diagram method:the systematic search for means to achieve the goal
3.Affinity diagram method:from the chaotic language data in the information extraction
4.Matrix diagram method:examining the relationship between the variables of the problem from multiple perspectives.
5.PDPC method:predicting the possible obstacles and results in the design.
6.Arrow Chart Method:Reasonable preparation of a plan of action
7.Rectangular data analysis method:transforming multiple variables into fewer variables.