As a company that started with quality control management, we first implement strict management and requirements for the production of our own products:
1. Customer product inquiry stage
1.1 Product Analysis
Includes: product drawing analysis, determining whether the product can be produced, and determining the production process based on product characteristics
1.2 Quote
After product analysis by relevant departments, we recommend the most cost-effective production process to customers and quickly complete the quotation
2. Sample stage
2.1 Determine production equipment
According to the product design process, it is allocated to the most suitable production equipment
2.2 Mould development
We select appropriate mold materials and structures according to the actual situation of the product to save mold costs for customers. At the same time, we follow the CQS Mold development procedure to help customers complete mold development in a short time.
2.3 Sample development
2.3.1 Production plan
Multiple process tests are carried out simultaneously to help customers find the production solution with the highest production efficiency and yield rate in the shortest time.
2.3.2 Production parameters
The samples are measured in full size, and the mold and equipment parameters are accurately adjusted according to the data to obtain products with close to average dimensions.
2.3.2 Quality Confirmation
The samples must pass the size inspection, appearance inspection, and internal quality inspection at the same time before they can be judged as qualified and handed over to the customer for further confirmation of whether the samples are successful
2.4 Sample confirmation
2.4.1 Rough products
The samples will first simulate the customer's foreign machining process in China. After confirmation, the blank samples will be sent to the customer for machining abroad, and the customer will make the final confirmation.
2.4.2 Machining products
The finished sample is sent directly to the customer for final confirmation
2.4.3 Finished product
The samples are assembled and sent directly to the customer for final confirmation
2.5 Process finalization
After the customer confirms that the sample is successful, the final production plan of this product will be determined according to the trial production plan of the sample sent to the customer, and no changes will be made without the customer's permission.
3. Small batch production
3.1 Product Inspection
3.1.1Size and appearance
For small batch products, 50 samples are usually randomly selected for dimensional measurement to understand the dimensional stability of the product. When the dimensional instability is found, the mold and production parameters are adjusted in time according to the measurement data until the requirements are met.
The product appearance is 100% inspected, and when problems are found, timely analysis is conducted to determine whether the production process needs to be improved.
3.1.2Intrinsic quality
Three products are randomly selected for internal quality confirmation. When the customer does not require RT inspection, the product is usually cut for confirmation. Only when everything is qualified and the data is stable can the product be judged to enter the formal mass production stage.
3.2 Preparation of work instructions
After the small batch product production is confirmed to be qualified, the operation instructions for each process are compiled to strictly regulate the operation of each production process of the supplier to ensure the stability of mass product production to the greatest extent.
4. Batch trial production
4.1 Product Inspection
4.1.1Size and appearance
30 samples are randomly selected for dimensional measurement to confirm the dimensional stability of the product, and the product appearance is 100% inspected to confirm the stability of the production process.
4.1.2 Make a size check sheet
After the dimensional data is qualified and stable, we will discuss with the customer the size inspection position of the future batch products, draw a schematic diagram of the size inspection position of this product, and prepare a special size inspection table to conduct targeted and efficient product size inspection during formal mass production.
4.1.3 Materials and performance
Confirm the working conditions of various product-related inspection equipment, such as spectrometer, mechanical properties test equipment, impact test equipment, etc.
4.2 management
In order to ensure the quality of customer products, each project product will strictly implement incoming material control, mold management, tooling management, process transfer management, product batch management, product inspection management, product inspection control, etc.
5. Mass production of products
5.1 Production plan tracking
Actively inform the production progress in each time window, and inform customers in time when the production plan changes to avoid any impact
5.2 Production process control
Each project product is managed strictly in accordance with the operating instructions to ensure that each production process is effectively controlled
5.3 On-site inspection
We use a strict company management system to ensure the authenticity and rigor of customer product inspection data. After our factory inspection, the Dalian Inspection Center will randomly select products for secondary inspection to ensure product quality. When problems are found, we will provide customers with solutions to solve the problems with the support of the quality control department and the technical department to ensure the smooth progress of customer projects.
5.3.1 Dimensional Measurement
30 samples are randomly selected and measured according to the batch product size inspection table. If a certain size is unqualified, the size of all products will be measured if necessary to ensure that the shipped products are qualified.
5.3.2 Data analysis
After measuring the dimensional data of each batch of products, CPK analysis is carried out in a timely manner. When a certain dimension is found to have an unstable trend, improvement suggestions are made in a timely manner to avoid the generation of defective products in future production.
5.3.3 Inspection and appearance inspection
We usually conduct 100% appearance inspection on customer products, including various inspection and regulation inspections, to ensure the quality of the products. During the inspection, we distinguish and count the defective products found, and make relevant reports.
During the inspection, we repair the defective products that meet the repair requirements, and conduct a second inspection to ensure that the products are qualified. For scrapped products, they will be uniformly destroyed at the end of the inspection to ensure that defective products are not mixed in
5.3.4 Make a report
After each inspection, we will provide customers with a comprehensive report based on the inspection results, which usually includes:
a) Product size measurement report
b) Product size CPK analysis report
c) Product Image Report
d) Product inspection statistical report (detailed data on qualified products, defective products, returned products, scrapped products, etc.)
e) Product Material Report
f) Product Mechanical Properties Report
g) Special product special project inspection report
5.4 Shipping Control
5.4.1 Batch Management
After completing the inspection of the customer's delivery quantity, there are usually some products left. We will seal the qualified products and record them in the designated area for another appearance inspection during the next shipment. Labels are used to distinguish them during shipment to ensure that they are not mixed with new batches of products.
We strictly supervise the factory to ship according to the first-in-first-out principle, give priority to the remaining products of the previous batch, and then ship the products produced in this batch, ensuring that there are no more than two production batches of products shipped each time.
5.4.2 Packaging inspection
Before delivery, we confirm the product packaging according to the customer's contract requirements to ensure that the packaging is qualified.
5.4.3 Packing list check
After packaging, we will carefully check the shipped products according to the packing list to ensure that no mistakes occur
When our company was first established, we relied on quality control management for procurement projects in China for many well-known Japanese companies. We have always adhered to strict management and meticulous work attitude. We take every project of our customers seriously. After the company was transformed into a parts manufacturer, as a supplier, we are more serious about our products. Providing customers with good service experience and excellent product quality is our core competitiveness.