IPQC and its working characteristics
What is IPQC
IPQC is the quality control of the manufacturing process. IPQC generally refers to the process patrol inspection, which refers to the use of circuit inspection in the process of product manufacturing to regularly check and confirm whether the process parameters, operation change content, and standards used meet the requirements, and record the inspection status, and carry out necessary control and supervision.
Patrol inspection: Inspections are carried out on a rotational basis according to the designated items at the time of designation.
Process: refers specifically to the manufacturing process of the product.
1. Deal with process abnormalities immediately on the spot
2. Seek truth from facts and feedback on non-conformities
IPQC shall stand on an independent and impartial standpoint and objectively report non-conformities:
Independence: that is, in the process of work, without the interference of external factors, independent work.
Justice: It is to take the system as the criterion, be impartial and seek truth from facts.
Objectivity: Seeing is believing, and there must be evidence when talking about things.
3. Thoroughly track down bad issues
Problems that occur should be pursued until they are satisfactorily resolved.
IPQC Job Requirements
One look, two movements and three inspections: "one look" is diligent looking; "Two movements" is a hands-on inspection, moving the mouth to say; "Three inspections" are to inspect incoming materials, process operations, and products.
The first inspection and its precautions
1. What is the first inspection?
The first inspection refers to the inspection of the first article (usually 3-5 pcs) before production, and its purpose is to prevent systemic risks from producing batch defects (such as defective workmanship, poor equipment or tooling, defective incoming materials, and poor operation).
2. Key points for the implementation of the first inspection
Inspection of the first article prior to production.
In particular, it is aimed at processes that rely on equipment and tooling that are prone to systemic risks, such as coating and laser welding.
Processes that may result in batch defects, such as pulping, coating, laser welding, liquid injection, etc.
3. Problems that are prone to occur in the first inspection
Only pay attention to the product, do not pay attention to the incoming materials and tooling, process, structure and performance testing issues.
The first inspection is qualified but the first inspection procedure is not completed, and there is no first inspection report, which makes it impossible to trace and analyze the cause of the problem.
The failure of the first inspection was not reported immediately.
4. Risk control of the first inspection
After the first inspection, the first batch of 50-100pcs products will be tracked and re-inspected.
If the first inspection is abnormal and the relevant departments do not cooperate, they should be reported immediately and level by level until the problem is resolved.
If problems are found during the inspection, the relevant records of the first inspection should be checked first, and the re-inspection should be carried out in a timely manner if necessary.
Inspection and its precautions
1. What is Patrol Inspection?
Inspection refers to the regular inspection of the product after the first inspection is qualified, and the inspection is carried out in turn according to the specified items.
2. Key points for the implementation of inspection
The first inspection must be qualified and the procedure must be complete.
The focus of the inspection is: new products, new equipment and tooling, new incoming materials and abnormal incoming materials (such as reviewed materials), new employees, and changes in the unstable process, such as repairing machines in the middle of production, replacing materials, changing processes, replacing people, debugging equipment, etc.
3. Problems that are prone to occur during inspection
The exception was not solved, the last exception was not closed, and I forgot to confirm the improvement effect, and the production was carried out again. Production of unresolved previous anomalies should be rejected and reported immediately.
The real cause of the anomaly has not been found, and the source of the defect is still producing defective products.
Only pay attention to the defective products, do not pay attention to incoming materials and processes, equipment tooling management and maintenance.
Only the defects of the samples taken during the inspection were emphasized, and the defects of the conversion sequence were not monitored.
Only the defect rate is emphasized, and the defect distribution is not emphasized.
Only pay attention to key processes and do not pay attention to general processes.
Insufficient monitoring and understanding of the full inspection station.
4. Risk control of inspection
Focus on "new": new people, new machines, new processes, new products, new materials.
Strictly control the frequency of key stations, and generally stations should be at normal frequency, and no one should be missing.
As a key monitoring of the full inspection station, the problem of the full inspection station can be traced back to the specific job post, and the source can be traced from the back to the front and controlled.
Regularly conduct random inspections of the transferred products according to the sampling plan, and it is easy to find problems that cannot be found even in the full inspection. It is the best way to effectively cross-control the risk of sampling.
If a problem is found, the next process must be notified in time, so that the next process can be assisted in prevention and checks, and the next process should also be notified of temporary changes.
Quality anomalies and their handling
1. Abnormal quality conditions
The defect rate exceeds the control target (determined by the supervisor or above according to the different development levels of products and quality).
In the SPC system, the conditions for differentiation are met.
The actual amount of scrap or wear is large and needs to be reacted to.
The first inspection is unqualified or still unqualified after the first inspection after adjustment. (After the first inspection is unqualified, adjustments must be made before the first piece can be made again, without any adjustment of machines, personnel, operations, and processes, and the first inspection may be an illusion again, and it cannot be ruled out that there will be problems in mass production, and the purpose of the first inspection cannot be achieved)
2. Problems that are prone to occur in the management of abnormal quality
Quality inspectors tend to ignore the report of abnormal problems in the process, incoming materials, operations, and equipment, and only pay attention to the abnormality of products and defect rates.
Focus only on the defect rate and not on the defect distribution.
3. Handling of IPQC in quality abnormalities
It is necessary to detect it in time, detect it early, and report it accurately.
Before issuing the report, the 5W2H elements should be checked and verified.
Communicate effectively with the management of the production site to carry out shutdown or shutdown treatment (according to the authority requirements).
To track the progress and effectiveness of exception reports, report immediately or skip reports when they are invalid or recurring.
Be fully prepared and provide the necessary data to prove the data before and after the abnormality and proof of improvement
How to control the risk of sampling
Due to the fluctuation of product quality and the accidental nature of sample drawing, misjudgment is inevitable, and the risk of such misjudgment is called sampling risk.
Control of sampling risk:
The number of samples should be as close as possible to the number of batches.
During the inspection, the number of samples (usually 5pcs/hour/station) can be expanded or sampled multiple times and the team leader can be re-tested when the number of samples (usually 5pcs/hour/station) cannot be determined.
According to the characteristics of different sampling objects, appropriate sampling methods are adopted, and if necessary, more than two sampling methods are used to play the role of self-review. (Especially suitable for batch inspection and judgment such as reciprocation)
Quality "Three Character Classic"
1. "Three Prohibitions" of Quality Management
Unqualified raw materials are not allowed to be put into production, unqualified semi-finished products are not allowed to flow into the next process, and unqualified products are not allowed to leave the factory.
2. "Three processes" of production site management
Review the previous process, check the current process, and serve the next process with high quality and efficiency.
3. Quality inspection "three inspections"
Self-inspection, mutual inspection, special inspection.
4. Carry out "three analysis" in case of quality accidents
Analyze the causes of accidents, analyze the hazards of accidents, and analyze the measures that should be taken.
5. In the event of a quality accident, it is necessary to carry out "three analyses" and adhere to the "three don't let go"
If the reasons are unclear, we will not let go of the responsibilities, and we will not let go if the measures are not implemented.
6. Production employees should adhere to the "three presses, one control" in the production process
According to the drawings, according to the process, according to the standard, control the defective rate.
7. Do a good job in inspection work should be good "three members"
Product quality inspector, quality first propagandist, production technology counselor.
8. Inspectors should be good at the "three members" and at the same time achieve "three satisfactions"
The attitude of service, the staff is satisfied, the inspected products are satisfied, and the products are satisfied with the customers.