富士康验厂制程能力评估

2 制程能力 / Process Control   
2.1 General                    
 2.1.1     机器设备的日常保养记录挂在机器处而且都是最新的吗? Are Daily Maintenance logs kept at the machine and are they up to date?
 2.1.2     量测仪器如卡尺、色差计、三次元设备、分光仪…(可读取数值)是否有保养与维修记录? 是否有校验标示, 有否过期? 免校仪器是否有明确标示? Are there maintain and repair record of test equipments such as caliper, chromatic aberration meter, 3D equipment, spectrometer (numerical value available)? Is there calibration mark and if outdate.
 2.1.3     "生产前是否对所有设备与夹治具实施检查? 检查结果是否记录?
Whether all equipments and fixtures are checked and recorded before production? "
 2.1.4     对于仪器设备和治具上的耗材(如cable, connector等)是否符合使用要求? 是否有汰旧换新计划? Does the consumable (consumable material, expendable) such as cable, connector using in the equipment and fixture meet the use requirement? Is there a change plan for them?
 2.1.5     是否作业员身边都有机器设备操作的SOP? Does the Operator have the Standard Operating Procedure (SOP) for the machine available to them at all times?
 2.1.6     是否有证据显示对操作员进行过SOP的训练和鉴定? Is there evidence that the Operator has been trained and certified against the Standard Operating Procedure for the Machine?
 2.1.7     操作员知道机器SOP的内容?他们遵守了吗? Does the Operator know the content of the Standard Operating Procedure for the Machine and do they and follow it?
 2.1.8     "生产前是否对所有材料进行确认，外观及P/N是否对应?
Are all materials checked, such as appearance and P/N before production?"
 2.1.9     "生产线之质量报告，是否作归纳分析，如材料、人员或设计不良? 质量报告是否作追踪对策报告并反馈给相关单位?
Whether the quality report of product line perform the conformity analysis (such as materials, stuff and mis-design) and make the tracking report of improvement to feedback related department?"
 2.1.10 停线标准是否清楚说明质量和缓冲的限制要求? Are line shutdown criteria clearly specified for both quality and buffer limiting requirements?
 2.1.11 是否有証据显示质检员经过培训认証并且具有基本的品保和统计知识? Is there evidence that quality inspector has been trained/certified in basic quality practices and statistics/SQC?

2.2    富士康验厂进料管控   
 2.2.1      是否将物料按其编号、名称、规格、消耗量、供应商进行分类编号，建立物料清单？Do you divide the parts and creat the BOM by the PN, name, Spec., quantity the parts will be used and vendors of the parts?
 2.2.2      物料的储存环境是否严格按要求控制温、湿度? Do you require storage environment's temp. and the humidity as it is prescribed?
 2.2.3      是否有检验规范介定物料的常规检查项目以及检查方法? Whether inspection rule includes normal inspection items and methods?
 2.2.4     待检材料和已检验的材料是否被适当的隔离并标识? Do you devide and label the materials which are to be inspected and the materials which have been inspected properly?
 2.2.5     合格材料和不合格材料是否被适当的隔离并标识? Do you devide and label the qualified material and disqualified material properly?
 2.2.6     是否有做进料检验记录及历史记录以备查?Do you take records of import inspection and store them for review?
 2.2.7     不良物料讯息是否以书面形式及时反馈供应商并要求其改善?whether the message of bad materials feedback to the supplier in time,and demand the supplier improve?
   
2.3 富士康验厂仓库管理 Ware House
 2.3.1     对工序中使用的化学品保存条件是否有标准指导书，并有相应记录? Is there a SOP and related record for the chemical storage condition?
 2.3.2     对油墨，粘胶等重要物品如何进行保存?是否妥当? How to storage the ink and glue? Is it correct?
 2.3.3     是否对仓库的温湿度进行管制并记录? Is the temperature and humidity of the warehouse controlled and recorded?
 2.3.4     在材料的外箱上对材料的保存期限是否有适当的定义及鉴别?Do you define and discriminate the materials' limited storage periode on the material box properly?
 2.3.5     是否有书面程序文件根据材料的保存期限规定先进先出原则? Is there a written process document which prescribed the FIFO rule according to the materials' storage period?
 2.3.6     是否有定期实施库存呆料及过期材料处理及标示.Whether the stocks and overdue materials were dealt with and marked?
 2.3.7     是否有规定原材料及成品摆放高度? Do you crescribe the limited height the raw material and finished products stack?
 2.3.8     对生产线退还部件是否有管制? 是否有相应标准? Are the components back from the product line controlled with the related standards?
 2.3.9     是否清楚的划分区域摆放部件及标记? Is the area plotted and marked clearly for different components?
 2.3.10 如何确保发料不会产生混料问题﹖是否有做混料防止措施? Is there a effective measure to avoid material mixing?
 2.3.11 成品摆放是否明确区隔，不会造成出货错误? Are the final products plotted distinctly to avoid shipment mistakes?
 2.3.12 成品堆栈摆放是否适宜，不会造成产品损毁? Are the final products stacked correctly to avoid damage?

2.4 "原纸-辊轧-粘合-纵切-横切-纸板堆码-印刷-分纸-压线-开槽-钉箱-粘箱
Raw material-Wheel press-Paste-Cut-Storehouse-Print-Die cut-Rail-Paste"                           
    "瓦楞加工：原纸-辊轧-粘合-纵切-横切-纸板堆码 Raw material-Wheel press-Paste-Cut-Storehouse"           

 2.4.1     "是否有相应的设备操作说明书及紧急异常处理说明书悬挂于操作者可视位置.作业员是否有经充分的培训上岗并佩戴相应标识.
If have SOP to instruct operate and issue deal with? If abundant train for operator before work on the station?"
 2.4.2     是否有办法或应急机制确保加热系统,空压系统,电气系统的稳定 ，以满足生产制造的顺利进行？If the SOP defined  and implemented for heating system, air pressure system,electric system stable and ensure the smoothly production?
 2.4.3     "作业现场是否有相应的流程卡及SOP指导如何作业.流程卡是否有对原物料,日期,定单号,客户,进料批次,规格,机台,治具等信息做定义.SOP中是否有详细定义如何确认这些信息？
If hang some flow chart and SOP on site? If record raw material,date code,PO,customer,lot no,spec,equipment,fixture information in flow chart,if SOP instruct how to double check."
 2.4.4     "生产前是否有做首件检查,首件是否有检查产品的关键尺寸(长,宽,厚度)及材料,外观等重点项目.
If FAI execution before production, if FAI define how to check the dimension,raw material and cosmetic information?"
 2.4.5     "是否定义原纸支架的进给速率？
If defined the feed speed for the paper brack?"
 2.4.6     "是否有文件定义原纸预热器的温度及预热时间？
If defined the equipment temparature and heating time for paper pre-heating ?"
 2.4.7     "是否有文件定义瓦楞辊的配合压力(间隙)、平行度、中高等重要技术指标.
If defined the gap,parallel and high etc imprtant parameter for reel?"
 2.4.8     "是否有文件定义单面纸板的固化时间?
If defined the time of solidify for corrugated paper？"
 2.4.9     "是否有文件定义单面纸板预热器的温度及预热时间?
If defined the equipment temparature and heating time for corrugated paper?"
 2.4.10 "是否有文件定义瓦楞涂胶胶量及如何确保涂胶均匀？
If defined the glue dosage for corrugated paper? How to ensure the glue self?"
 2.4.11 "是否有文件定义上胶后纸板固化环境(温度,压力,时间)
If defined the environment(temparature,pressure,time etc...) of glue solidify after corrugated paper coated glue?"
 2.4.12 "是否有文件定义涂胶的原物料成分及比例?涂胶的特性如何管制？
If defined the ingredient of glue and dosage? How to control the sticky character for glue?"
    印刷制程-Print
 2.4.13 是否有文件规定印刷材料规格,产品承认,ECN之标准作业程序并实施？If the procedure about process and material Qualification , ECN control prepared and implemented ?
 2.4.14 素材表面是否清洁干净,拿取/转移方式是否合适?SOP 是否明确定义  Make sure that part suface is clean and  methord of hold/transferproduct   is good and it can protect products not bring defect. Whether SOP has been defined?
 2.4.15 环境是否清洁,是否有定期监测？是否采用水帘、风淋、静电除尘等方式?
      If the  environment is clean and tested  regularly? If the methond  of suface clean is suitable?
 2.4.16 网板,刮刀或胶头,钢板规格型号是否符合SOP要求？是否对网板或胶头,钢板使用寿命进行管控？履历卡是否制做并管理?保管状态是否良好?是否有检查、维修、保养,报废和更换作业记录？Is the tooling type apply with sop requment? Is there tool  history card for management? Is the molding state good or not?  Any record for tool inspection,repair,maintain,change and abolition?
 2.4.17 "油墨粘度,刮刀角度,速度和压力是否合适?(丝印)                                                   
If the parameter Ink stickness,blade angle/speed/pressure is suitable?"
 2.4.18 "操作员是否能及时调节丝印网板与承印物之间的距离?(丝印)                                  
Could the operation  adjust the height of screen and part according to the status?"
 2.4.19 油墨粘度, 胶头压力,取墨速度和上升速度是否合适?操作员是否经过相关培训,考核?(移印) If the parameter Ink tickness, pin pressure/speed/ is suitable?
 2.4.20 工件/胶头定位是否精确,丝网/钢板是否锁紧?  Location of part and pin is correct,the screen is fixed
 2.4.21 产品涂层检查如何管控？检测项目（膜厚、硬度、附着性、耐磨性等）是否按要求进行检测？测量结果是否记录并符合产品要求？                            How to control the coating? The test of thickness/hardess/adhesive etc.  are done, and record the result
 2.4.22 无尘室是否有定期监测?有无检测记录？If the clean room is tested regularly and record the result.
 2.4.23 膜厚计是否有校正,并定期更换归零片? If the thickness jig is regulated,and modify the part?
 2.4.24 "在制品是否依lot no.是否识别管理 以方便异常追溯处理?                                  
         If the mold WIPs are managed following lot no. or not for abnormal traceability management?"
 2.4.25 作业现场 产品外观检验条件如照度值是否标准？是否有标准如限度样品方便作 检查比对？作业人员对外观检查标准是否了解？如果零件外观超出限度样品管控，如何处理？If the surrunding conditions are suitable ,  SIP and limited samples are avaliable for operators and QC implementing  cosmetic inspection? How to hadle if any cosmetic issue found?
    "分纸-压线-开槽-钉箱-粘箱
Die cut-Nail-Paste"
 2.4.26 "是否有文件定义圆模模切的转速?  If defined the roll speed for die cut?"
 2.4.27 "SOP是否详细定义纸板的定位？
If SOP defined the location of paper board?"
 2.4.28 "是否有文件定义平模模切的上下形程？
If defined the route of the cutter?"
 2.4.29 是否有文件定义箱钉的定位？
If defined the location of nail for fix the paper board?"

2.5 包装出货 Packing and Shipment                   
 2.5.1     是否有包装规范? Is there packing specification?
 2.5.2     包装前是否对外观进行检查? 是否制定检查标准? Is there appearance inspection before packing? Is there inspection standard?
 2.5.3     是否有方法预防短料的现象? Is there method to prevent less or more prodcuts for shipment?
 2.5.4     是否有产品出货检验相关标准?是否规定重点检查项目? Is there a shipment inspection standard? Are there key items defined to check?
 2.5.5     检查站别是否有适当的检查工具?检查时灯光是否足够? Are there proper inspection tools in the inspection station? Is the light enough when inspect?
 2.5.6     以前的质量问题和客户抱怨点是否被写在相关料号的检查记录上? Do you take relative records for former quality issues and customers' compliants?
 2.5.7     是否执行检查的追踪和控制?如果检查人员的能力不够，是否进行再培训或工作的转换? Do you control inspection and tracing? Do you retrain or shift the inspectors if the inspectors are not competent?
 2.5.8     对出货中的不良品, 是否有专门的处理程序? 是否会发出不良报告? Is there special procedure to deal with the failure product in the shipment? Is there failure report to be released?
 2.5.9     是否建立Hold Shipment作业程序? Is there procedure of Hold Shipment?
 2.5.10 当产品为特采品时，产品是否完成特采流程并留下记录? Is there special-adopted procedure and record when the product is  special-adopted?

2.6 富士康验厂可靠性管控  Reliability Managerment                   
 2.6.1     是否有测试设备及治具管理之一览表? Is there a management list of the test equipment and fixture ?
 2.6.2     是否对测试设备进行定期校正? Is there periodic calibration for the test equipment?
 2.6.3     新产品开发流程中是否有进行可靠性测试? 是否有依照开发流程进行可靠度测试? Is the reliability test done during the new product development process?  Whether it follow the development process?
 2.6.4     有无环境、运输等的可靠度测试计划并进行测试, 比如温度、湿度、振动、冲击、跌落等? Is there the reliability test plan about environment and transportation, as temperature, humidity, shock, vibration, drop, etc?
 2.6.5     检测异常发生时，是否有可靠度测试异常处理程序，是否严格按照程序处理? Is there the reliability test abnormal disposal program when the abnormal happen, and whether deal with the abnormal according to the program strictly?