1.0 purpose

1.01 Effective and reasonable verification of new products designed and purchased materials;

1.02 Small batch SMT chip processing can be carried out in an orderly manner, and provide guarantee for the mass production of subsequent products;

 

2.0 range

  Applicable to the company's new products, research and development engineering changes, quality improvement and experimentation of incoming materials, new suppliers, new materials and verification of PE department tests.

 

3.0 Responsibilities

3.1 Production department

3.1.1 Responsible for personnel arrangement and product production for small batch SMT patch processing;

3.1.2 Propose product problems during small batch SMT chip trial production;

3.1.3 Statistics of various bad data in trial production products.

3.2 PE department

3.2.1 Responsible for the provision of tooling fixtures before small batch trial production of SMT patches;

3.2.2 Drafting of "Operation Instructions" at the initial stage of trial production;

3.2.3 Analysis and solution of product problems during trial production;

3.2.4 Collection and sorting of various data during trial production.

3.3 Quality department

3.3.1 Responsible for the tracking and inspection of small batch SMT chip trial production;

3.3.2 Judgment and confirmation of quality standards in trial production, and close quality problems at the summary meeting;

3.3.3 Application and follow-up of the reliability test of trial production products;

3.3.4 Reliability experiments and data provision of trial production products.

3.4 Material Control Department

3.4.1 Responsible for the time arrangement of small batch patch trial production;

3.4.2 Trial product material preparation;

3.4.3 Issue of "Production Order";

3.4.4 Responsible for organizing relevant departments to evaluate unfinalized products.

3.5 Purchasing Department

3.5.1 Responsible for the procurement of small batch SMT trial production materials;

3.5.2 The introduction of new material suppliers, recognition and initiation;

3.5.3 Purchase of materials required for trial production;

3.6 R&D Department

3.6.1 Responsible for the convening of the trial production summary meeting;

3.6.2 Provide technical support, participate in the follow-up of the small batch trial production process and the analysis and treatment of process problems;

3.6.3 Handling of poor reliability test of SMT small batch patch processing;

3.6.4 Handling of research and development issues in the small batch trial production summary report;

3.6.5 The application and change of design involved in the process of SMT small batch patch processing.

3.6.6 Follow up the whole line during the trial production process.

 

 

 

4.0 Definitions

SMT small batch patch processing

 

 

5.0 Working procedures

5.1 Received an application for SMT small-batch patch processing and trial production (application department: R&D DepartmentQuality DepartmentPurchasing DepartmentPE Department)

5.1.1 The trial production of new products and design engineering changes shall be submitted by the R&D Department;

5.1.2 The procurement department shall apply for the verification of the replacement of new materials that have been batched;

5.1.3 The quality department will improve incoming materials and test verification, and the quality department will submit an application and follow up on trial production;

5.1.4 For the experimental verification of the PE department, the PE department shall submit an application;

5.1.5 For the verification of SMT small-batch patch processing trial production of undefined products, the R&D, engineering, quality, marketing, procurement and other departments are convened by the material control department to participate in the review of the process status, material assurance, process assurance, production process control, etc. Clarify the person in charge and the specific time requirements, form a meeting record and implement it by each department, and the material control department is responsible for the follow-up and confirmation of the process;

5.1.6 When the small batch trial production department has completed the "Small Batch SMT Trial Production Application Form", the marketing department will reply to the order status, and the factory director/general manager will review the "Small Batch SMT Trial Production Application Form" After the content review and approval is passed, copies are sent to R&D, PE, quality, material control, procurement, production, marketing, factory director/general manager and other departments.

 

 

 

5.2 Small batch trial production arrangement

5.2.1 The Material Control Department shall issue the "Material Application Form" to the Purchasing Department to order materials in time after receiving the "Small Batch SMT Trial Production Application Form" after the review;

5.2.2 Purchasing After receiving the planned "Material Requisition Form", it is necessary to order materials in time according to the approval base of the small batch quantity:

5.2.3 After the complete set of product materials, the material control will issue a "production order" to prepare for small batch trial production. The quantity of small batch trial production is generally 200-500PCS.

5.2.4 Before small-batch trial production of new products, the R&D department makes production samples and distributes them to PE department, quality department, and production department; and organizes pre-trial production meetings;

 

5.3 Small batch trial production preparation

5.3.1 After the engineer in charge of the R&D case receives the "Application Form for Small Batch Trial Production of SMT Chips", he will conduct inspection and tracking according to the various contents in the "Application Form for Small Batch Trial Production";

5.3.2 After the production department receives the "Production Order" issued by the material control, it starts to prepare materials (receive materials) for small batch trial production;

5.3.3 SMT chip processing

After receiving the "Production Instruction Sheet" issued by the material control, the production personnel will make the first piece according to the production sample provided by the research and development, fill in the "First Piece Inspection Record Form", and start production after the first piece is qualified; problems in SMT trial production Timely feedback to the engineer in charge of the case and the project leader of the R&D department for processing; after the production of semi-finished products is completed, the qualified products will be stored in the warehouse, and SMT will submit the production data to the engineer in charge of the case.

*If there is a problem, the Quality Department fills in the "Small Batch SMT Trial Production Record Form", including DIP and various processes;

 

5.4 DIP small batch trial production process tracking and exception handling

5.4.1 Before the trial production, the production personnel make the first piece of the product and fill in the data in the "First Piece Inspection Record Form"; after the first piece is qualified, the trial production is carried out according to the requirements of the drawings and the "Work Instructions", and the case is developed at the same time The responsible engineer and the project leader of the R&D department must go to the site to follow up the trial production process; when there is a problem in the small batch trial production, the small batch trial production engineer and the R&D department will jointly lead the on-site processing;

5.4.2 During the trial production process, the production data shall be provided by the production department to the engineer in charge of the R&D case, and the IPQC random inspection data shall be provided to the engineer in charge of the case by IPQC. Record the problems, causes and solutions in the process, and put them forward in the trial production summary meeting;

5.4.3 PE personnel are responsible for providing technical support for the trial production process, and together with the project leader of the R&D department to solve the abnormalities in the trial production process; After the experiment is completed, the test report will be provided to the engineer in charge of the R&D case; if there is a reliability test problem, it must be handled by the project leader of the R&D department.

5.4.4 The engineer in charge of the research and development case must complete the collection and sorting of various trial production data within 2 working days after the trial production is completed.

 

5.5 Summary of Small-batch SMT Pilot Production

5.5.1 After the small batch data sorting is completed, the R&D department will convene production, quality, PE, material control, R&D, procurement and other departments to hold a small batch trial production summary meeting;

5.5.2 In the small batch trial production summary meeting, the QC qualified data and IPQC sampling data in the trial production process shall be published by the quality manager, and the problems arising in the trial production process shall be raised;

5.5.3 For problems that arise during the trial production process, the engineer in charge of the R&D case and the project leader of the R&D department will analyze the cause and propose solutions; the person in charge of the corresponding problem and the completion time must be confirmed for the solution;

5.5.4 R&D Department, PE Department, Material Control Department, Production Department, Quality Department and Purchasing Department conduct mass production review based on the first pass rate and production efficiency in the "Small Batch Trial Production Summary Report";

5.5.5 Questions about the minutes of the small batch trial production summary meeting shall be sorted out by the engineer in charge of the R&D case and recorded in the "Small Batch Trial Production Summary Report". Quality Department and Purchasing Department etc.

 

5.6 Tracking and Confirmation of Trial Production Problems

5.6.1 After receiving the "Summary Report of Small Batch Trial Production", the R&D Department, PE Department, Material Control Department, Production Department, Quality Department and Purchasing Department should, according to the problems in the "Small Batch Trial Production Summary Report" Solve it and complete it in time, the quality department will follow up the completion progress and record whether it is closed;

5.6.2 R&D issues: such as size, function, performance issues, etc., R&D engineers must provide 2-5PCS improvement samples and other complete sets of materials within 15 days according to the actual situation (R&D engineers need to verify by themselves) together with the verification samples and Closed after being confirmed by the quality department;

5.6.3 Incoming material problem: IQC must immediately give feedback to the supplier for improvement. If it involves sending improved samples, IQC must notify the purchaser and provide it to the engineer in charge of the R&D case within 3 days (IQC has verified OK) for verification; After the qualified department is confirmed, when there is an order, it will be closed by the quality department after the small batch is verified to be qualified.

5.6.4 Process problems: The engineer in charge of the R&D case will give on-site guidance and solutions;

5.6.5 Reliability Experiment Problems

5.6.5.1 For reliability issues such as quality aging, vibration, shock, drop, etc., the engineer in charge of the research and development case will determine the responsible unit, and the responsible unit will give the treatment measures and close it after passing the verification of the quality department;

5.6.5.2 For new products, the Quality Department shall apply for the reliability test and follow up the results according to the "Operating Procedures for Reliability Test", and the PE Department shall confirm whether the test method and operation are correct;

5.6.6 Remarks

5.6.6.1 When the problem cannot be dealt with on time, the engineer in charge of the R&D case must be notified by email and the time point for next improvement will be given until the quality problem is closed;

5.6.6.2 When the problem points are shirked without reason in each improvement process, resulting in the improvement department not being able to change and deal with it on time, resulting in a delay in the trial production of the next order, the corresponding responsibility must be investigated.

5.6.6.3 Any finalized product that needs to be changed, amended, replaced or significantly changed must go through the procedure of "Small Batch Trial Production Management Regulations".

 

5.7 Formal mass production

5.7.1 After the various problem points of the small batch SMT chip trial production have been dealt with, the manager of the R&D department will confirm and pass the audit before mass production can be carried out;

5.7.2 Regarding the introduction of new materials, after passing the trial production in small batches, it is necessary to import batches to ensure the stability of the quality of subsequent large batches. The batch size is generally 1000PCS-5000PCS;

5.7.3 If the trial production of materials and process changes is passed, the R&D department shall update the latest production data in time, and notify all departments to sign the "ECN" and issue it;

 

6.0 Related documents

6.1 "Reliability Test Operating Procedures"

6.2 "Work Instructions"

 

7.0 Record form

7.1 "Small Batch Trial Production Application Form"

7.2 "Production Order"

7.3 "First Article Inspection Record Form"

7.4 "Small Batch Trial Production Record Form"

7.5 "Small Batch Trial Production Summary Report"

7.6 "Material Application Form"

7.7 "ECN"