Plastic Quality Process Audit

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100%Counts:37Subtotal:371. Tooling, Machine and Fixture#DIV/0!Counts:0Subtotal:0Y=1N=0N/A=xY=1N=0N/A=x

1.11.21.31.41.51.61.71.81.91.101.111.121.131.141.151.161.171.181.191.201.211.221.231.241.251.261.271.281.291.301.311.321.331.341.351.361.371.38Plastic Quality Process ATemperatures set properly Barrel throat, Barrel temps保养历史和保养政策的管理(含螺杆、料桶、模具、机台等)以及油类的使用和管理1DFS Avg Score:Process Set-Up sheets on machines机台参数,料桶及射出料口温度的设置(过程和内容等)

Self ScoreDFS ScoreSelf Avg Score:

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Runnerless molding … adequate temperature controllers干燥过程是否文件化?对树脂材料干燥的条件是否遵照了不同的材料厂家的规格说明来定义?Wiring of mold (zone 1, zone 2, etc.) employs standard process是否在公母模上都有温度控制器?模温的设置是否参照树脂材料的不同而定义?Machine hopper sized for proper throughput成型产品是否能从成型机上自动脱模?如果产品自由落下,是否采取了措施已防止其损坏?Tooling - machine sizes, EDM, mills adequate to support manufacturing产品从机台上包装和移转时是如何进行的?Material dryer maintenance process (desiccant, filters, gauges, etc.)是否对过程测量设备的能力进行了比对、研究和分析?

Drying process per resin supplier specifications?成型条件中的重要参数是否进行了SPC监控或管制?Maintenance of drying system版本控制:如何使作业人员知道生产的是正确的版本?Is there a temperature controller for each side of the mold?模具是否能够得到很好的修复(修模能力、修模前的评估、修模后的验证等)

Housekeeping (machine area)是否使用真空送料器?真空送料器的清洁频率如何?Hoses and clamps adequate, accessible加工区域的整理和存贮管理1Mold water circuits fed by manifolds (or looped)有无过程控制设备对机台的状况进行校准和监控?这些设备是否进行了有效的校验?1

1Mold set up includes low pressure safety checking机台烘料(送料)系统能否满足正常生产能力的需求1

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Machine control types / adequate模具温度控制、寿命管理、成型次数记录、水路管理11Machine lock-out to protect miscellaneous changes对于无水路模具是否有足够的温度控制器1

1Types of check rings / valves acceptability机台有无自锁和稳定装置、相关程序文件和方针以及执行情况,机台防护罩打开时,机台能否自锁1111Nozzle configuration and style Correct for resin / mold?机台控制方式,有无足够的警示零、指示灯等1Types of (L/D, compression, screw design known?)加热系统的管理,如加热器、热电偶、线圈等1Maintenance policy Oil management, etc.机台设计和工作原理的了解和应用1Are these process-control instruments within the calibration dates? 当材料或颜色变化时,送料管、烘干机、料桶等是如何进行清理和净化的?11Centralized dryer system or hopper dryer?成型条件是否被文件化?作业时是如何选择成型条件的?Are the mold temperatures within the guidelines from the resin supplier?模具的保养记录是否完整并保存?crew and barrel / machine maintenance:射出喷嘴的结构和类型是否与树脂以及模具相匹配,能否满足不同情况下的需求Barrel capacity / barrel utilization correct?射出能力的参照和比对Heater bands / thermocouple / wire management模具安装作业中应包含低压安全检查Profile of injection capability水路和接口能否满足需求,模具水路用水是循环水还是一次性水Machine lock-out procedure document / policy adherence模具配线作业有无标准的作业流程和方法、人员obotic efficiencies是否有足够的设备支持模具的制造的需求,如机床尺寸、火花机、研磨机等Mold temperature controllers, vintage, accessibility, hose management使用的集中烘料系统还是烘料机单机干燥材料?材料干燥系统或干燥机的维护和保养方法以及流程(如干燥剂、过滤网、测量设备等)

Management of maintenance (history)料桶的容量是否满足需求,是否能有效利用,机台作业的自动化效率如何?是否自动循环作业?

Machine lockout for open gate?机器停工的标准?Fully automatic cycle?完全自动的循环?111x11Documented drying process?当成型条件超出规格时,机台是否会自动报警?Are process-control instruments in machines calibrated?送料器是否依据不同的材料进行了有效和正确的标识以避免误用?11111111

Are parts robotically removed from molding machine?部件通过机械手自动从射出机台中移开?If parts free fall, are they protected from being damaged?如果部品自动落下,是否有保护措施防止损坏?How are parts packaged and transported away from machine?是否所有的部品从机器上移走有包装和运输?111

Form No.: A-0D-002-20(120416) 保存期限:3年 保存單位:QA過期處置:背面紙100%Counts:12Subtotal:122. MANPOWER#DIV/0!Counts:0Subtotal:0

2.12.22.32.42.52.62.72.82.92.102.112.122.132.14100%Counts:12Subtotal:123. MATERIAL#DIV/0!Counts:0Subtotal:03.13.23.33.43.53.63.73.83.93.103.113.12100%Counts:21Subtotal:214. METHOD#DIV/0!Counts:0Subtotal:04.14.24.34.44.54.611Machine set up / operating parameters documented机台设置、操作参数文件化11Self Avg Score:Holding area for suspect product secure可疑产品的待处理存放区的划分、使用及保护Molds / dies manufacturing per document parameters模具自开模到报废整个环节中是否有文件化的参数进行记录和衡量?1Solvents/Flammables/Oils storage marking / secure成品仓库的安全性、标识等问题的管理以及执行情况Warehousing of finished goods (secure and marked and accessibility)成品仓库的安全性、标识等问题的管理以及执行情况111Adequate method of material change / purge compound材料(产品)运输方法的效率,材料和产品是如何运输的,有无进行有效的管控?1Regrind mixing - policy, method, control process有机溶剂、易燃物、油类的存储、标识和安全性管控?1Regrind labeling and separation to prevent contamination材料变更和清除混合物时是否有足够的方法?1Regrind mixing/metering method secure粉碎料应正确标识和区分以防止污染?11Regrind "fine" separation粉碎料的混合、测量方法的安全性和可靠性,粉碎料的混合比例、方法以及过程的控制11Are the material requirements documented?进料文件控制,对材料的要求是否进行了文件化的定义?11Adequate staffing for quantity of machines机台人员的配布是否合理?11Machine history screen is referred to for process stability机台的历史信息是否能够展现生产过程的稳定性?11XObserve proper runnerless and machine shut down process是否遵守了无水路模具和机台的关闭程序XTooling - observe work in process, employee engagement在制程间流转和员工间交接时是否对加工过程进行了有效监测?1Is the certification criteria includes written and practical tests?员工上岗资格的评定是否包含书面和实际操作能力和测试?1Operator training (machine savvy, safety)员工操作培训(对机台的了解、安全等)1Set up training - mold and machine模具和机台安装和设置的训练1