Compile:
Audit:
Ratification:
20 1 1 year1month
Chapter 1: The concept of quality management in production site.
The first section, the basic concept of quality management in production site.
First, the production site quality management and its characteristics.
1, production site quality management refers to the quality management of the first line of production, which runs through the manufacturing stage of the quality formation process of raw materials and products, taking the work quality of various functional departments of the enterprise and the operation quality of operators as the guarantee conditions, aiming at the conformity of product quality, and finally achieving the purpose of improving product quality, reducing costs, improving production efficiency and economic benefits, and meeting user needs.
2, the production site quality management has the following characteristics:
(1) Production site quality management takes the production site as the activity place;
1) direct production workshop, whose task is to directly change the shape, size and performance of materials (blanks or semi-finished products) until they are assembled into products.
2) Indirect production workshop, whose task is to provide necessary material conditions for direct production workshop. It is responsible for manufacturing mold tools, providing maintenance and energy supply for production equipment.
3. Production site quality management is an important part of manufacturing process quality management;
(1) The process of product quality formation consists of three aspects: design process, raw material processing and manufacturing process and use process. Quality management in production site is the requirement of realizing design process through manufacturing process.
(2) That is, to achieve the qualified quality of products and lay a foundation for the use process. The connotation of quality management in manufacturing process is broader than that in production site (for example, quality management in foreign cooperation and outsourcing also belongs to the category of quality management in manufacturing process, but it cannot be classified as on-site quality management), but quality management in production site is an important link in quality management in manufacturing process.
1) Production site quality management is a management activity;
The production process is realized through technical activities and management activities, and the quality management at the production site is a management system activity, which realizes the management of the physical quality of products at the production site.
2) Focusing on the production site, it is the central task of quality management in the production site to improve the work quality of functional departments and the operation quality of operators;
① All functional departments should provide necessary production conditions and good services around the site to realize comprehensive management, and operators should master norms and correct operations to realize "automatic control". The function of quality management in production site is to control, guarantee and improve the physical quality of products;
② The goal of quality management in production site is to realize the conformity quality of products; Product quality is the applicability of the product. At present, the design, manufacture and use quality of the complex basically depends on the design quality level, and the manufacturing quality reflects the degree to which the products meet the design requirements, that is, the conformity quality. Achieving the goal of production quality management and conforming to product quality is an important way to achieve the ultimate goal of improving product quality, reducing consumption, improving production efficiency and economic benefits, and meeting user needs.
Second, the production site quality management functions and basic links.
1. The role of quality management in the production site: control (1), (2) ensure (3) improve the physical quality of products. Through control, the process quality is always in a stable state, the quality of ex-factory products is guaranteed by means of prevention and inspection, and the improvement activities are improved through quality improvement activities to ensure the quality level of products.
(1) Basic links of on-site quality management:
(2) By organizing relevant functional departments and operators to control all factors that may cause product quality fluctuation on site (namely, the five factors of people, machines, materials, laws and environment are referred to as "4MIE factors" for short), that is, the control factors ensure "results" and "product quality".
2. Detecting the data of the "result" in a specified period means detecting the "result" and adjusting the "factor". Use charts
Reflect whether the process factors are in a normal and stable state, and take adjustment measures when there is abnormality to ensure the stability of the process. (1)(2) These two links are collectively called process quality control, and the control function of on-site quality management is realized through process quality control.
3, through the operation of all three automatic control and full-time first inspection, inspection and completion acceptance means. Realize quality control, that is, check and ensure quality, and realize the guarantee function of on-site quality management. The above links (1) (2) and (3) belong to the function of "maintaining" quality and improving the quality management of the production site.
4. Carry out targeted and planned quality improvement activities in view of the defects that often appear in the production site, so as to make a breakthrough in improving the product quality level, and then "maintain" the improvement process in stability on a new basis, and seek stability on the basis of improvement.
3. The importance of implementing quality management in production site;
1. The need to improve the physical quality, whether the total quality management work produces actual results, first depends on whether the product quality has been really improved, and whether the on-site quality management directly serves this purpose. Only by doing a good job in on-site quality management can we ensure the stable production of high-quality products.
2. Forming the key link of product quality
Product quality is the comprehensive embodiment of design, system and use quality, but design quality can only be achieved through manufacturing quality. The information obtained in the manufacturing process can be fed back to the design department, which can also promote the improvement of product design and process design and further improve the design quality, while the quality of use is the verification of design quality and manufacturing quality. On the premise of advanced and reasonable design, product quality is basically determined by manufacturing quality, and field quality is an important link of manufacturing quality. Therefore, in order to improve product quality, we must start with on-site management.
(1) is conducive to solving the main contradiction of quality;
The reason of poor product quality in China is poor technical level and backward management, and the main contradiction is management. On-site quality management mainly solves quality problems from the perspective of management technology, so the implementation of on-site management can make a breakthrough in the main contradiction of quality.
(2) Website is the focus of enterprise activities;
The production site is the combination point of various factors of enterprise productivity, and it is the foothold and service object of various management. Most employees are concentrated in the production site, and most product quality problems are exposed in the production process. Therefore, the production site is the focus of the enterprise, and the quality management of the production site can ensure the enterprise to establish a normal production order.
3. Need to deepen process management
Process management is the technical basis to ensure product quality. Only by closely combining process management with on-site quality management can we optimize process parameters, deepen process management, refine process documents, make process research methods scientific and process organization systematic, thus greatly improving the scientific level of process management.
In short, the implementation of on-site quality management should be the focus of total quality management in enterprises.
The second quarter production site quality management and process management
Product quality is a prominent problem in industrial enterprises, and weak process management and lax process discipline are the main aspects that cause quality problems. In order to make the process management develop its content on the original level and make it scientific, further improve the process documents, establish and improve the management system of total control products, and raise the process management to a new level on the basis of modernization. At present, enterprises should first deal with the relationship between process management and quality management on the production site, distinguish their personalities and their internal relations and interdependence, and solve the phenomenon of "two skins". We should closely combine, improve and develop process management, implement total quality management, grasp practical results, and promote the stability and improvement of enterprise product quality.
First, the function of process management
The function of process management is to ensure that process technology is carried out and implemented in production practice, and its main work includes:
1, review the manufacturability of the design;
2. Correct selection of materials and equipment;
3. Make process plans and prepare process regulations;
4. Design, manufacture or purchase process equipment with reliable quality, reasonable structure and convenient use;
5. Formulate process pricing (including the pricing of working hours and material consumption);
6. Provide a complete set of correct, unified and clear process documents;
7. Develop a complete set of inspection documents;
8. Process testing and process and tooling verification.
The above eight points are all production technology preparation, aiming at providing necessary material technology and management conditions for the production of products. But any advanced technology can only be realized through the guarantee of management. In order to establish a normal process order, a set of process management system, process responsibility system, process discipline, process document preparation, modification, distribution and replacement management system should be established.
Second, the relationship between process management and production site quality management
(a) process management and production site quality management * * *
1, the purpose is the same, * * The same purpose is to make the production of enterprises meet the requirements of ensuring and improving product quality, and realize the overall quality target policy of enterprises.
2, the function is the same, both of which are important links in the product manufacturing process, and both of them play their respective functions in order to realize the conformity and quality of products in the manufacturing process.
3. The attributes are the same, and both have the basic attributes of management. It is a kind of management behavior to organize relevant departments and personnel within the enterprise to realize management functions according to their different angles and priorities, and lead all work to the same goal.
The two kinds of management have the characteristics of the above three aspects, but they can't replace each other and each has its own personality.
(B) the personality of process management and production site quality management system
1. Different tasks.
The technological work mainly solves the problem of how to process and manufacture to meet the product quality requirements, which is reflected in the compiled technological documents. (Technical disclosure)
The formulation of on-site quality management system should solve the problems of how to control factors, ensure quality, and how to find and propose solutions in time once abnormal fluctuations occur. (Technical disclosure)
2. Different management categories
The foundation of process management is professional technology. It belongs to the category of technical management to take technical measures and management measures to establish normal flow and order to ensure the conformity and quality of products.
On-site quality management, mainly from the perspective of management technology, uses various means of control and improvement to ensure product quality, which belongs to the category of quality management system.
As can be seen from the above, the process management system is the foundation and the on-site management is the guarantee. The two types are different, but not opposite, but complement each other, complement each other and depend on each other.
3. Different functions
The function of technological work is to ensure manufacturing quality and provide necessary materials, technology and management, which belongs to technical preparation before production.
On-site quality management is a series of activities that make the intention of "planning" (design and technology) put into practice by systematically adopting control means.
4. The breadth of the scope varies.
Technical work not only guides processing operation, technical experience and safe production, but also is the technical basis for enterprises to plan and arrange production, production preparation and civilized production, involving a wide range.
Quality management on the production site mainly focuses on quality and organizes all departments to carry out their work.
5. Different organizational systems
Traditional process management is basically implemented by enterprise process departments alone, and practice has proved that a single department can't do it well.
According to the basic theory and method of total quality management, the quality management of production site advocates organizing all relevant departments to play their respective quality functions, and forming a multi-level, widely connected, up-and-down and horizontally coordinated system within the enterprise. This system performs its own duties within the enterprise, realizes comprehensive management, and ensures the full implementation and implementation of the process from the organization. Therefore, on-site quality management makes up for the shortcomings of traditional process management, and also promotes the improvement of the management level of each specialty.
6. The person in charge of the document is different.
The responsibility of process technical documents should basically be borne by the process department alone. In on-site quality management, the process quality analysis table compiled by the process department needs to compile a complete set of process control documents, and the process department and other relevant departments are responsible for the correctness of these documents.
Section 3 Responsibilities of Team Leaders and Operators in Site Quality Management
1. Quality responsibilities of team leaders;
1. The team leader is directly responsible for the quality of products (semi-finished products or parts) manufactured by himself, and ensures that unqualified products (semi-finished products or parts) do not leave the team.
2. Seriously study the principles and policies related to quality work and the rules and regulations of the workshop, and conscientiously implement them in the team.
3. Implement the process regulations, strictly abide by the process discipline, carefully record the original records, make all employees operate carefully, reduce or eliminate nonconforming products, classify and record the nonconforming products that have appeared, and conduct review and disposal.
4. Do all the work of quality control points according to the specified requirements. If any abnormality is found, it should be eliminated or fed back, and the relevant personnel department should be asked to solve it.
5. To implement the "three inspection system" in the team, we should actively organize and take the lead in participating in the activities of the quality management team. If the team-based "QC" team wants to combine "QC" group activities with team building, the team should also carry out other forms of quality management activities.
6. In case of quality problems, it is necessary to analyze the problems, study and take necessary measures, and determine the target policy and activity plan according to PDCA cycle work method (P stands for plan; D stands for implementation, on-site doing and realizing the contents in the plan; C stands for inspection, summarizing the results of the implementation plan, paying attention to the effect and finding problems; A stands for action, which deals with the results of summary inspection. The successful experience is worthy of affirmation and proper promotion, and the lessons of standardization failure should be summarized to avoid recurrence. ), constantly improve the quality of work, improve product quality.
7. Regularly educate the employees of this team on the basic knowledge of quality management, so as to improve the quality awareness of all employees. Team leaders should master the ideas, theories and simple methods of total quality management.
8. Establish the idea that "the next working procedure is the user", visit users frequently, and constantly improve product quality.
9. The team leader should master and understand the quality requirements of each position in the team.
2. The operator's quality responsibility
1. Operators should operate in strict accordance with the process, operate according to the work instruction, observe the process discipline, process according to the drawing and produce according to the standard (according to the system).
2. Master the basic knowledge and working methods of total quality management system, and master the working methods of quality improvement and simple statistical tools.
3. Operators should master the quality requirements and testing methods of this position.
4. Understand the leading factors among the five factors that affect the quality and control them according to the regulations.
5. The control chart should have correct data, be true and reliable, and be clear and tidy.
6. Actively report and isolate waste products and defective products to ensure that the unqualified products do not leave the factory and do not turn to the process.
7. Do a good job of quality information feedback of upper and lower working procedures, and report any problems found in time.
8. Actively participate in the activities of the "QC" team, complete the tasks assigned by the "QC" team, actively put forward reasonable suggestions, and continuously improve the product quality of this process.
9. When dealing with the problems of production quantity and product quality, we should adhere to the principle of "quality first" and resolutely do a good job in all quality work in accordance with the requirements of quality veto.
Chapter II Quality Control Points
An industrial product or a part always requires many quality characteristics, and the importance of these quality characteristics or the degree of influence on product use are not exactly the same, so it is unnecessary, uneconomical or even impossible to take the same management measures for many quality characteristics of a product or part with different importance.
The concept of quality control point is gradually formed according to the requirements of key quality control and management for important quality characteristics, and it is the concrete embodiment of the basic principle of "key minority, secondary majority" in quality management.
The first section, the concept of quality control points
1. Setting of quality control points
(1) Determine the object of the quality management point;
(1) products processed in this process.
(2) Eigenvalues of parts
③ Key features of working procedure
④ Main technical conditions
The work of determining the quality control point object is mainly carried out in the product development and design stage, that is, the quality characteristic classification and defect severity classification are the responsibility of the development and design department.
(2) Classification of the importance of quality characteristics
① Key feature: refers to the failure or damage of this feature that may endanger personal safety or hinder the product from performing the specified tasks.
② Important feature: refers to the failure or damage of this feature, which may quickly lead to or significantly affect the failure of the final product to complete the required tasks.
③ General features: refers to all features in a unit except key features and important features.
(3) Classification of defect severity
① Grade A-Fatal defect
② Grade B-serious defect
③ Grade C-mild defect (general defect)
2. Implementation and execution of quality control points
According to the classification clearly specified in the technical documents, combined with the specific conditions and technical requirements of the processing procedure, the main factors are analyzed by the way of causality diagram, and then the main factors are expanded step by step until countermeasures are taken, and then the specific control points of this procedure are implemented.
Setting of Quality Control Points in the Second Section
I. Basis and principles for setting quality control points
Where to set quality control points is generally decided by the process department.
1. Basis for determining quality control points
(1) Classification and importance classification of product quality characteristics
(2) Make a comprehensive analysis of each working procedure in the manufacturing process.
2. The principle of setting quality control points:
(1) Quality control points shall be set for key quality features, key components or important influencing factors that have a serious impact on the applicability (performance, precision, life, reliability and safety) of products.
(2) Quality control points shall be set for the key quality characteristics with strict technical requirements and serious impact on the next working procedure.
(3) For the processes with unstable quantity and many unqualified products, the topic selection control points should be established.
(4) Quality control points shall be established for important bad items fed back by users.
(5) For the key projects that are in short supply or may have a serious impact on the production arrangement, the topic selection control points should be established.
3. Types of quality control points
(1) Long-term type: key and important items in design and process requirements must be controlled for a long time.
(2) Short-term type: items with unstable process quality and many unqualified products, or special needs in a certain period due to material supply, production arrangement and other reasons.
4. Cancel the quality control point
Generally, it is the implementation of technical improvement projects, the substitution of new materials, and the standardization of management measures. Can be revoked after a period of validity verification, and then transferred to general quality control. The establishment and revocation of an enterprise shall be carried out in strict accordance with the system, and the control points set for key quality characteristics, key process quality characteristics and special processes cannot be revoked.
Two. The role of quality control points
By setting (1) products at control points, the key characteristics, special processes, key parts and important factors are effectively controlled, and the conformity quality of products is reliably guaranteed.
(2) A large number of useful data and information can be collected to provide a basis for quality improvement.
(3) Setting up quality control points and strengthening process control are the basic links for enterprises to establish quality assurance system at the production site.
Three. Steps to implement and implement quality control points
1. Determine the process control points and prepare the list of process control points, which shall be the responsibility of the process department.
2. The process department is responsible for drawing the "Process Quality Control Flowchart".
3. The Technology Department is responsible for organizing relevant workshop technicians to conduct process analysis and find out the leading factors affecting the quality characteristics of control points.
4. The process department shall prepare the "Process Quality Analysis Table" according to the process analysis results, which stipulates that:
(1) Clear control range
(2) Control requirements
5. The process department is responsible for the preparation of control work instruction and self-inspection table.
6. Equipment, tools, measurement, inspection and other departments shall formulate corresponding daily inspection cards for equipment, measuring instruments and inspection guidance cards according to the requirements of the process quality analysis table.
7. The Technology Department is responsible for formulating the "Control Point Management System", which is incorporated into the company's "Quality Responsibility System" and linked to rewards and punishments.
8. The Technology Department is responsible for organizing relevant workshops and departments to implement the system.
9. Relevant workshops respectively feed back the control status and stability of the control points of the whole workshop to the process department according to the statistical table formulated by the process department.
10. Workshop, inspection and other relevant departments should organize relevant personnel to learn and master documents and systems related to control points.
1 1. The process department is responsible for coordinating, supervising and inspecting the implementation of quality control points by relevant departments and workshops, and conducting strict assessment.
Four. Responsibilities of quality control point operators
1. Learn to understand and master the statistical methods and charts commonly used in this position, and implement the quality responsibility system and the management system of quality control points through self-study.
2. Operate and test in strict accordance with technical regulations such as work instructions to ensure the process quality of control points is stable.
3. Understand the leading factors of the five factors clearly specified in the process quality analysis table and control them according to the regulations.
4. Fill in the data record form and related charts as required, and report to the workshop technical group regularly.
5. If any abnormality is found during processing, the reason shall be analyzed immediately and corrective measures shall be taken. If there is any difficulty, report to the team leader, workshop technician and workshop leader immediately.
Verb (abbreviation of verb) The responsibility of quality inspector at quality control point.
1. Learn and master the management system and related requirements of quality control points.
2. Take the working procedure of quality in recent years as the focus of inspection, help operators to implement the relevant technical documents of quality control points, put an end to illegal operations, and make records.
3. In the process of inspection, check the leading factors of quality characteristics, find problems and help analyze and solve them.
4. Be familiar with the quality requirements of the control points within the scope of responsibilities and conduct inspection according to the "Inspection Instruction".
5. Be familiar with the chart method used in quality control points and its function, and check whether the operator's records are correct through sampling.
6. The operator's self-inspection record should calibrate its self-inspection accuracy, and report and publish it monthly.
Chapter III Specific Contents of Workshop Site Quality Management
The specific content of the scene
1, on-site quality management tasks of managers and technicians
(1) stably and economically produce products that meet the requirements of users.
(2) Provide necessary material, technical and management conditions.
(3) Participate in reviewing the manufacturability and economy of product design.
(4) Cooperate with the technical department to prepare reasonable technical documents such as process regulations and work instructions.
(5) Ability to research and analyze the process
(6) Organize balanced production and make production plans.
(7) Organize quality improvement and tackle key problems.
(8) Strengthen the management of equipment and raw materials
2. Responsibilities of production workers in site management
(1) Be familiar with design drawings, internal control standards and processes, correctly understand and master various requirements, and analyze the possibility of meeting requirements and existing problems.
(2) Check raw materials and semi-finished products according to drawing standards and process requirements, and adjust specified processing facilities such as equipment, tools, measuring tools, instruments and meters to keep them in good condition and strictly abide by process discipline.
(3) Study and analyze the process capability, eliminate abnormal factors, make the process in a stable control state, and focus on controlling the influencing factors of key parts or key quality characteristic values. (control point)
(4) Regularly record and count the original record qualification rate and primary qualification rate in accordance with the regulations, and compare them with the specified assessment indicators for self-quality control.
(5) Learn and improve operation skills, meet quality requirements and practice basic skills.
(6) Strictly implement the "three-press" production, and do a good job of "three self-control" and "one control"
Three presses: according to pattern, according to process and according to standard.
Three selves: ① Workers conduct spot checks on their products (self-sampling); ② Distinguish qualified products from unqualified products (self-sorting); ③ Mark the processor, date and quality status by yourself. (Number of self-employed)
One control: control the correct rate of self-inspection. The correct rate of self-inspection is the ratio of qualified inspectors to qualified production workers.
Operators should strive to achieve the self-checking accuracy of 100%.
(7) Do a good job of counting and keeping raw materials and semi-finished products, so as to achieve limited acquisition and exclusive use of special materials, and return the surplus materials and waste materials in time to prevent material deterioration.
(8) Do a good job in the maintenance and storage of equipment, fixtures, molds and measuring instruments, use them correctly, and adhere to the daily inspection system for key parts.
(9) Adhere to civilized production, maintain good environmental conditions, ensure that the equipment, tools, materials, semi-finished products and finished products in the workplace are neat and clear, and eliminate all factors that may cause bumps, scratches, rust, corrosion, pollution and mildew of finished products.
(10) Do a good job in unqualified management.
(1 1) Adhere to balanced production, correctly handle the relationship between quantity and quality, strive for high-speed daily and hourly balance on the premise of ensuring product quality, and should not neglect quality in order to catch up with tasks.
(12) Actively participate in the activities of the quality management team and constantly carry out on-site improvement activities.
Every production worker should establish the idea of continuous progress, never be satisfied with the achievements he has made, constantly strive to find and discover the bad, unstable, unbalanced, inadequate and unreasonable phenomena in his post or set new enterprising goals, tap the potential and continuously improve the quality level of compliance.
Thoughts on quality management and quality control points in production site
1. What is the role of quality management in the production site?
Answer: 1. Control function 2. Safeguard function 3. Improve the function.
2. What is the conformity quality of products?
Answer: The degree to which a product meets the design requirements is the conformity quality.
3. What is the goal of realizing quality management at the production site?
Answer: Realize the conformity of product quality, and achieve the ultimate goal of improving product quality, reducing consumption, improving production efficiency and economic benefits, and meeting users' needs.
4. What are the factors that cause product quality fluctuation?
Answer: There are five factors, namely, human, machine, material, law and environment, which are referred to as 4MIE factors.
5. What is the operator's three self-control and one control? What is the inspector's "three inspections"?
Answer: The "three selves" are self-inspection, self-division and self-employment number. One control: self-inspection accuracy = qualified number of special inspection/qualified number of self-inspection × 100%.
6. What is the importance of implementing quality management on the production site?
Answer: 1. The need to improve the quality of goods.
2. Form the key link of product quality.
3. It is beneficial to solve the main contradiction of quality.
4. Website is the focus of enterprise activities.
5. Need to deepen process management.
7. What is the essence of process management and quality management in production site? What are different personalities reflected in?
Answer: * * * Gender: 1. The same purpose-improving product quality.
2. The same function-an important link in the product manufacturing process
3. The same attributes-have the basic attributes of management.
Personality: 1. Different tasks
2. Different management categories
3. Different functions
4. The breadth of the scope varies.
5. Different organizational systems
6. The person in charge of the document is different.
8. What are the responsibilities of production workers in on-site quality management?
A: According to Chapters III and II.
Nine. What is the classification of the importance of quality characteristics and the severity of defects?
Answer: 1. Classification of the importance of quality characteristics:
Grade A: Main features
Class b: important characteristics
Class c: general characteristics
2. Classification of defect severity:
Class a-fatal defect
Grade b-serious defect
Grade c-mild defect (general defect)
10. What are the principles for setting control points?
Answer: 1. Key quality characteristics, key components and important influencing factors that have a serious impact on product applicability.
2. The key quality characteristics and parts that have strict requirements on the working procedure and have a serious impact on the work of the next working procedure.
3. The process with unstable quality and many unqualified products.
4. Important bad items of user feedback.
5 key projects that are in short supply or may have a serious impact on production arrangements.
XI。 The role of quality control points
Answer: 1. The key characteristics, special processes and important factors of key components are effectively controlled, and the qualified quality of products is reliably guaranteed.
2. A large number of useful receipts and information can be collected to provide a basis for quality improvement.
3. Strengthening process control is the basic link for an enterprise to establish a quality assurance system at the production site.
12. What are the responsibilities of the operators of quality control points?
A: Press Chapter II, Chapter II and Chapter IV.