Product production control procedure
1.Purpose
Control the manufacturing process to ensure process capability and manufacturing quality.
2.Scope
Applicable to the company’s auto parts production process control.
- Responsibility and authority
The production department is responsible for this process management.
- Workflow
4.0 process input: order/delivery plan; Inventory; Product specification/work instruction.
4.1 production plan
4.1.1 receive orders
After signing the contract, the sales department issues the production order to the production department, and the production department signs it.
4.1.2 status survey (inventory, order demand, production capacity, wip)
Production department according to the production orders issued by the sales department, inventory statistics, production capacity analysis.
4.1.3 decompose the production plan
Production department according to master the relevant information (safety inventory, production capacity, order demand, wip) according to the relevant requirements of order demand, and consider the priority of each order, do the monthly order decomposition, using the production schedule, regular weekly or daily production plan to the relevant workshop.
4.1.4 production realization
4.1.4.1 under normal circumstances:
Workshop production plans issued from the production department, in order to further review, have the ability to produce according to the sales department and production department of production plan and instructions, decomposition to the team and individuals, and completes the process of design, material of the declaration, tooling equipment, acquisition and related preparatory work, at the same time to organize the process production scheduling work.
If the workshop is unable to produce or the production plan has relevant problems, the head of the workshop shall report to the production department and sales department, and the production department shall make a clear reply and adjustment within one day.
4.1.4.2 in case of abnormality:
- A) in case of emergency orders from customers, the production department shall give instructions according to the demand of emergency orders and issue relevant workshops as required. The workshops shall organize production scheduling in the form of fast lanes.
- B) inspection and coordination
In the process of production operation or the current month, the production department shall check and track the production schedule of the production plan, communicate and coordinate the problems encountered, and make mandatory requirements when necessary.
- C) program evaluation
During the production operation or at the end of each month, the production department will make summary analysis and report according to the completion of the production plan of each workshop, that is, the completion rate of the plan and the failure rate of the working procedure, and make rewards and penalties evaluation through the production management system.
- D) demand analysis of equipment and personnel
The workshop shall make a comprehensive analysis of the monthly production plan, make a rectification plan if it is unable to complete the task according to the relevant plan indicators, and report to the production department in time.
- E) management review
After receiving the workshop’s rectification plan, the production department shall review the rectification plan according to the relevant requirements, and feed back the implementation of the relevant instructions to the workshop.
4.2 production process management
4.2.1 production preparation
4.2.1.1 the production department shall implement cleaning site and stationary site.The regulations on the cleaning of the factory and the location of tools and articles on site shall be implemented in accordance with the 5S related specifications.
4.2.1.2 the production department shall prepare materials, and external procurement or outsourcing shall be carried out according to relevant procedures.
4.2.1.3 the production operation plan shall be arranged according to the requirements of customers, according to the principle of priority and priority, which is conducive to quality control, and conducive to logistics.
4.2.1.4 the production department shall be responsible for the training of operators, and the training of operators in key processes shall be strengthened according to the human resource control procedures.
4.2.1.5 the equipment management personnel of the production department shall be responsible for checking the production equipment and molds, carrying out regular maintenance, and carrying out pre-maintenance, which shall be carried out in accordance with the equipment and tooling control procedures.
4.2.2 job preparation verification
4.2.2.1 timing of verification: during the initial production, material replacement and operation change.
4.2.2.2 the production department is responsible for the verification of facilities and environmental preparation conditions, including equipment, tooling, measurement system, operation documents, material preparation, etc.
4.2.2.3 the production department is responsible for verifying process status to ensure process capability. Generally, the first piece inspection is adopted.
4.2.2.4 if the quality is not stable, the production department shall continue to adjust the machine tools and tooling.
4.2.2.5 normal production can only be started after the first piece of inspection is qualified.When the material is changed, the operation is changed, and the production is resumed after a long period of discontinued production, it should be verified in time.
4.2.3 normal production
Under normal circumstances:
- A) the production unit shall, according to the production plan issued by the production department, organize production according to the product operation instruction and process specification.
- B) the control of process documents shall meet the requirements of technical document management measures.
- C) the process documents must specify the product processing process, process parameters, material requirements, tooling requirements and related inspection requirements, etc. as the basis for process control.
- D) product storage and handling in the production process shall be carried out according to the product protection and control procedures.
- E) each inspection shall be carried out according to the requirements of process control in the production process, and the specific implementation shall be in accordance with the product monitoring and control procedures.
4.2.4 in case of abnormality:
- A) suspicious or unqualified products found in the production process shall be subject to the control procedures for nonconforming products.
- B) after any abnormality occurs in the production process, corrective measures shall be put forward according to the improvement control procedures for continuous improvement.
- C) relevant leaders (scheduling) of the production department, who are directly responsible for coordinating quality-related activities and problems.
4.2.5 inspection and coordination
In the process of production operation or the current month, the production department shall check and track the production schedule of the production plan, communicate and coordinate the problems encountered, and make mandatory requirements when necessary.
4.2.6 production inspection
Product in the production process, on-site quality control personnel to carry out inspection, in accordance with the “product monitoring and control procedures” implementation.
4.2.7 identification management and protection
According to the labeling management “product packaging, labeling provisions” control implementation.
4.2.8 production records
4.2.8.1 control the production process and fill in corresponding records according to the product control plan.
4.2.8.2 after the end of the production on the day, the team leaders shall fill in various production statistical statements, submit them to the production supervisor of the unit for summary, and make a daily report to the production supervisor of the workshop of the production department
4.2.9 final inspection
In the process of production or after the completion of product processing, the inspection shall be carried out according to the requirements of drawings and process control, and the specific implementation shall be in accordance with the product monitoring and control procedures.
4.2.10 handling warehousing
4.2.10.1 after the product is processed, relevant warehousing procedures, such as warehousing receipt and inspection report form, shall be handled after passing the inspection.
4.2.10.2 product storage and handling in the production process shall be carried out in accordance with the product protection control procedures.
4.2.11 delivery
The sales department will implement the delivery according to the arrangement of customers, and follow up the situation of the product delivery. Implement delivery control procedures.
4.2.11 statistics
4.2.11.1 the production department shall make statistics on the planned completion status (completion rate) of the corresponding production units.
4.2.11.2 the quality control department shall make statistics on the defective rate of process.
4.2.12 production evaluation and improvement
During the production operation or at the end of each month, the production department will make a summary analysis and report according to the completion of the production plan of each workshop, that is, the completion rate of the plan and the defective rate of the process, and the responsible unit will analyze the causes, compile and implement the rectification plan, and implement the improvement control procedure.
5.Relevant documents/records
- 5S management specification
- Product inspection specification
- Provisions on product packaging and marking
- Product protection control procedures
- Work instruction/process card for each process
- The production plan
- Three control record
- Product inspection record
- Process SPC records
- Batch number management ledger
