QPQ006 模具管理控制程序.docx

1、QPQ006 模具管理控制程序1.目的Purpose 为使本公司之模具从使用、校正、修理及报废阶段作业皆有依据可循，特制订本管理办法。This management regulation is made to standardize the operation of using, adjusting, repairing and scrap mold. 2.范围Scope全公司所有使用之注塑模具均适用之 It applies to all injection molds of VTYC.3定义 definition模具维修：涉及产品外观、尺寸和模具异常的量产模具修理。Repairing: it

2、 refers to repair SOP mold on the appearance, dimension and abnormity.维护保养：正常情况下模具生产达到一定数量后的例行维护及保养。Maintenance: regular maintenance after it reaching certain shot volume.4职责duty4.1常州采购单位：负责依单据发包承制、采购等作业。Purchase department in Changzhou: be responsible for outsourcing and purchasing mold in accordan

3、ce with the documents.4.2常州模具单位：负责模具规划、制作并确认。Tooling department in Changzhou: be responsible for planning, manufacturing and confirming of molds.4.3重庆模具课：负责模具的验收与管理，维修与保养等作业。Engineering department in Chongqing: be responsible for checking, managing and maintaining of molds4.4 质量单位：确认该模具生产出产品符合品质要求。Q

4、A: ensure product made by the mold meets the quality requirement.4.5 精益生产部：负责模具的保管和配合模具课保养等作业VS: be responsible for keeping and working together with tooling department to maintain molds.5.程序 procedure5.1简易流程 simple process验收管理-维修-保养-报废Checking &acceptance management repairing maintenance -Scrap5.2具

5、体描述specific description:5.2.1验收checking & acceptance:5.2.1.1在重庆生产的模具的验收，需要在重庆连续生产250模以上作为量产验证，记录在产品试模状态统计表FRC(FM-T089)中； To accept a mold in Chongqing needs continuously manufacturing over 250 products in the plant for mass-production verification, the mold trail condition should be recorded in mold

6、 trail FRC form (FM-T089). 5.2.1.2生产良品率要求到达95%以上。试模生产情况记录在产品试模状态统计表由精益生产部提供(FRC) (FM-T089) The mold is OK when the yield rate has reached 95%. VS offer mold try-out statistical table(FM-T089). 5.2.1.3接收模具资料(最新3D数据，模具备件清单)点检模具外观，包括模具信息铭牌，热流道铭牌，水路铭牌，感应开关，接线盒等。验收完毕以后由模具部填写模具验收报告（FM-T088）. Tooling depar

7、tment should complete the “mold receiving report”(FM-T088) for receiving mold materials such as the latest 3D data, spare parts, and inspecting mold appearance such as mold nameplate, hot runner nameplate, water gate nameplate, sensor switch and terminal box.5.2.1.4 模具部根据精益生产部提供的“试模统计表FRC” (FM-T089)

8、以及“模具验收报告（FM-T088）作为验收合格的佐证，记录保存在模具部。 Mold trail FRC form (FM-T089) and mold checking & acceptance report (FM-T088) offered by VS are used as evidence of accepting a mold by tooling department. The tooling department should keep these forms.5.2.1.5如果模具验收不合格，由模具部负责通知常州模具单位，配合维修工作。If a mold NG, the to

9、oling department informs CZ tooling department of working together to repair it.5.2.2管理：management5.2.2.1由模具部对所有在重庆工厂生产的模具建立模具清单（FM-T082）；并根据每付模具信息建立模具履历表（FM-T086）包括模具编号、材质、尺寸等信息。The tooling department should establish mold inventory (FM-T082) for all molds in CQ plant, and mold information sheet (F

10、M-T086) for every individual mold, detailing in mold number, material and dimension, etc.5.2.2.2模具的备品建立备品清单及备品库存。每月对模具备件的清查，保证备件和日常工具的库存。Establish spare parts list and spare parts inventory. Take spare parts stock monthly to ensure enough reserve.5.2.2.3待模具卸下机器以后，由注塑课负责在模具上挂上由模具部提供的状态标识。When the mol

11、d remove from the machine, tooling dept responsible for make the status sign for each mold. 模具正常：模具维修、保养以后挂上（模具正常）的标识牌。Mold ok: refers to the mold status is ok, after repair or preventive maintenance. 模具故障：在需要维修的模具上，挂上（模具维修）的标识牌。Mold failure: refer to the mold need to be repaired.模具保养：在待保养的模具上，挂上（模具

12、保养）得标识牌。Mold preventive maintenance: refers to the mold need to be done the preventive maintenance.模具报废：等待报废及已经报废的模具挂在模具明显部位挂上（模具报废）的标识牌。Mold scrap: refers to the mold scraped.5.2.3模具维修：当模具出现异常时，由模具使用单位开出模具修改申请单（表单编号：FM-T085），所在部门主管签字确认后，交往模具课。由模具部判定自行修理或者委外修理。Repair: finding abnormality, the using

13、unit complete mold modification application (FM-T085) and send it to tooling department after the using unit supervisor signed it. The tooling department evaluate to repair it itself or to outsource repairing. 5.2.3.1自行维修的模具，由注塑课挂好（模具维修）标示，拉到模具部的模具待修区，模修跟产品有关系的必须在模具上留下最后一模产品，并在产品上标示需要修正的位置。以便下次验证修正问

14、题点的核对。然后再开出模具修改申请单（表单编号：FM-T085）,所在部门的课长或者经理签字确认后，交往模具课 。内容必须和样件问题点一致。然后由模具部负责提出维修方案和时间计划，并邮件形式通知各单位主要人员，待物流计划员确认后通知模具课开始模修。维修完成后登记在模具履历表（FM-T086）上。并把已修好的模具换上（模具正常）的标示牌拉到模具已修区。并以邮件形式填写（试模通知单）给物流计划员和各部门相关人员。物流计划员安排试模后提前通知各部门相关人员参与试模和确认。产品修正确认后模修提出者在模具修改申请单上确认签名，以便备档。For mold can be repaired by toolin

15、g department，the tooling department should draft repair scheme and register it on mold information form(FM-T086).5.2.3.2需要委外修理的模具，由采购单位和模具单位共同选择供应商维修或外包维修。注塑课挂好（模具维修）标示，拉到模具部的模具待修区，模修跟产品有关系的必须在模具上留下最后一模产品，并在产品上标示需要修正的位置。以便下次验证修正问题点的核对。然后再开出模具修改申请单（表单编号：FM-T085）,所在部门的课长或者经理签字确认后，交往模具课 。内容必须和样件问题点一致。然

16、后由模具部负责提出维修方案和时间计划，并邮件形式通知各单位主要人员，待物流计划员确认后通知模具课开始模修。维修情况登记在模具履历表上（表单编号：FM-T086-V1）. 并把已修好的模具换上（模具正常）的标示牌拉到模具已修区。并以邮件形式填写（试模通知单）给物流计划员和各部门相关人员。物流计划员安排试模后提前通知各部门相关人员参与试模和确认。产品修正确认后模修提出者在模具修改申请单上确认签名，以便备档。For mold needs outsourcing repairing, the purchase department and tooling department should work

17、together to find out the supplier. Record repair condition on mold information form (FM-T086-V1).5.2.3.3模具或者镶件需要协外维修或者加工时，由模具部填写原物料放行单，并由模具主管和物流计划员或者物流主管签字后才能放行，如果是节假日要电话通知警卫放行，但星期一要及时补交。5.2.4保养：maintenance5.2.4.1根据模具保养及检验表（FM-Q083）的要求，物流部根据QAD系统统计本周该模具使用数量，并且加入下周生产计划的模具使用数量，如果其总数达到保养要求时由物流部提供模具保养通知

18、单（FM-T087）通知模具部安排保养。模具单位收到模具保养通知单以后，回复物流单位保养所需时间，物流单位根据保养安排调整下周生产计划。MP&L summarize how many molds have been used every week per QAD data and add how many are needed next week to it as mold maintenance & checking form (FM-Q083) requires. If the result reaches maintaining requirement, MP&L complete mo

19、ld maintaining notification (FM-T087) to inform tooling department of maintenance. Receiving the notification, tooling department gives feedback to MP&L on when to maintain mold. MP&L rearrange next week manufacture plan.5.2.4.2模具部负责在待保养的模具，挂上（模具保养）标识牌。Tooling department should put up maintaining ta

20、g on mold needing maintenance.5.2.4.3模具保养频次严格按照模具保养及检验表（FM-Q083）要求执行，在保养完成后在模具保养及检验表（FM-Q083）和模具履历表（表单编号：FM-T086）及模具清单表（表单编号：FM-T082）上登记。Abide by mold maintaining & checking form (FM-Q083) on the frequency of maintaining a mold. Register in mold maintaining & checking form (FM-Q083), mold informatio

21、n form (FM-T086) and mold inventory (FM-T082) after finishing maintenance.5.2.4.4 模具保养完成后，由模具单位挂上“模具正常”的标识牌。并把模具拉到模具已修区，并以邮件形式告知各部门相关人员。After finishing maintenance, the tooling department should label normal tag.5.2.4.5 在每次保养时，模具工程师查阅模具履历表(FM-T086)中的记录，根据该模具发生过的历史故障原因和使用情况，由模具工程师判定，是否需要对该模具进行针对性保养，并

22、记录在模具保养及检验表（FM-Q083）中. When doing the preventive maintenance, the tooling engineer responsible for check mold information form (FM-T086), and analyze the using of mold to find the main fault cause. The mold engineer should assess if it is necessary to make targeted maintenance for it. Record related

23、 information in mold maintaining & checking form (FM-Q083).5.2.5报废方法：使用单位于每年 9/1-9/30 间提出拟报废模具之明细 于模具单位，并召集相关部门判定是否可继续修理。营业单位根据明细与车模协商是否报废或回收，若车模同意报废，报公司最高主管核准后交财务按照固定资产报废管理办法执行；若不同意报废，由营业单位告知各单位原由。Scrap: using unit should list detailed scrap mold table to tooling department from Sep. 1 to 30 and ga

24、ther related departments to decide whether it can be repaired or not. The sales department communicates with customer engineer to decide whether to scrap or recycle the mold. If customer engineer agrees to scrap, report it to VTYC highest management for approval. Getting the approval, finance depart

25、ment scrap it as fixed assets scrap management regulation requires. If customer engineer refuses to scrap, sales department informs related unit of reason.6使用表单forms6.1重庆模具供应商评审表（FM-T081）.Chongqing mold supplier review sheet (FM-T081)6.2模具清单（FM-T082）.Mold inventory (FM-T082)6.3模具保养及检查表（FM-T083）.Mold

26、 maintenance & checking sheet (FM-T083)6.4模具备品清单（FM-T084）. Mold spare parts inventory (FM-T084)6.5模具修改申请单（FM-T085）.Mold modification application (FM-T085)6.6模具履历表（FM-T086）.Mold information sheet (FM-T086) 6.7模具保养通知单（FM-T087）Preventive maintenance notice sheet （FM-T087）6.8模具验收报告（FM-T088）mold receiving report (FM-T088)6.9 试模状态统计表FRC （FM-T089）Mold trail condition record FRC（FM-T089）6.10试模申请单 （FM-T090）