注塑零件关键项目检查清单

RESULT54%NOTACCEPTABLEItem#MandatoryItemstobecheckedatSupplierOK/NOKRecommendation1Arethematerialpropertiesconform?(viscosity,color…)原材料性能是否符合？（熔体流动速率，颜色...）OKEachbatchshouldbedeliveredwiththematerialcertificateandshouldbewithinagreedtolerances每批须随附原材料出厂检查报告，各项指标必须符合要求。-Checkthematerialconformityindex(viscosity…)检查材料各项指标的符合性（熔体流动速率...）ForexampleforPCmustcomplywithSAEJ576-1991referenceASTMD128requirement14.5-21.9g/10Min.比如，PC,必须符合SAEJ576-1991ASTMD128熔体流动速率14.5-21.9g/10Min。2Istherawmaterialhumidityundercontrol?原材料的含水率是否受控？OKDryerismandatoryonsensitivematerial(allmaterialexpectPP&PE)对于敏感材料（所有材料，PP,PE），必须配备干燥箱。-checkdryingcapacity(sizecomparedtoproductionlevel-minimumtimebymaterial)检查干燥能力（干燥箱大小是否能满足生产所需的原材料的最少干燥时间）-checkdryingtemperature/dewpoint检查干燥温度/露点Thecontrolplandefinesthetimeandtemperatureneededinthedryer.监控计划中定义了材料在干燥箱中的温度和时间3IsthepercentageofregrindcontrolledandconformtoVALEOrequirement?再生料的配比使用是否受控，是否符VALEO的要求，NOKTheregrindmaterialproportiondoesnotexceedVALEOspecification再生料的配比含量不能够超过VALEO技术要求-fromtherawmaterialpurchased原材料采购的控制-fromtheinternalregrindinstallation内部原材料的回收使用EX:Nomorethat10%ofregrindmaterialforbufferapplication比如：不允许超过10%的回收料使用。4AretheprocessparametersusedforstartingtheproductionaccordingtostandardProcesssheet?生产启动的注塑参数是否符合工艺卡？OKTheprocesssheetisTHEreferencedocument.工艺卡是受控的，有文件编号的正式文件。5Isthemoldpre-heatedbeforemoldchangeontheinjectionmachine?模具换型上机前是否经过了预热？Itisnotallowedtoshutofwaterlinetoheatfasterthemold.禁止为使模具升温加快而关闭水路。NOKShuttingoffmanuallythewaterlinestobringthetooltooperatingtemperaturequickercanresultintheoperatorforgettingtore-openthelinesandthereforenotcontrolingtheprocess(partdeformation)人为的关闭水路而为了使模具升温加快的后果是忘记再打开水路而生产，会导致产品变形。6Arefixingwaterconnectionsnumbered?水管接头是否有编号？NOKAllconnectiontobenumberedinordertopreventawrongconnectionandrepercussiononthepart(distortion,shortcut...).所有连接头必须有编号以防止接错，导致产品不符合（变形，注塑不满...）7Afterputtingupthetoolingonthemachine,doessupplierchecktheaxisofnozzlewithaxisoftoolingopening?模具上机之后，是否检查了喷嘴和浇口同轴？NOKTobecheckedinordertopreventthedamageofhole'snozzle.Thenegativeimpactscouldbe:shortmoulding,burrs,…duetotheneedformorepressure.为了防止喷嘴被破坏必须检查。否则会有以下后果：注塑不满，飞边…因为压力不足等问题。8Istherevisiblecirculationofwater?水流量是否可视可控？NOKAlarmtobeimplementedsothattocontroltheT°andthewatercirculation温度和水流量须有警报提示9Doessupplierchektheinjectionbalancingincaseof2ormorecavities?大于两腔的模具是否检查的注塑平衡？OKIncaseofwrongbalancing,qualityissueshouldbe:shortcut,burrsandwornoutofthetoolingduetotheneedformoreinjectionpressure.不平衡的情况下，产品会有以下质量影响：注塑不满，飞边，甚至因压力不足而损坏模具10DoessuppliermeasuretheT°attherightplaceinthetooling?供应商量测模温是否在正确位置？NOKSheetintructiontoindicatetherightlocationformeasurement;Devicemeasurementtoberelevant,thetemperatureofthewaterisafirstinformationbutnotenough,thetoolingT°tobemeasuredT°toberecordedbeforestartup作业指导书中标示出测量的正确位置，明确测量设备，只测量水温是不足够的，模具的温度需测量并记录在启动检查单上。11IfHandlingSystem(asrobot)inuse:Istoolingdesignedtopreventanyshortmolding?如果机械手取件，模具设计上是否考虑有防止缺料现象发生？NOKThedesignofthetoolhastoincludeinanappropriatelocationacavityorapocketinstrumentedwithsensortoallowmaterialtoflowinandthisinordertocontroltherightquantityofplasticmaterialfillinginthemold.Thismeanwillallowtopreventshortshot模具设计必须包含在型腔内适当的位置袖珍传感器存在检测材料流入与否，来保证流入模腔的料量合适足够。总之可以避免缺料现象发生。12IsplasticinjectionpressPLClockedtopreventoperatortoadjustprocessparametersonhis/herownandalogbookisexistingforfollowingeveryprocesschanges?塑料注塑工位的参数调整面板是否被锁，防止随意调整，并在工作台放置记录本来记录参数的任何变动。OKThesetterrecordshischangesinthelogbook.Afterseveralrecurrencetheprocesssheethastobeupdated.工艺员记录每次调整，在发生几次后需更新工艺卡。PLASTICINJECTIONKEYITEMS-CHECKLIST注塑零件关键项目检查清单SupplierValeoSQADateRawmaterial原材料Startup生产启动13Doesthesupplieroperatorcheckthestartupchecksheetpriormassproductionstarts?供应商处的工人是否依据启动检查清单在批产前进行了检查？OKTheoperatorrespectstheStartupchecksheetincluding:-thepreparationofthematerial(qty/time/temperatureofthedryer),-first&lastpartsvalidation:functionalrequirement,interfaces,flash,weight,cosmeticconformity-setuppartstobescrapped,inlinewiththecontrolplan-dimensional/Assembly/Optical/...functionaltest-coolingtimeforpartstobedefinedbeforeanymeasurement;inthemeantimesuppliercanproducepartsifthereisaclearinformationonthepackagingwiatingfordecision-rawmaterialinusetobeclearlydisplayedonthematerial'stank工人遵守“启动检查”，包含以下几项：-原材料的准备（数量/烘干时间和温度）-首末件的确认：功能要求，装配点，飞边，重量，外观的符合性-调试产品的报废，与控制计划的要求保持一致-尺寸/装配/外观...功能试验等-测量之前产品的冷却时间必须定义，此期间生产的产品必须有“待确认”的标示在外包装上-在使用的原材料料筒上必须有明确的材料标示14Arethefirst5setuppartsautomaticallydisposed(trashed)?是否调试的前5模产品自动报废？NOK5partshastobeconsideredasanexample-certaingeometryorprocesscomplicationcouldrequiremoresetupparts.Anyhowallthesetuppartswouldneedtobedisposed（5件产品）是参考数量，工艺出现异常时肯定调试产品数量会增加，无论如何，所有调试产品都必须报废。15Arefirstandlastpartsoftheshiftcomparedtoamastersampleforvalidatingthestartupchecksheet?首末件是否与用于启动检查的标准样件做了比较？OKThe1stsetandthelastsetarecomparedtoamastersampleforcheckingtheconformityof100%onfunctionalrequirement,interfaces,flash,&cosmeticconformity.ThisispartoftheStartofproductionandEndofproductionprocedure.This2setsarekeptuntilnextproduction.首件月