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- 6SQ币
- 182
- 热心
- 1
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2#
发表于 2005-4-6 17:44
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后续审核果如下
RECEPTION CHECKS
Incoming Inspection results and inventory of the storage
o All the data in terms of incoming inspection results, grade, size, quantity, heat Number, tonnage, balance must be properly recorded by the use of a computer system
Incoming Raw material – General condition
according to the IVECO STD 18-1307 for Long Structural Steel products
Spark Test
o 100% of billets, bars etc must be sparkled before the delivery by the steel makers.
In case of Continuous Casting Process, the Supplier shall guarantee that:
o the casting section reduction has to be 8/1 as minimum
MANUFACTURE/PRODUCTION CHECKS
Batch number/job order
o For traceability needs, all the data in terms of manufacturing date, batch number, product number and name, heat number, Supplier name, quantity and tonnage, etc must be properly recorded in a computer system
Handling
o Parts must be properly identified by the use of suitable traceable tags to be applied to the trolley and or pallet used for the internal handling, with references to the batch number, status of the parts (approved, not approved) and with the identification of the following operations.
Product Identification
o Torsion Bars must be identified by the manufacturing date of the batch, according to the IVECO std 18-5510 and 10-0812
Operations
OP 30 Quenching
o The batch furnaces must be equipped with a suitable system: timer and lamp to inform the operator about the end of the Heating period and the bars must be pickup accordingly.
o The cooling system of the oil quenching shall be fully automatic (today it is manually driven by the operator) and the oil temperature shall be visible at the work station
OP40 Tempering
o Work instruction for the rotation speed and time shall be present at the work station and applied. Today the setting of the rotation speed was not according to the specification.
o X bar R charts must be organised on the Hardness after tempering – minimum 3 time per shift (5 samples each time) – to be included in the Control Plan
o Capability Study must be organised and systematically monitored. In case of CPk less than 1.33 a 100% inspection is required.
OP90 Painting
o the painting shop needs a complete refurbishing including the control units, that are in very poor conditions and a total review of the process parameters, also to guarantee a full compliance with the IVECO std 18-1600. Today the set up of the machine is mainly based on the experience and on the skill of the operator.
Delivery
o The storage and the delivery of the finished products must be organised according the FIFO criteria
o Packing condition for overseas delivery must be defined with the IVECO receiver Plant
Crack Detection
o The torsion bars shall be inspected 100% for crack detection according to the IVECO std 18-5510. Jigs and fixtures must be available. Today the crack detection is not applied to the torsion bars produced for Naveco, because not required as the Supplier said.
o Work instructions have to be properly defined and to be checked at the beginning of every shift
o Set up Conditions and Process Parameters have to be defined part number wise
o Special master piece for set up inspection to be procured (star sample) if not available
o Operators have to be trained by an external accredited Company and certified
Traceability
For each and individual batch the following data and results shall be traceable with reference to the production date, batch number visible on the bars:
o Supplier Heat number and Chemical composition
o Metallurgical checks: Hardness, microstructure and tensile strength
o Dimensional checks, according to the control plan
o Record of the main process parameters like temperatures, etc
Gauge Calibration
o The planning for the periodical calibration shall be implemented in the computer by the use of a suitable and specific software with the possibility to get automatically the list of the gauges to be inspected, according to the scheduling.
Maintenance
Preventive maintenance
o the check list, that is already available, shall be completed with suitable Work Instructions for the key characteristics based on the hand book of the manufacturers of the machines
Break down maintenance
o Trend analysis to be organised family wise, production unit wise
Quality Issues
Hardness Checks
o Historical charts to be organised furnace wise and grade wise on the CP-CPK values for the leaf-spring as well as for the torsion bars
Qualified Product Rate / Internal Rejection
o Analysis to be organised product family wise and customer wise
o Pareto analysis, identification of the major reasons of the non conformities to be organised Operation Wise
o Effectiveness of the corrective action to be monitored
Customer Complaints
o Files shall be available Customer wise.
o The 8 D Report discipline shall be applied in case of Customer complaints
o Trend analysis shall be organised on the number of the complaints in terms of time to close the issues and effectiveness of the corrective actions
Conclusions
The survey has identified positive aspects in terms of know how, experience, technology, and Quality System, but also several weak points, that need to be corrected, like:
o the incoming warehouse, that need improvement in terms of layout, handling, product location and product identification;
o the painting shop, that needs a complete refurbishing including the control units, and a total review of the process parameters, also to guarantee a full compliance with the IVECO std 18-1600. Today the set up of the machine is mainly based on the experience and on the skill of the operator.
and some other issues that need to be optimised, according to the above paragraphs.
Under quality point of view, the completion of a suitable action programme to correct the above criticalities, is mandatory before the development of any potential business with IVECO.
Company to be revisited.
The Company shall update IVECO about the progress and the completion of the program with a complete list showing the actions, the responsibility and the scheduled dates for implementation.
The above issues shall be used only as examples of the conditions found on the shop floor. The supplier shall have the full responsibility and the knowledge to guarantee the necessary reliable condition for each single operation.
Leaf-springs
This Audit has been mainly focused on the manufacturing of the Torsion Bars, even if many of the concerns can be applied to the production of the leaf-springs also. Corrective Actions to be extended to this production area, where applicable.
In addition to that, there are several topics that are specific for the leaf-springs that need to be corrected or to be implemented in case of any potential business with IVECO, that are:
o use of optical pyrometers to check 100% the temperature of the leaf before of any hot forming operation;
o use of continuous furnaces to replace the existing furnace for preheating before the rolling operation, that are manually driven by the operator to load and unload the single leaf
o use of load cell to press any type of bushes including the bushes used in the two eyes of the leaf-springs
o use of much more mechanised machines in the assembly line, suitable to read simultaneously the value of the load and the movement for preloading and for final check (camber
This in advance to a specific audit for the supply of leaf-springs that has to be organised in case of any potential extension of business with IVECO.
Production for IVECO
In case of IVECO orders the following Quality items are required for each new part number:
o Manufacturing Process Lay out
o Classification of Characteristics
o Process FMEA;
o Capability Study Cpk >1.33, to be communicated in a monthly base to Iveco during the production
o Control Plan
o Work Instructions and Process Parameters
o Flow Chart
o PPAP: Parts have to be made on production tooling and according to the Manufacturing Process Lay out; Report is expected according to the Drawing requirements and IVECO specs, that has to be released and approved by IVECO. |
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