Shanghai Jinting Automotive Wiring Harness Co., Ltd

SHANGHAI JINTING AUTOMOBILE HARNESS LTD. Distribution Number:No.

Program Documents

File Name: Error Prevention Manager

File number: JAH-QMS-P22

Version: C

Page:Page 1 of 7

Editor: Sun Fuquan Date: 2023.6.27

Review: Sun Qiang Date: 2023.6.27

Approval: Zhou Xuemei Date: 2023.6.27

Statement:

○It can only be considered valid if it is stamped with a red control stamp.

○ This is an internal document of Shanghai Jinting Automobile Wiring Harness Co., Ltd., and may not be reprinted without permission.

Document Revision History

objective

This document stipulates the normal process of the design, procurement, acceptance and management of all the company's tooling to ensure that the company's tooling can be purchased, accepted and maintained in a correct and timely manner.

range

It is suitable for the management of all the company's tooling including molds, tooling fixtures, and inspection tools, including assembly and standing plates, and rubber sleeve machines, and inspection tools including inch/appearance/final inspection inspection boards, conduction test benches, and fuse detection equipment.

definition

3.1 Error-proofing: the design and development of products and manufacturing processes to prevent the manufacture of substandard products.

3.2 Challenge: A part that has a known specification, is calibrated and traceable to an inverted standard, and is specifically designed to confirm the functionality of the error-proofing device.

3.3 Reaction plan: When an abnormal or non-conforming event is detected, control the actions or series of steps specified in the plan. This program document refers to the temporary measures taken to ensure normal production under the premise of ensuring the quality after the failure of the error-proofing device, such as 100% manual inspection; Use of other alternative production or inspection tools, etc.

4. Process flow diagram

5. Additional Notes

5.1 Establishment of error-proofing devices in the development phase

5.1.1 In the early stage of product development, consider the establishment of error-proofing devices based on the experience of similar products (product unqualified reports, customer opinions and problems in information collection products), the establishment of similar manufacturers, etc. In principle, but not limited to the following, the establishment of error-proofing devices should be considered.

a) Performance, security

b) High risk factor and severity

c) Error-proofing of left and right parts

d) Priority is given to the use of error-proofing devices for key special features

5.1.2 In the process design and process design verification phases, error-proofing methods are the key outputs of the PFMEA.

5.1.3 Error-proofing methods and test frequencies for all process design and process design verification outputs should be integrated into the control gauge and strictly enforced during the mass production phase, while their reliability confirmed.

5.2 Production of error-proofing samples

5.2 1 The process department is responsible for the production of challenge pieces according to the needs.

5.3 Error-proofing work instructions

5.3.1 The engineering department shall formulate a detailed and clear "error-proofing verification work instruction" for each error-proofing device, and the work instruction shall include:

a) The number of the error-proofing device (corresponding to the control plan);

b) How it works;

c) Spot check methods;

d) Frequency of inspections.

e) Response plan in the event of failure.

Response plans may include:

a) 100% manual inspection;

b) Adopt other alternative production or inspection equipment.

Control of the implementation process of the reaction plan:

a) 100% of the inspected characteristics are visually identified (stated on the product label);

b) Records of the application of the reaction plan should be maintained for traceability;

c) The reaction plan is proposed by the quality department and confirmed by the relevant departments. The parts produced under the reaction plan should be able to ensure that the unqualified parts produced do not flow into the next process;

d) The measures taken after the failure of the error-proofing device should be recorded in the error-proofing verification record sheet (including the treatment measures of the product and the error-proofing device).

5.3.2 The "Error-proofing Verification Work Instruction" is displayed at the on-site workstation and is easy for the operator to obtain.

5.3.3 Fill in the error-proof verification record with reference to the "Error-proof Verification Record Form Filling Guide".

5.4 Management of error-proofing challenges

It is common practice to check error-proofing devices using error-proofing challenges, also known as boundary samples, to demonstrate non-conforming operations or non-conforming products that can be detected.

The challenge must:

a) Jointly confirmed by the quality department and the production department;

b) Correct identification (the name of the part and the equipment to which it is applied must be indicated on the standard sample);

c) Clearly distinguish from normally produced parts (identified with paint or labelled);

d) It should be fixed, and do a good job of rust prevention, stored in a location near the error-proof device, convenient for the operator to access, if there are environmental requirements, it should be kept as required, and the use department should do a good job in the daily maintenance of standard samples;

e) The quality department shall conduct regular inspections to ensure that the challenge parts meet the requirements for error proofing;

f) The challenge is valid for 6 months;

g) The process department establishes a list of error-proof challenge parts.

5.5 Use of Error-proofing

5.5.1 The production department shall correctly check the error-proofing device according to the specified frequency, generally after the first article inspection, mold replacement and equipment maintenance. If necessary, check whether the error-proofing device is effective with a fault-proofing challenge.

5.5.2 Production can only be continued after passing the error-proofing verification, and the record should be made according to the "Error-proofing Verification Record Form".

5.5.3 It shall be ensured that the error-proofing device is effective at all times, and if the error-proofing fails, the operator shall take the following measures:

a) Immediate shutdown (the operator has the right to stop production);

b) Report to the team leader;

c) All products after the last verification of the error proofing device should be inspected and recorded.

5.5 4 The production department and the quality department should do a good job of daily confirmation and audit of error-proofing, including whether the error-proofing device is effective and whether the operator avoids the error-proofing device.

5.6 Bypass

5.6.1 When the error-proofing verification determines that the error-proofing device fails, the engineering department shall immediately convene the production department, process department, quality department, logistics department and other relevant departments to review and determine whether to enable the temporary change method (such as bypass);

5.6.2 After the review of each department, the production department will start a temporary change method to replace the original error-proofing device, and record the production batch, quantity and other information in the daily production report for traceability;

5.6.3 During the temporary change period, the production department shall organize at least daily meetings of the quality department, process department, engineering department, logistics department and other relevant departments to determine the impact of the temporary change method on quality, production cycle and the time schedule of returning to normal production activities;

5.6.4 The logistics department shall make special marks for the products produced during the temporary change of the method to distinguish them from the normal production of products;

5.6.5 For details, please refer to the "Temporary Replacement Management Process".

6. Record

7. Attachments

无

8. References

8.1 Error-proofing Verification Work Instruction JAH-QMS-P22-001-W

8.2 Ruiyi Conduction Station Error-proofing Verification Operation Instruction JAH-QMS-P22-002-W

8.3 TSK Conduction Station Error-proofing Verification Work Instructions JAH-QMS-P22-003-W

8.4 Error-proofing and Verification Work Instructions JAH-QMS-P22-004-W

8.5 Error-proofing Verification Guide JAH-QMS-P22-005-W

8.6 Error-proofing Verification Work Instructions for Inclined Conduction Stations JAH-QMS-P22-006-W

8.7 Bug-proofing Verification Operation Instruction JAH-QMS-P22-007-W

8.8 Interim Substitution Management Process JAH-QMS-P22-008-W

8.9 Instructions for Filling in the Error-proofing Verification Record Form JAH-QMS-P22-009-W