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Quality control inspection & on-site process inspection every 2 hours
Process inspection is a quality management activity that aims to ensure products meet required standards and quality specifications during the manufacturing process. It involves regular inspection and monitoring at various stages to detect and resolve potential problems early, thereby improving product consistency and quality.
Shipping inspection (each batch is inspected according to AQL4.0)
"AQL 4.0" refers to the standard with an Acceptable Quality Limit of 4.0, which is usually used to set upper and lower limits for quality inspection and quality control. AQL is used in quality management to decide whether to accept or reject a product batch based on the results of sampling inspection and quality standards.
The lower the AQL value, the higher the quality requirements for the product and the smaller the number of defects allowed. In the case of AQL 4.0, the number of defects in each inspection lot must be limited to a specific number, otherwise the lot may be rejected. Here are some explanations of AQL 4.0:
AQL (accept quality restrictions)
AQL represents the maximum allowable number of product defects during sampling inspection. For instance, an AQL of 4.0 indicates that the number of defects in each inspection batch cannot exceed 4.0.
Test batch
A group of products that undergo quality testing, usually divided according to a specific time period or product quantity in the production process.
flaw
Refers to defects or faulty parts of a product that do not meet specifications.
Sampling inspection
A method of randomly selecting a portion of a product from an inspection batch for evaluation to estimate the quality of the entire batch.
The choice of the AQL value typically depends on the product's usage scenario, market demand, and quality control requirements. A lower AQL value implies higher quality requirements but may increase the risk of product rejection. Conversely, a higher AQL value allows for more defects, but it may lead to a higher number of acceptable products.
Please note that AQL 4.0 represents a specific quality standard. In reality, different industries and applications may have varying AQL values and quality requirements.
Three-dimensional inspection and various quality control instrument testing
Coordinated Measuring Machine (CMM)
CMM is a high-precision three-dimensional measuring instrument commonly used to assess the size, shape, and position of workpieces. Measurements can be conducted using mechanical probes or optical systems.
Optical measuring instrument
Optical measuring instruments utilize optical technology to measure the size, surface shape, and contour of workpieces. They can efficiently capture a large number of measurement points and generate accurate 3D models.
Laser measuring instrument
Laser measuring instruments use laser beams to measure the size and surface shape of workpieces. They enable non-contact measurement and are suitable for workpieces with complex shapes.
Image measuring instrument
Image measuring instruments use digital cameras and image processing technology to measure dimensions, angles, and contours by capturing images of workpieces.
Laser measuring instrument
Laser measuring instruments utilize laser beams for high-precision distance measurements.
Hardness tester
Used to test the hardness of materials, this method aids in evaluating the durability and performance of materials.
Tensile testing machine
Test materials for tensile strength and durability to ensure they conform to design and quality requirements.
Contour projector
Use optical projection technology to measure the contour and shape of workpieces.
Surface roughness tester
Used to measure the roughness of the workpiece surface, ensuring that it meets the required surface quality.
spectrum analyzer
Conduct tests on the composition and properties of materials, particularly focusing on metallic and chemical materials.
Measuring tool control/regular calibration
Measurement tool control and regular calibration are essential components of quality management. They aim to ensure that the measuring tools used can maintain accuracy and reliability, thereby guaranteeing the precision and consistency of product measurements and testing results. The following are some key points regarding measurement tool control and regular calibration:
Measuring tool control
This process involves ensuring that all gauges and measuring tools are properly managed and maintained.
Logo and identification
Each gage should have a unique identification to ensure it can be properly identified and traced.
Storage and protection
Gauges should be stored in a dry place away from humidity and extreme temperatures to prevent damage.
Periodic inspection
Regularly inspect measuring tools to ensure they are in proper appearance, functioning condition, and free from damage.
Appropriate use
Users should employ measuring tools according to the correct methods and procedures to avoid damage or misuse.
Regular calibration
Regular calibration involves sending the measuring tool to a certified testing agency to ensure the accuracy of its measurement results. These institutions typically possess the necessary equipment and standards for performing calibrations. The frequency of regular calibration depends on the usage frequency and importance of the measuring tool.
calibration certificate
After the calibration is completed, the testing agency provides a calibration certificate that certifies the accuracy of the gauge as of a specific date. This certificate is crucial for quality management and enables customers to verify the qualification of the measuring tool.
record retention
Maintain relevant records for all measuring tools, including calibration certificates, inspection records, maintenance records, etc. This aids in tracking the status and history of the gauges.
Quality control & on-site measuring tools are divided into two groups to mutually verify their accuracy
Dividing quality control and field gauges into two groups for mutual verification is an effective quality control method designed to ensure the reliability and consistency of the measurement process. This approach aids in identifying any potential measurement errors and ensures the accuracy of the measurement results. Here are some key points related to this methodology:
Quality control measuring tool set
This set comprises gauges that are calibrated and maintained in a controlled environment for making critical and highly accurate measurements. These gauges may require more frequent calibration to ensure the high accuracy of their measurements.
On-site measuring tool set
This set consists of measuring tools used in the field for routine measurement and inspection tasks. These gauges also require periodic calibration but may not necessitate the same level of accuracy as quality control gauges.
Verification Test
Regularly conduct verification tests on the quality control measuring tool set and the on-site measuring tool set to ensure the consistency of their measurement results. This can be achieved by measuring standard samples or verification workpieces.
comparison test
Utilize both quality control gauge sets and field gauge sets for the same measurements, and then compare their results. Consistent results indicate reliable accuracy for both sets of measuring instruments.
Adjustments and corrections
If a gauge's measurement results are found to be off during comparison testing, it may be necessary to adjust or calibrate the gauge to ensure its accuracy.
Record and track
Maintain records of all verification tests, including measurement results, adjustments, and correction information. This practice aids in tracking the status and history of the gauge.
This method of grouping and verification ensures the accuracy and reliability of gauges and measuring tools used during quality control. It guarantees consistency in the measurement process, thereby improving product quality and reducing measurement errors.
Full appearance inspection by dedicated personnel
Full appearance inspection by dedicated personnel is a quality control method that entails trained professionals conducting a detailed inspection of a product's appearance to ensure it meets the required standards. This method is typically employed for products with high-quality appearance requirements, such as consumer goods, electronic products, decorations, etc. The following are some key points of a professional appearance inspection:
professionals
Personnel conducting appearance inspections need to undergo specialized training to comprehend the product's appearance requirements and defect types. They must be able to accurately identify any unqualified appearance features.
standards and specifications
Professionals must inspect the product according to the appearance standards and specifications to ensure that it meets the required appearance quality.
Comprehensive inspection
Specialized appearance inspection entails a detailed examination of every part of the product, including the surface, shell, details, logos, labels, etc.
Defect identification
Professionals need to be capable of identifying various potential cosmetic defects, including scratches, blemishes, color differences, spots, deformations, etc.
Documentation
The results of the inspection by a dedicated person should be recorded, including the product number, inspection date, and inspection results, among other relevant information.
problem solved
If cosmetic defects are identified in a product, professionals should promptly report the issue and actively participate in the problem-solving process to ensure the proper handling of non-conforming products.
keep improve
Using the results of the visual inspection, it is possible to analyze and evaluate potential production problems, facilitating continuous improvements to reduce the risk of cosmetic defects.
Specialized appearance inspection is an effective method to ensure the quality of product appearance, particularly for industries and products with high requirements. However, this method may be time-consuming and costly, so appropriate selection should be made based on the characteristics and needs of the product in practical applications.
Product process card system to facilitate traceability
The Product Process Card System is a document system used to control and manage the production process. It provides detailed information about the product manufacturing process, ensuring consistency, quality, and efficiency in production. This system typically includes steps in the manufacturing process, process requirements, quality inspection points, material usage, and related documentation. Here are some key points of the Product Process Card System:
Process description
The product process card should outline the manufacturing process from raw materials to the final product, with each step clearly listing the required actions, tools, equipment, and related instructions.
Process requirements
The process card should clearly state the requirements and standards for each process. This encompasses measurement and inspection requirements, operating procedures, as well as temperature and pressure specifications, among others.
quality control point
Product process cards should specify the locations where quality inspections and measurements are conducted, ensuring that products meet quality standards throughout the production process.
Materials used
If specific raw materials or components are necessary for the production process, the process card should document the name, specifications, and quantities of these materials.
file connection
In the product process card, relevant documents, such as engineering drawings, technical specifications, and standard operating procedures, can be referenced.
Process time
In the process card, recording the expected completion time of each operation can aid in planning and scheduling the production process.
Sign and approve
At each important stage, process cards should include signatures and approvals from relevant personnel, ensuring that the process is controlled and monitored.
Updates and revisions
Product process cards should be dynamic, being updated and revised as the production process changes, to ensure that the information is accurate and up-to-date.
The product process card system can help ensure the consistency, quality, and efficiency of the production process, providing a framework for executing, monitoring, and improving production. This is essential to meet customer needs and maintain high-quality standards.