QCOS detailed explanation of quality tools
The QCOS (Quality Check Operation Sheet) quality control operation table is a quality tool used for process control from the GM system.
It can help us to detect control defects in key manufacturing processes and reduce the risk of defects (including safety items, laws and regulations, torques that directly affect customer satisfaction, solder joints, equipment, personnel operations, etc.) The key process) is a quality monitoring activity involving all employees, including those in the design, manufacturing, and quality control departments.
1. Pre-work content of QCOS using quality tools
Using QCOS quality tools to monitor critical processes requires four preparations for critical control points:
(1) Classification of risk values ​​of QCOS processes;
(2) Organizing process control resources;
(3) Calculating the process control value;
(4) Verify the minimum guaranteed value.
1.1 Classification of process risk values
During the product design phase, product engineers assess the importance of a product's components by considering product safety, legal and regulatory requirements, and customer satisfaction, and assign a risk value. The higher the value, the more important this feature is.
Through the risk level assessment, understand the key control points and key control parameters that need to be strengthened in the product, and provide the basis for the organization process control resources. Detailed grading method (see Table 1).
1.2 Organizational Process Control Resources
Select appropriate and effective process control resources based on the risk level assessed by QCOS. When selecting process control resources, pay attention to the following law: If high-tech and low-manpower modes are adopted, high investment of equipment is required, but monitoring power can be appropriately reduced; on the contrary, low-tech tools and multi-manpower control require powerful control. And a high degree of self-discipline, increasing the cost of monitoring the manufacturing process.
Therefore, according to the risk level of the key control points, the correct and appropriate control resources should be selected. In accordance with the principle of adhering to the quality bottom line, it is necessary to meet the process control requirements and minimize the management cost. This is the focus of the organization process control resources.
There are five elements to consider when organizing process control resources: control tools, error prevention, data logging (analysis), 100% inspection, process monitoring; the first three are in the manufacturing process, and the last two are in the quality monitoring inspection process. The classification of specific process control resources and the scores (see Table 2).
1.3 Process Control Value (PGV)
After the process control resources and the classification points required by the project have been determined, the process control values ​​of a process can be calculated to assess whether the selected control resources meet the process control requirements. Process Control Value Calculation Formula = Sum of Process Control Resource Points / Classification points required for the project.
Judging whether the process requirements are met: When the process control value is equal to or greater than 1.0, it can be considered that the process has a more appropriate control method, and the control point has a low risk. When the process control value is less than 1.0, it is necessary to increase the process control resources, improve the process control capability, and improve the process to a process control value equal to or greater than 1.0.
1.4 Minimum guaranteed value
For each project level, in order to ensure that the process is in a normal state, beware of carelessness, and quickly confirm changes in the normal process, it is necessary to assign a minimum guarantee value to these processes to ensure (see Table 3).
1.5 Application examples (see Table 4)
2. Process of implementing quality tools QCOS and duties of various departments
Quality tool QCOS is a person who needs to participate in the joint implementation to effectively realize its role. It involves personnel in the design, manufacturing, quality monitoring and other departments of the product.
2.1 Implementation of the quality tool QCOS process (see Figure 1)
2.2 Responsibilities and work points of each department during the implementation process
2.2.1 Design Department
(1) Submit a list of KPCs and corresponding severity or PQC;
(2) Participate in the review of the QCOS Summary Form submitted by the workshop to jointly determine the QCOS point;
(3) Participate in solving problems existing in the implementation of QCOS;
(4) Work points - provide accurate and complete key control points and corresponding risk level list.
2.2.2 Quality Control Department
(1) Organizing QCOS training work;
(2) Organizing the workshop and technical center to review the QCOS Summary Form submitted by the manufacturing department to jointly determine the QCOS point;
(3) Establishing “QCOS Accounts†and incorporating them into orderly management;
(4) Track the implementation of QCOS in the car, and organize and solve the problems in the implementation of QCOS;
(5) Regularly analyze the implementation of QCOS in the workshop, formulate rectification plans and track rectification;
(6) Work points - organize training, establish "QCOS account book", track the implementation of QCOS and organize the resolution of defects.
2.2.3 Manufacturing Department
(1) Develop QCOS points according to the special characteristics of the products provided by the design department, the list of key control characteristics, and the corresponding risk levels, after-sales feedback information, and weak links in quality control;
(2) According to the final QCOS control point, organize appropriate and effective resource control quality (including selecting appropriate data collection and release forms), and compile corresponding "Quality Control Operation Table" and "Control Trend Table";
(3) Organizing the backbone of the manufacturing department (segment leader, squad leader, employee) to conduct QCOS training;
(4) Weekly self-assessment of the implementation of QCOS, monthly summary, and the next month's improvement plan based on the assessment of the previous month;
(5) Work points: Formulate QCOS control points, organize effective and appropriate process control resources, organize all-person training, and prepare relevant forms for on-site use.
3, application examples
To implement QCOS, attention should be paid to the classification of each control point, the selection of five control resources, and whether the process control value satisfies the condition greater than or equal to 1. The process control resources are balanced and selected to ensure that the control resources selected by each control point meet the minimum guaranteed value and reduce the occurrence. The risk of defects.
The work of process monitoring (see Table 5):
(1) How to use the correct tool/equipment;
(2) Confirm the key quality point calibration in QCOS;
(3) have the choice of the correct parts;
(4) measuring or judging the quality of the product;
(5) Confirm that the problem reconnaissance equipment is in good condition (such as the ANDON system).
4 Conclusion
At present, the general system is widely used QCOS tools to monitor the assembly quality of automotive fasteners and has achieved great success.
At the same time, through the use of QCOS tools to monitor the key processes such as solder joints, filling, timely detection of existing defects, and targeted improvements, effectively reduce the control risk and ensure the key quality.
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