Quality control

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NPI Quality Control

Risk Assessment is taken as a key process for NPI project at the early stage NUDD tool has been implemented to figure out the risks of the project development

APQP tool is well executed to ensure the project development and output to meet the customer requirements QCP is well maintained and updated to ensure all the controls are well defined and monitored during NPI PPAP process is implemented to make sure the process is designed well for MP with controlled quality and yield rate

Readiness checklist is reviewed in details before each build to ensure all the resources, tools, documents etc are tracked and prepared well MIL is recorded well to follow up all build issues and solutions, ensure all the actions to be closed in time Regular Lesson Learnt is reviewed for each build to avoid the repeated issues

CPK and CMK data analysis is being taken to verify the process stability DOEs are conducted to find the best solution; Minitab tool is used for the DOEs data analysis

Sub-Tier Quality Control

Ideal has strict Sub-Tier evaluation process to choose right sub-tier, Sourcing, Quality and Engineering team are involved to evaluate the Sub-Tier Sub-Tier quality system, engineering and production capability are key factors to be evaluated and scored Evaluation scores and team decisions are well recorded for each Sub-Tier

Ideal has standard actions to monitor the Sub-Tier production process Sub-Tier production consistence is the key monitoring item, any disobey will be recorded and scored

Ideal release the LAR and VLRR data to Sub-Tiers weekly and monthly to feedback their quality performance and request improvement accordingly SIs are assigned to control the Sub-Tier outgoing aligned with Ideal quality spec MRB is implemented to avoid over reject

SMIL is recorded tracked by SQE/SQM with Sub-Tiers to close the issue timely SQE team and engineering team, when needed, are assigned to support Sub-Tier to take improvement actions for efficiency and yield improvement to ensure the material supplying

Internal Process Quality Control

Clear standards for MP are defined and executed before the project enters from NPI All the documents (BOM, SOP, SIP, Drawings etc.) are under DCC control PCN is well executed to ensure any change is under standard control

Clear and strict daily process is monitored to ensure the production line under control FAI is daily controlled to ensure the product quality IPQC audit line regularly to ensure the production line consistence of all the parameter settings, SOPs executions etc.

CPK data is collected on line to monitor the process stability Regular ORT tests are conducted per customer request to avoid any function failure at customer side

5S & online visual management are taken as basic line capability and take action to ensure the line neat and organized TPM is managed to minimize the equipment downtime and avoid its impact to products quality Daily online quality review is well executed to solve issues online timely

Continuous Improvement mindset drives us to hold quarterly CI review meetings, each team has at least 2 CI actions on quality and efficiency LEAN actions are taken in teams’ daily work for both quality and efficiency improvement

System Implement

Quality System construction has been maintained ISO9001, ISO140001, IATF16949 and ISO45001

SCM system is being used to track all the information of the incoming RM and outgoing FGs, including production batch, produced date, production line, etc. WMS system is executed for warehouse material storage management, is good to support the sensitive material storage control and monitor

The procedures are being reviewed regularly to ensure the effectiveness of the current quality system PCN procedure is conducted to optimize the control chain Tooling trial procedure is being reviewed and updated to clarify the responsibility for trial issues verification and solving

Cradle to Cradle system is being introduced to maximize the recycle material and environmental friendly methodology