1、Revision History 版本記錄Rev.版本Change Description 修改內容Originated By編寫Date日期123 4 5New release 1.Change the forms of Incoming Defect Return To Store and Scrap Material Review List. See 9.1 and 9.2.Cancel items 5.3, 6.3.5.1, 5.3.5.2, 6.6; Modify items 6.2.3.1, , 6.3.2.Change the forms of Incoming Defect R

2、eturn To Store and Scrap Material Review List. See 9.1 and 9.2., 6.2.3.6, 6.3.1 and Flowchart.KS YangKS YangKS Yang Frank Peng Frank PengSep.1,2006Mar.21,2007Nov.21,2007Nov,23,2009Approval & Distribution審批&分發APP審批 Dept. 部門Signature/Date簽署/ 日期APP審批 Dept. 部門Signature/ Date簽署/ 日期生產部PRD 人力資源部HR品

3、保部QA 財務部 FIN 資材部 Sourcing 倉儲部 WH工程部Engineering管理者代表MR 生產及物料管控PMC廠長Plant ManagerOther Distribution Location : Checked by (Doc. Con.) : _ Effective Date : _Confidential & Proprietary Information of Beckett (ZhongShan). 百可德(中山)機密及專利文件1. PURPOSE 目的:To establish a procedure for reviewing and disposin

4、g non-conforming materials, semi-product, finished products and RMA control in Beckett (ZhongShan).本程序規定對來料檢驗及生產過程中發現的不合格物料,半成品,成品及客戶退回品的評審及處置方法.2. SCOPE 范圍: This procedure is only applicable toXXXX (ZhongShan).本程序適用于XXX(中山)公司.3. DEFINITIONS 定義:3.1 PRD: Product Department 生產部3.2 ME: Manufacture Engi

5、neering 制造工程3.3 RTV: Return To Vendor/Supplier 退回供應商3.4 UAI: Use As It Is 讓步接受3.5 SORT: Segregation Of Bad And Good Unit 選用3.6 SCAR Supplier/Sub-contractor Corrective Action Request (8D) 供應商改進行動要求 (8D) 3.7 GRN: Goods Receipt Note 收貨單3.8 MRR: Material Review Record 物料評審記錄4. REFERENCE DOCUMENT 參考文件:4.

6、1 BZQP-7-05 Raw Material Quality Control Procedure原材料質量控制程序4.2 BZQP-8-05 Nonconforming Control Procedure 不合格品控制程序4.3 BZQP-8-06 Stop Shipment and Purge Order Procedure 停止出貨和清除指令程序.4.4 BZQP-8-07 Corrective and Preventive Actions Procedure 糾正及預防措施程序. 5. RESPONSIBILITY 職責:5.1 QA is responsible to chair

7、MRB meeting when defective material are defected in line, QA review the non-conforming products and issue SCAR (8D) if necessary.當不合格物料在產線發現時,QA負責主持MRB會議, 確認不合格產品, 并在必要的情況下發出SCAR(8D).5.2 PRD is responsible to fill MRB label and inform QA members to review the non-conforming products, and return them

8、 to warehouse.生產部負責填寫MRB標簽并通知品質部成員評審不合格品, 并將不合格品退回貨倉.5.3 PUR/ IQC are responsible to inform supplier of the non-conforming data, PUR responsible to arrange the non-conforming materials RTV. 采購/IQC負責將不合格批物料狀況通告客戶或供貨商, 采購還負責安排將不合格品退回供貨商.5.4 PUR is responsible to charge the supplier of sorting/reworkin

9、g cost and other loss due to material quality issue, and call MRB meeting to review the reject lots of IQC raised.采購負責向供貨商索取選用或重工費用及由于物料問題而導致的損失, 并召集MRB會議處理IQC拒收的緊急物料.5.5 ME is responsible to analyze non-conforming products.ME負責分析不合格品.5.6 All MRB members are to propose and decide on defective materi

10、al disposition and carry out the follow-up actions as agreed in the meeting.所有MRB成員負責執行MRB會議之決議,并跟進MRB會議決定的所有行動措施.5.7 IQC is responsible to confirmed material which is suspected has defect. And IQC drive supplier to take corrective action if necessary .IQC負責對被懷疑的物料進行確認,并且在必要的情況下,將要求供貨商對其進行改善.6. PROC

11、EDURE 程序:6.1 MRB team consist MRB小組成員Normally, MRB team consists QA, PRD, PMC, PUR managers or whose dictated representative, if necessary other related members also can attend the meeting (such as supplier, customer etc.).通常, MRB小組由品質部、生產部、物料部、采購的部門經理或其指定代表組成, 如有必要其它相關的成員也應參加(例如供貨商, 客戶等).6.2 Incomi

12、ng Inspection Reject 來料檢驗不合格6.2.1 When the incoming lot is rejected by Beckett (ZhongShan), IQC for quality or other causes, it should be marked on the GRN sheet. 當來料檢驗批判定不合格后,由IQC注明于收貨單.6.2.2 The rejected lot will be put into IQC Reject area by WH. If the coverage of defects is beyond IQC area, IQC

13、 shall work with QA to consider raising a purge order.不合格物料由貨倉轉移至IQC拒收區隔離存放, 如果不合格不僅僅發生在IQC, IQC需會同QA發出清除指令.6.2.3 IQC fill in MRB form to QA manager and related departments for reviewing the rejected lot, the result maybe as below:IQC開出 MRB單給品質經理及相關部門對不合格物料進行評審, 處理結果有如下幾類:6.2.3.1 RTV: Per PUR confir

14、m, the rejected lot can be returned to supplier, this decision should be made, the MRB decision should be noted on the MRB form, it must be approved by the QA manager or whose representative at least. RTV: 經采購確認, 如果不良批可退返供貨商, 應做出RTV的決定, 此決定需注明于MRB單上, 且至少由QA經理或其指定代表簽署.6.2.3.2 UAI: Use as it is. If th

15、e material lot is very urgent to the production and according to the evaluation of MRB members, the defect/nonconformity will not lead impact/defect to our finished product quality, the decision of UAI may be made and recorded on the MRR sheet, it need be approved by the QA manager, ME, and PUR. or

16、whose representatives of other department, it needs Production managers approval if necessary. QA and ME should monitor the effect of UAI material using.Note: if the defect maybe cause finished products quality issue, it must be promised by our customer first, then can be made the UAI decision.UAI:

17、讓步接受.如果該物料為生產線急需并根據MRB成員的評估不會對成品質量產生影響, 則可做讓步接受, MRB評判結果記錄在MRR單上, 且至少有QA經理，采購和工程部或其部門經理的指定代表簽署，必要時需生產經理簽署。. QA和ME應監控生產中使用效果.注意: 如果此不良有可能影響到成品的質量問題, 則必須得到客戶的許可才能做出讓步接受的決定.6.2.3.3 Sort/Rework: If the material is urgent for produce, and for MRB evaluation the defect will be full eliminated by easy sort

18、/rework, the SORT/Rework decision will be made based on the negotiation with the supplier, the MRB result should be recorded on the MRR sheet, it must be approved by the managers or whose representative of QA, ME, PRD, PUR. The sorting/rework responsibility by either a specified department or suppli

19、er. Namely, sort internally or sort externally.選用/返工: 如果該物料為生產線急需, 且經MRB小組判定經簡單加工/挑選即可完全消除不良缺陷, 根據與供貨商談判的結果可進行選用/返工處理, MRB評審結果記錄于MRB單上, 至少有QA經理, ME經理, 生產部經理, 采購或其指定的代表簽署, 指定由供貨商或相關部門篩選,即分為內部篩選和外部篩選.6.2.3.4 Scrap: If the defect cant be retrieved or the supplier authorizes to scrap the rejected part,

20、the decision should be recorded on the MRB form. The authorization of scrap must be approved by the manager QA, PUD at least, if necessary the scrap should be submitted to Plant Manager for approval.報廢: 不可修復的缺陷或得到供貨商授權報廢的不良品，其決議內容都應記錄于MRB單上. 至少由QA經理, 采購經理簽署, 如有必要, 報廢申請需提交廠長作批準.6.2.3.5 The dispositio

21、n to the material purged out should be confirmed by QA manager.對被清除物料的處置, 物料評審會議結果須由QA經理確認.6.2.3.6 If the MRB meeting result is sorting/reworking, an incoming sorting/reworking report should Be filled out (Form No:BZQP-7-08F04.1) when it is necessary. When the sort/rework over, IQC must re-inspect t

22、he good part upon normal sampling plan. If its a supplier problem, Purchaser should raise the charge request of sort/rework cost to the supplier and follow up.如果MRB結果為選用/返工, 必要時需填寫物料選用/返工報告(Form No:BZQP-7-08F04.1), 選用/返工完成后, 需經IQC重新檢驗. 通常情況下, 如果是供貨商的原因, 選用/返工費用由物料供貨商支付. 采購負責跟進對供貨商索賠結果的落實情況.6.2.3.7 I

23、f a certain part should be restricted using as per the MRB decision, this part should be identified with a MRB label and note “UAI” marking.如果MRB會議決定需限制使用的物料, 可讓步接受后再加貼MRB標簽, 并注明UAI.6.2.3.8 IQC inspector will stamp or label the material with corresponding remarks, such as RTV, UAI, Sort, Rework or S

24、crap as per MRB decision. The receiving person should transfer the material to the part store accordingly.IQC檢驗員根據MRB結果對物料進行相應標識,比如退回供應商，讓步接受，選用，重工或報廢，并由收貨人員將其轉入相應位置存放.6.3 Line Reject Material semi-products / finished products生產過程中不合格品6.3.1 For the mass lot non-conforming products were found in proc

25、ess or QA inspection, IPQC should report to supervisor at once, and QA manager issue line stop order when it is necessary, QA (for finished products) purge out all non-conforming lot products and PQC issue Process Abnormity Handing Sheet to related department for analysis and following up related ac

26、tions.對于在生產過程中或QA檢驗時發現的大批量不合格品, PQC向上級緊急匯報，必要時QA經理需下達停線指令, QA(對于成品)需立即清除所有的不合格批產品，PQC開出制程異常處理單給相關部門進行分析并跟進相應的行動措施.6.3.2 For the little lot non-conforming products were found in process, PRD should fill MRB label and paste the label on related materials, then inform ME and QA to review the non-confor

27、ming products and make interim disposition, for semi & finished products, ME should provide FAR (Fail Analysis Report) to support the MRB judged. Then write down the disposition result on the MRB label. PRD staffs sorted the non-conforming products with incoming defect and process defect; genera

28、lly the returned products shall have the original tray or box.對于在生產過程中發現的小批量不合格品, 由生產部填寫MRB標簽并通知ME和QA對不合格品做評審, 并做出處理結果填寫于MRB標簽上, 對于成品和半成品, ME需提供不良分析報告, 作為MRB裁決的依據, 生產部根據此臨時結果將不合格品分為來料不良類和制程損壞類,原則上被退回的不合格品應保持原包裝.6.3.3 For the process defect products, PRD list them on the “Scrap Material Review List”

29、and submit to PRD, QA managers or whose representative to sign, then return the defective products to WH. WH handler transfer the defective products to scrap store and replenish the balance to PRD in time. “Scrap Material Review List” sheet should be distributed to PRD and WH by PRD members for cons

30、ervation.對于制程損壞的產品, 生產部將其列入“報廢物料審核單”并提交至生產部經理, QA經理或其指定代表簽署, 再將不良品退回貨倉, 貨倉物料員將不良品轉入報廢倉并及時補料給生產部. “報廢物料審核單”由生產部物料員分發至生產部和貨倉存檔.6.3.4 For incoming defect products, PRD list them on the “Incoming Defect Return To Store” sheet, and submit to PRD, QA managers or whose representative to sign, then return t

31、he defective products to WH, WH handler transfer them to MRB store and replenish good materials to PRD. The “Incoming Defect Return To Store” sheet should be distributed to PRD, IQC and WH by PRD members for conservation.對于判定為屬來料不良的產品, 生產部將其列入“來料不良退倉單”并提交至生產部和QA經理或其指定代表簽署, 再將不良品退入貨倉, 貨倉物料員將其轉入MRB庫位并

32、及時補料給生產部, “來料不良退倉單”由生產部物料員將其分發至生產部、IQC和貨倉存檔.6.4 The products returned by customer can be reviewed and dealt with as sort, rework or scrap as per theauthorization of this procedure.對于客戶退回的成品,依據本程序評審和處置權限執行挑選,返工或報廢.6.5 If it is necessary, IQC should issue a SCAR (8D) to supplier for the material defec

33、t or where applicable keep customer aware of the disposition of the defective product. Refer to “Corrective and preventive actions procedure”.在必要的情況下,IQC應將不良物料狀況通知供貨商 , 并發出SCAR(8D), 參照“糾正及預防措施程序”.7. RECORD 記錄: Record Description記錄描述Maintained by維護責任Retention Time(min)至少保存時限Obsolete Disposition過期處理Incoming Defect Return To Store來料不良退倉單BZQP-7-08F01.1PRD, IQC, WH生產部, IQC,倉儲Three years 三年Tearing銷毀Scrap Material Review List報廢物料審核單BZQP-7-08F02.1PRD, WH生產部,倉儲Three years 三年Tearing銷毀MRB Meeting Review RecordMRB 會議評審記錄BZQP-7-08F03.