Automation Cleaning Process Control Plan

Operation
No. Flow 		Process Decription Chemical
Used 		Make-up Water / Chemical Time
(min) 		Bath
Change
Frequency 		Filteration size /
Frequency Changes 		Conveyor
Speed 		Process Control /
Parameters 		Spec. Limits Special
Character 		Analysis Frequency Who Analysis /
Equipment 		Trigger Point Alert
Level 		Contingent Action
Start                                
1 Incoming Inspection - - - - - - Travel Ticket
Incoming Inspection Record 		AQL 0.65% Every lot IQC Visual Inspection
Delivery Order 		When rejected 1 Inform customers' QA Department / return to customer
2 Mat'l Input - - - - - 50 Hz Quantity Load -   - Production - - - -
Degreasing - According to chemical's specification (2 ± 0.5) min Once / Day 10 μm X 7pcs (weekly)
Maintenance for nozzle (weekly) 		Automation Cleaning Record:
Temperature
pH
Conductivity reading 		According to chemical's specification Twice / Day Production Thermometer
pH paper
TDS meter 		When rejected 2 Adjust set temperature
Replenish or change bath
Replenish or change bath
Rinsing (x2) Dionized water - (5 ± 0.5) min Once / Day 5 μm X 7pcs (weekly)
5 μm X 7pcs (weekly)
Maintenance for nozzle (weekly) 		Automation Cleaning Record:
Temperature
pH
Conductivity reading 		According to chemical's specification   Twice / Day Production Thermometer
pH paper
TDS meter 		When rejected 2 Adjust set temperature
Replenish or change bath
Replenish or change bath
Oven Drying - - (4 ± 0.5) min - - Temperature 80 ± 5 °C Twice / Day Production Control Panel
Temperature 		Temperature > 85 °C 2 Adjust set temperature
Material Output - - - - -   Part Inspection Report -   - - - - - -
End                                
 
*Note:
  1. All chemical used are RoHS Compliance
  2. - Critical Process
 
Alert Level
  1. Inform QE
  2. Inform Production Supervisor
 

Powder Coating Process Control Plan

Operation
No. Flow 		Process
Decription 		Time
(min) 		Process Control /
Parameters 		Spec. Limits Special
Character 		Analysis
Frequency 		Who Analysis /
Equipment 		Trigger Point Alert
Level 		Contingent Action
Start From Cleaning Process
3 Jigging - Follow customer requirement (if necessary) -   Every jig Production 100% checking for every jig Incomplete material and incomplete part for jigging Production supervisor Conduct 200% inspection
4 Coating Follow parts requirement Coating thickness Follow customer requirement - IPQC Control Panel Gun When rejected QE Adjust gun setting
Oven Curing Follow powder requirement Temperature
Glossiness 		Follow powder specification - Production Control Panel Temperature When rejected QE Adjust temperature setting
5 Unjigging - Follow customer requirement (if necessary)
Design on request 		-   - Production Thickness gauge
Gloss meter
Colorimeter
Solvent rub test
Cross hatch test 		Tests failed QE First piece confirmation
6 Visual inspection for parts' appearance - Refer limit samples from customer (reviewed & signed by customer) Follow customer visual acceptance criteria   100% inspection for all produced parts QC Operator conduct 100% visual inspection Visual inspection follows defect catalogue and limit sample from customer Production supervisor and QE Segregate rejected parts and inform customeer's QA Dept
Review limit sample and defect catalogue once a year
7 Packing Storage / Delivery - Packing label and shipment label
Packing standard
Powder coating outgoing report 		AQL 0.65%   Every lot OQC Visual inspection When rejected Production supervisor Sorting
End                      
 
*Note:
  1. All chemical used are RoHS Compliance
  2. - Critical Process
 
Alert Level
  1. Inform QE
  2. Inform Production Supervisor