試產報告
Johnson Electric Industrial Manufactory Limited
德 昌 電 機 工 業 製 造 廠 有 限 公 司
. DEPARTMENT 生產工程部
PILOT RUN REPORT
試 產 報 告
PROJECT NO.
項目編號
MODEL CODE
馬達型號
PDP/PEP CLASS
工程類別
REVISION
版 本
LOCA/LINE
區間/線區
DATE
日 期
LEADER: ENG
組長 PE:
MEMBER:
成員 QE:
PM:
AU:
FORM NO:
馬達生產流程
馬達生產流程
Motor flow chart
電樞段裝配 膠蓋段裝配 磁底段裝配 馬達段裝配
Arm ass'y End cap ass'y R/H ass'y Motor ass'y
A01 E01 R01 M01
A02 E02 R02 M02
A03 E03 R03 M03
A04 E04 R04 M04
A05 E05 R05 M05
A06 E06 R06 M06
A07 E07 R07 M07
A08 E08 R08 M08
A09 E09 R09 M09
A10 E10 R10 M10
A11 E11 R11 M11
A12 E12 R12 M12
A13 E13 R13 M13
A14 E14 M14
A15 E15 M15
A16 E16 M16
A17 E17 M17
A18 E18 M18
A19 E19 M19
A20 E20 M20
Symbols符號:
Series/馬達系列: preparedby/制表人: :Operation process/操作工序
motor code/馬達型號: date/日期: :100% Inspection/測檢
REV/版 次: approved by/審核人: :OP+100% testing//操作工序+100%測檢
date/日期: :QA outgoing Inspection抽樣檢查
FORM NO: PIE-950601-2
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Pilot Run log
Project Num.: Project Holder: Production PE: Schedule Start:
Model Num.: Project QE: P/R Owner: Actual Start:
Motor Series: Process Eng: AU Head & Line: Actual End:
Material Issues:
Machine & Fixture Issues:
Specs Issues:
Mfg Document Issues:
Other Issues:
Conclusion:
FROM NO: WAT-000601-0
Pilot Run close meeting
Pilot Run Close meeting minutes 结束会议记录
Project No: Motor No:
Time/会议时间: Date/会議日期:
Chairman/会议主席: AU:
Participants/会议参加者: (PROJECT ENGINEER, EVC, PE, AU, OMC, PM, QE, PS, EVC,etc….)
W3's 问题及行动: (4 Ms/规格,工序文件,机模,测量工具,品质问题,物料,等等.)
NO Problem/问题 When/时间 Who/跟进人 Status/结果
AU comment 意见: a. Rejected /不接收生产( ) b. Accepted/接收生产( ) /有条件接收生产( )
Stated reason to a or c /详细说明(如选项为a或c)
AU signature/签名:
QA Comment 意见: ) ) )
Stated reason to a or c /详细说明(如选项为a或c)
QA signature/签名:
PS / OMC Comment/ 意见: ) ) )
Stated reason to a or c /详细说明(如选项为a或c)
PS/OMC signature/ 签名:
Senior AU Leader comment/意见:
/不接收生产( ) b. Accepted /接收生产( )
Prepared by/制表 Date/日期 Approved by/楼层生产主管批准 日期
Remarks/备注: to production must be approved by OM/如最后结论为:不接收生产,需得到执行经理或經理助理批准.
the pilot run log if necessary/必要时附上P/R Log.
P/R date/日期:
BOM
BOM list
Description Part number Lot number
report progress
Pilot Run Progress
Motor code: Project no: Motor application:
Prod schedule date: Actual prod. date
PVR received date: Introduction mtg date:
Motor spec received date: PM received date:
Packing spec. received date: PM available date:
Mat'l available date: Fixture available date:
P/R schedule date: Actual P/R date:
P/R completed date: P/R close meeting date: P/R report completed date:
Date Progress Problem
capability (1)
Pilot Run Capability Analysis Summary
Process Item Unit Ppk Pp Mean Max. Min. Spec. report No
capability (2)
Pilot Run Capability Analysis Summary
Process Item Unit Ppk Pp Mean Max. Min. Spec. report No
馬達試產電繞錄
Winding process record/馬達試產電繞記錄
P/R/試產人:_________ Date/日期:___________
Spec./圖紙資料:
Magnet wire OD/線徑:____________ Turns/圈數:_____ Winding method/過線方法:________________
Tension/繞線拉力:_______________ Arm. Resistance/電樞電阻:________
M/C model/電繞機型:_____________ M/C No/機號:____________________
IC No/ 編號:________________________ MODE NO:______________________
Actual tension/ 實際拉力:_________ M/C head type/機頭類別:_________
CT/周期時間: Min/per arm. /每只電樞繞線時間_____分鐘
Remarks/校機情況:
PM/校機填寫人:____________
wire variety after and before/漆皮線變化資料:
Before,with coating/繞線前: 連漆皮 Without coating/不連漆皮____________
After,with coating/繞線後:連漆皮 Without coating不連漆皮____________
QA / 填寫人:_____________
Remarks/備注:
FORM NO: WPS-021101-0 PSG91004
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FPY
新工序首次成功率及所需时间
New Process FPY and Cycle Time
Process NO. Process Name Cycle Time (sec/pcs) Defect Quantity First Pass Yield Remarks
工序编号 工序名称 工时 (秒/件) 次品数目 工序首次 成功率 备注
FROM NO: WAT-000701-0
工具清單(1)
________pilot run fixture list/型號工具清單
Output/排工數:____________ 制單:_______ 日期:_________
Process/工序名稱 Fixture name/工具名稱 PM's No/流程編號 Actual No/實際編號 Fixturesource/ 工具來源(全新/舊有) Output per hour/ 每小時產量 Qty/需用數量 Setup/調較參數
注:工具來源填寫原線已有或者夾具倉有
FROM NO:HDC-960101-1 審核:___________
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圓 度
工具清單(2)
________pilot run fixture list/型號工具清單
Output/排工數:____________ 制單:_______ 日期:_________
Process/工序名稱 Fixture name/工具名稱 PM's No/流程編號 Actual No/實際編號 Fixturesource/ 工具來源(全新/舊有) Output per hour/ 每小時產量 Qty/需用數量 Setup/調較參數
注:工具來源填寫原線已有或者夾具倉有
FROM NO:HDC-960101-1 審核:___________
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圓 度
工具清單(3)
________pilot run fixture list/型號工具清單
Output/排工數:____________ 制單:_______ 日期:_________
Process/工序名稱 Fixture name/工具名稱 PM's No/流程編號 Actual No/實際編號 Fixturesource/ 工具來源(全新/舊有) Output per hour/ 每小時產量 Qty/需用數量 Setup/調較參數
注:工具來源填寫原線已有或者夾具倉有
FROM NO:HDC-960101-1 審核:___________
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圓 度
圓度表
光潔度
光潔度
FORM NO.: PIE-941204-0
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Roundness/圓 度
圓度表 (2)
Profile curve/光潔度
Profile curve/光潔度
FORM NO.: PIE-941204-0
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Roundness/圓 度
data
Johnson Electric Industrial Manufactory Ltd. Range Frequency Plot Points Value Limits
General Information Results 0 Min 0 0
Project Number : Report No. : 0 0 Max 0 0
Model Number : Date : Process Potential 0 0 0 0
Motor Number : Inspector : Pp = 0 0 0 0
Process : Location : Process Capability 0 0 0 0
Characteristic: Ppk = 0 0 0 0
Instrument : 0 0 0 0
Specification 0 0 0 0
Maximum = Nominal = 0 0 0 0
Minimum = Range = 0 0 0 0
Sample Test Results 0 0 0 0
1~10 11~20 21~30 31~40 41~50 51~60 61~70 71~80 81~90 91~100 0 0 0 0
1 0 0 0 0
2 0 0
3 0 0
4
5
6
7
8
9
10
Mean : 0 Mean + 3s : 0 Pp :
SD (s) : 0 Mean - 3s : 0 PpL :
Minimum : 0 PpU :
Maximum : 0 Mean + 4s : 0
Range : 0 Mean - 4s : 0 PpK :
Distribution Graph
data
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
馬達附加工序
馬達附加工序及包裝情況
Motor attached process & packing status
process?/ 馬達是否有包線、銲線、銲電容、銲圈仔.
Packing lead wire/包線: Yes/有 No/無
Soldering lead wire/ 銲線: Yes/有 No無
Soldering Cap./銲電容: Yes/有 No無
Soldering varistor/ 銲圈仔: Yes/有 No無
Status/ 包線、或銲線、銲電容、銲圈仔情況:
keeper ring?/馬達是否有保磁圈: Yes/有 No/無
Identification dot/line? /是否加色點/線辯別: Yes有 No/無
4-kunrling/打喱士: Yes/有 No/無
Multi-line kunrling /搓喱士: Yes/有 No/無
pinion?/馬達是否有加牙. Yes/有 No/無
Method/加牙方式: Fitting/ 啤牙 Drawing/ 抽牙
date code printing/ 馬達追溯編號方式:
Ink(Jet) printing油印/噴印 moving printing/移印 Labeling
gagues stated/馬達GO/NG基子簡述:
packaging/馬達包裝方式.
Inner box/種類: Paper box/ 紙盒 Polyfoam/發泡膠
Silica gel/是否有加防潮珠: Yes/有 No/無
Plastic sheet/是否有膠紙: Yes/有 No/無
Unclear printing/包裝時會否弄至馬達字朦: Yes/會 NO/不會
Wrested terminal/包裝方式能否保護插頭: Yes/能 No/否
Weight/10PCS馬達重量:
Packaging details/包裝方式簡述:
FROM NO: WAT-000702-0
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圓 度
DC馬達早期
DC motor life test report/DC馬達早期失效測試報告
No/報告編號:______________
Location/區間:__________ Line/線別:____________ Motor code/馬達型號:______________ REV.:___________
Lot No.:_________ Start date/開始日期:____________ End date/完成日期:_______________
Testing Condition./測試條件:
Voltage/試驗電壓:________ load condition/負載:____________ Spec.運行方式:_______________________________
Rotation/軸突向身轉向為:____________ Request/要求:___________________________
Observation in testing/測試過程中觀察到的現象:
Conclusion/結論和評語:
Prepared by/報告人:____________________
Confirmed by/認可: (PSG) (Process Eng.) (QA)
_____________(分組主管) ____________________(廠頭) AU
Form No.: PGA-970304-2
配件分析
No./報告編號:________________ Motor code/馬達型號:_________________
Sub-ass'y analysis配件分析:
item/測量項目 Before/試前 After/試後
Spec.
R/H bushing ID 磁底盃士孔
E/C bushing ID 膠(鐵)蓋盃士孔徑
Magnet chip/無磁碎
Gauss value/磁力
Arm resistance 電樞電阻(Ω)
Comm OD/換向器直徑
Comm profile 換向器光潔度
Comm roundness 換向器圓度
Bar to bar
Comm .
Comm outline 換向器外觀
Insulation resistance 絕緣電阻(MΩ)
Brush tension/碳精片彈力(g)
Brush length/碳精長度
Motor EF(RF)/前突
Motor endplay/虛位
Motor vibration/芯震
Motor popping/芯跳
F/L current/空載電流(A)
F/L speed/空載轉速(Rpm)
O/L current/ Fan 電流(A)
O/L speed/ Fan 轉速(Rpm)
Torque current/ g-cm電流(A)
Torque speed/ g-cm轉速(Rpm)
dBA
ECRN to accept/暫收資料:
Testing data/測試資料:
Date/日期 Time/時間 Total time 累積時間 Current 電流 Speed 轉速 Date/日期 Time 時間 Total time 累積時間 Cueernt 電流 Speed 轉速
Form No.: PGA-970304-2
