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1、Johnson Electric Industrial Manufactory Limited德德 昌昌 電電 機(jī)機(jī) 工工 業(yè)業(yè) 製製 造造 廠廠 有有 限限 公公 司司P.E.DEPARTMENT 生生產(chǎn)產(chǎn)工工程程部部PILOT RUN REPORT試試 產(chǎn)產(chǎn) 報(bào)報(bào) 告告PROJECT NO.項(xiàng)項(xiàng)目目編編號(hào)號(hào)MODEL CODE馬馬達(dá)達(dá)型型號(hào)號(hào)PDP/PEP CLASS工工程程類(lèi)類(lèi)別別REVISION版版 本本LOCA/LINE區(qū)區(qū)間間/線線區(qū)區(qū)DATE 日日 期期LEADER:ENG組組長(zhǎng)長(zhǎng)PE:MEMBER:成成員員QE:PM:AU:FORM NO:馬馬達(dá)達(dá)生生產(chǎn)產(chǎn)流流程程Motor f
2、low chart電電樞樞段段裝裝配配膠膠蓋蓋段段裝裝配配磁磁底底段段裝裝配配馬馬達(dá)達(dá)段段裝裝配配Arm assy End cap assyR/H assyMotor assyA01E01R01M01A02E02R02M02A03E03R03M03A04E04R04M04A05E05R05M05A06E06R06M06A07E07R07M07A08E08R08M08A09E09R09M09A10E10R10M10A11E11R11M11A12E12R12M12A13E13R13M13A14E14M14A15E15M15A16E16M16A17E17M17A18E18M18A19E19M19A2
3、0E20M20Symbols符符號(hào)號(hào):Series/馬馬達(dá)達(dá)系系列列:preparedby/制制表表人人:Operation process/操操作作工工序序motor code/馬馬達(dá)達(dá)型型號(hào)號(hào):date/日日期期:100%Inspection/測(cè)測(cè)檢檢REV/版版 次次:approved by/審審核核人人:OP+100%testing/操操作作工工序序+100%測(cè)測(cè)檢檢date/日日期期:QA outgoing Inspection抽抽樣樣檢檢查FORM NO:PIE-950601-2BRMPilot Run LogProject Num.:Project Holder:Producti
4、on 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-000601-0Pilot Run Close meeting minutes 結(jié)束束會(huì)會(huì)議記錄Project No:Motor No:Time/會(huì)會(huì)議時(shí)
5、間:Date/會(huì)會(huì)議議日日期期:Chairman/會(huì)會(huì)議主主席席:AU:Participants/會(huì)會(huì)議參參加加者者:(PROJECT ENGINEER,EVC,PE,AU,OMC,PM,QE,PS,EVC,etc.)W3s 問(wèn)題及及行行動(dòng):(4 Ms/規(guī)格,工序文件,機(jī)模,測(cè)量工具,品質(zhì)問(wèn)題,物料,等等.)NOProblem/問(wèn)題When/時(shí)間Who/跟進(jìn)人Status/結(jié)果AU comment 意意見(jiàn):a.Rejected/不接收生產(chǎn)()b.Accepted/接收生產(chǎn)()c.Other/有條件接收生產(chǎn)()Stated reason to a or c/詳細(xì)說(shuō)明明(如如選項(xiàng)為a或或c)AU
6、signature/簽名:QA Comment 意意見(jiàn):a.Rejected/不接收生產(chǎn)()b.Accepted/接收生產(chǎn)()c.Other/有條件接收生產(chǎn)()Stated reason to a or c/詳細(xì)說(shuō)明明(如如選項(xiàng)為a或或c)QA signature/簽名:PS/OMC Comment/意意見(jiàn):a.Rejected/不接收生產(chǎn)()b.Accepted/接收生產(chǎn)()c.Other/有條件接收生產(chǎn)()Stated reason to a or c/詳細(xì)說(shuō)明明(如如選項(xiàng)為a或或c)PS/OMC signature/簽名:Senior AU Leader comment/意意見(jiàn):a.Re
7、jected/不接收生產(chǎn)()b.Accepted/接收生產(chǎn)()Prepared by/制表 Date/日期 Approved by/樓層生產(chǎn)主管批準(zhǔn) 日期 Remarks/備注注:1.Rejected to production must be approved by OM/如最后結(jié)論為:不接收生產(chǎn),需得到執(zhí)行經(jīng)理或經(jīng)理助理批準(zhǔn).2.Attached the pilot run log if necessary/必要時(shí)附上P/R Log.P/R date/date/日日期期:BOM listDescriptionPart numberLot numberPilot Run ProgressMo
8、tor code:Project no:Motor application:Prod schedule date:Actual prod.datePVR received date:Introduction mtg date:Motor spec received date:PM received date:Packing spec.received date:PM available date:Matl available date:Fixture available date:P/R schedule date:Actual P/R date:P/R completed date:P/R
9、close meeting date:P/R report completed date:Date Progress ProblemPilot Run Capability Analysis SummaryProcessItemUnitPpkPpMeanMax.Min.Spec.report NoPilot Run Capability Analysis SummaryProcessItemUnitPpkPpMeanMax.Min.Spec.report NoWinding process record/馬馬達(dá)達(dá)試試產(chǎn)產(chǎn)電電繞繞記記錄錄P/R/試試產(chǎn)產(chǎn)人人:_ Date/日日期期:_1.Dra
10、wing Spec./圖圖紙紙資資料料:Magnet wire OD/線線徑徑:_ Turns/圈圈數(shù)數(shù):_Windingmethod/過(guò)過(guò)線線方方法法:_Tension/繞繞線線拉拉力力:_ Arm.Resistance/電電樞樞電電阻阻:_2.Setup/校校機(jī)機(jī)資資料料:M/C model/電電繞繞機(jī)機(jī)型型:_ M/C No/機(jī)機(jī)號(hào)號(hào):_IC No/編編號(hào)號(hào):_MODE NO:_Actual tension/實(shí)實(shí)際際拉拉力力:_ M/C head type/機(jī)機(jī)頭頭類(lèi)類(lèi)別別:_ CT/周周期期時(shí)時(shí)間間:Min/per arm./每每只只電電樞樞繞繞線線時(shí)時(shí)間間_分分鐘鐘 Remarks/
11、校校機(jī)機(jī)情情況況:PM/校校機(jī)機(jī)填填寫(xiě)寫(xiě)人人:_3.Magnet wire variety after and before/漆漆皮皮線線變變化化資資料料:Before,with coating/繞繞線線前前:連連漆漆皮皮 Without coating/不不連連漆漆皮皮_After,with coating/繞繞線線後後:連連漆漆皮皮 Without coating不不連連漆漆皮皮_QA/填填寫(xiě)寫(xiě)人人:_Remarks/備備注注:FORM NO:WPS-021101-0PSG91004新新工工序序首首次次成成功功率率及及所所需需時(shí)間New Process FPY and Cycle Time
12、Process NO.Process NameCycle Time(sec/pcs)Defect QuantityFirst PassYieldRemarks工工序序編號(hào)號(hào)工工序序名名稱(chēng)稱(chēng)工工時(shí) (秒秒/件件)次次品品數(shù)數(shù)目目工工序序首首次次 成成功功率率備注注FROM NO:WAT-000701-0_pilot run fixture list/型型號(hào)號(hào)工工具具清清單單Output/排排工工數(shù)數(shù):_ 制制單單:_ 日日期期:_Process/工工序序名名稱(chēng)稱(chēng)Fixture name/工工具具名名稱(chēng)稱(chēng)PMs No/流流程程編編號(hào)號(hào)Actual No/實(shí)實(shí)際際編編號(hào)號(hào)Fixturesource/
13、工工具具來(lái)來(lái)源源(全全新新/舊舊有有)Output per hour/每每小小時(shí)時(shí)產(chǎn)產(chǎn)量量Qty/需需用用數(shù)數(shù)量量Setup/調(diào)調(diào)較較參參數(shù)數(shù)注注:工工具具來(lái)來(lái)源源填填寫(xiě)寫(xiě)原原線線已已有有或或者者夾夾具具倉(cāng)倉(cāng)有有FROM NO:HDC-960101-1審審核核:_:_pilot run fixture list/型型號(hào)號(hào)工工具具清清單單Output/排排工工數(shù)數(shù):_ 制制單單:_ 日日期期:_Process/工工序序名名稱(chēng)稱(chēng)Fixture name/工工具具名名稱(chēng)稱(chēng)PMs No/流流程程編編號(hào)號(hào)Actual No/實(shí)實(shí)際際編編號(hào)號(hào)Fixturesource/工工具具來(lái)來(lái)源源(全全新新/舊舊有有
14、)Output per hour/每每小小時(shí)時(shí)產(chǎn)產(chǎn)量量Qty/需需用用數(shù)數(shù)量量Setup/調(diào)調(diào)較較參參數(shù)數(shù)注注:工工具具來(lái)來(lái)源源填填寫(xiě)寫(xiě)原原線線已已有有或或者者夾夾具具倉(cāng)倉(cāng)有有FROM NO:HDC-960101-1審審核核:_:_pilot run fixture list/型型號(hào)號(hào)工工具具清清單單Output/排排工工數(shù)數(shù):_ 制制單單:_ 日日期期:_Process/工工序序名名稱(chēng)稱(chēng)Fixture name/工工具具名名稱(chēng)稱(chēng)PMs No/流流程程編編號(hào)號(hào)Actual No/實(shí)實(shí)際際編編號(hào)號(hào)Fixturesource/工工具具來(lái)來(lái)源源(全全新新/舊舊有有)Output per hour/每
15、每小小時(shí)時(shí)產(chǎn)產(chǎn)量量Qty/需需用用數(shù)數(shù)量量Setup/調(diào)調(diào)較較參參數(shù)數(shù)注注:工工具具來(lái)來(lái)源源填填寫(xiě)寫(xiě)原原線線已已有有或或者者夾夾具具倉(cāng)倉(cāng)有有FROM NO:HDC-960101-1審審核核:_:_光潔度光潔度FORM NO.:PIE-941204-0Roundness/圓度Profile curve/光潔度Profile curve/光潔度FORM NO.:PIE-941204-0Roundness/圓度Johnson Electric Industrial Manufactory Ltd.General InformationResultsProject Number:Report No.:
16、Model Number:Date:Process PotentialMotor Number:Inspector:Pp=Process:Location:Process CapabilityCharacteristic:Ppk=Instrument:SpecificationMaximum=Nominal=Minimum=Range=Sample Test Results110112021303140415051606170718081909110012345678910Mean:Mean+3s:Pp:SD(s):Mean-3s:PpL:Minimum:PpU:Maximum:Mean+4s
17、:Range:Mean-4s:PpK:Distribution Graph10.80.60.40.2000.10.20.30.40.50.60.70.80.91HNSONELECTRICJ Page:16馬馬達(dá)達(dá)附附加加工工序序及及包包裝裝情情況況Motor attached process&packing status1.Soldering process?/馬達(dá)是否有包線、銲線、銲電容、銲圈仔.Packing lead wire/包線:Yes/有No/無(wú) Soldering lead wire/銲線:Yes/有No無(wú) Soldering Cap./銲電容:Yes/有No無(wú) Solderin
18、g varistor/銲圈仔:Yes/有No無(wú) Status/包線、或銲線、銲電容、銲圈仔情況:2.Motyor keeper ring?/馬達(dá)是否有保磁圈:Yes/有 No/無(wú)3.Motor Identification dot/line?/是否加色點(diǎn)/線辯別:Yes有 No/無(wú)4.Knurling?馬達(dá)是否要打喱士或搓喱士.4-kunrling/打喱士:Yes/有 No/無(wú) Multi-line kunrling/搓喱士:Yes/有 No/無(wú)5.Add pinion?/馬達(dá)是否有加牙.Yes/有 No/無(wú) Method/加牙方式:Fitting/啤牙 Drawing/抽牙6.Motor d
19、ate code printing/馬達(dá)追溯編號(hào)方式:Ink(Jet)printing油印/噴印moving printing/移印 Labeling 7.Motor gagues stated/馬達(dá)GO/NG基子簡(jiǎn)述:8.Motor packaging/馬達(dá)包裝方式.Inner box/種類(lèi):Paper box/紙盒 Polyfoam/發(fā)泡膠 Silica gel/是否有加防潮珠:Yes/有No/無(wú) Plastic sheet/是否有膠紙:Yes/有No/無(wú) Unclear printing/包裝時(shí)會(huì)否弄至馬達(dá)字朦:Yes/會(huì) NO/不會(huì) Wrested terminal/包裝方式能否保護(hù)插
20、頭:Yes/能No/否 Weight/10PCS馬達(dá)重量:Packaging details/包裝方式簡(jiǎn)述:FROM NO:WAT-000702-0DC motor life test report/DC馬達(dá)早期失效測(cè)試報(bào)告No/報(bào)告編號(hào):_Location/區(qū)間:_Line/線別:_ Motor code/馬達(dá)型號(hào):_REV.:_Lot No.:_Start date/開(kāi)始日期:_ End date/完成日期:_Testing Condition./測(cè)試條件:Voltage/試驗(yàn)電壓:_load condition/負(fù)載:_Spec.運(yùn)行方式:_Rotation/軸突向身轉(zhuǎn)向?yàn)?_Reque
21、st/要求:_Observation in testing/測(cè)試過(guò)程中觀察到的現(xiàn)象:Conclusion/結(jié)論和評(píng)語(yǔ):Prepared by/報(bào)告人:_Confirmed by/認(rèn)可:(PSG)(Process Eng.)(QA)_(分組主管)_(廠頭)AUForm No.:PGA-970304-2No./報(bào)告編號(hào):_Motor code/馬達(dá)型號(hào):_Sub-assy analysis配配件件分分析析:item/測(cè)量項(xiàng)目Before/試前After/試後Spec.No.1No.2No.1No.2R/H bushing ID 磁底盃士孔E/C bushing ID 膠(鐵)蓋盃士孔徑Magnet
22、 chip/無(wú)磁碎Gauss value/磁力Arm resistance 電樞電阻()Comm OD/換向器直徑Comm profile 換向器光潔度Comm roundness 換向器圓度Bar to barComm T.I.R.Comm outline 換向器外觀Insulation resistance 絕緣電阻(M)Brush tension/碳精片彈力(g)Brush length/碳精長(zhǎng)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(zhuǎn)速(Rpm)O/L current/Fan 電流(A)O/L speed/Fan 轉(zhuǎn)速(Rpm)Torque current/g-cm電流(A)Torque speed/g-cm轉(zhuǎn)速(Rpm)dBAECRN to accept/暫收資料:Testing data/測(cè)試資料:No.1No.2Date/日期Time/時(shí)間Total time累積時(shí)間Current 電流Speed 轉(zhuǎn)速Date/日期Time 時(shí)間Total time 累積時(shí)間Cueernt 電流Speed 轉(zhuǎn)速Form No.:PGA-970304-2
新產(chǎn)品試產(chǎn)專(zhuān)用表格
