特变电工变压器全过程质量管控介绍The-presentation-of-total-quality-control课件.ppt

1、 全过程质量管控介绍全过程质量管控介绍The presentation of total quality controlThe presentation of total quality control特变电工沈阳变压器集团有限公司特变电工沈阳变压器集团有限公司TBEA SHENYANG TRANSFORMER GROUP CO.,LTD.一、质量管理体系Quality management system质量管理体系的建立质量管理体系的建立The establishment of the quality management system公司根据ISO9001标准要求建立了质量管理体系文件，依

2、据HAF003核电厂质量保证安全规定建立了核电质保体系文件，明确了从产品设计开发、原材料检验、生产制造、交付到售前及售后服务、质量责任等一系列要求。Company according to ISO9001 standards established the quality management system documents,on the basis of Nuclear power plants quality assurance safety rulesestablished nuclear power quality system documents,made clear a seri

3、es of requirements from the product design and development,raw material inspection,production,delivery，to the pre-sale and after-sales service,quality responsibility.一、质量管理体系Quality management system必备的产品实现过程资源：按照人、机、料、法、环五要素配备生产所需资源。人力资源匹配，生产一线员工获得职业资格证书，具备上岗资格条件；生产过程包括的设备、工装工具、计量器具等以满足稳定生产符合强制性认证标

4、准的产品要求；严控各类物料的传递、交接验收流程，确保零部组件自身质量；提供良好的生产作业场地，保证作业环境符合产品制造标准要求。The necessary resources of product realization process：Equipped with resources needed for production according to the five elements including people,machine,material,method and environment.Human resource matching refers to the productio

5、n line employees to obtain professional qualification certificate,have mount guard qualifications;Production process using the equipment,tooling,measuring instruments conform to the compulsory certification standards of product requirements to meet the stable production;Strictly control the process

6、of the transmission of all kinds of materials and acceptance,ensure the quality of the parts and component;Provide good production area,ensure the working environment conform to the requirements of the product manufacturing standards.一、质量管理体系Quality management system建立、完善文件制度化的保障体系，为确保产品实现过程得到有效管控，产

7、品在制造阶段遵循5W1H5W1H原则。从产品开工前的质量策划、交底文件、工艺方案、人员组织机构、操作检查记录到产品完工后的组织鉴定、问题处理、转序，各环节均依据文件制度，各项规章制度贯穿整个生产过程，具备一套完整的文件制度保障体系。Establish and perfect the file institutional guarantee system,in order to ensure the product realization process to effectively control,follow the principle of 5W1H products in the man

8、ufacturing stage.From the quality planning before starting,clarification documents,processing plan,organization,operation and inspection records，to the identification after the completion,problem handling and transfer,each link all according to the file system,each rules and regulations throughout t

9、he whole production process,with a complete set of file system security system.一、质量管理体系Quality management system质量保证的措施质量保证的措施 质量保证信心来源于识别和确认顾客及法律法规要求、产品设计开发、优质采购、精细生产、严格检验和试验、周到细致的交付和售后服务过程的控制；质量意识的提升贯穿于全体员工；国际、国家及行业标准的贯彻；客观的内部质量体系审核；采用国际先进生产、试验设备、高精度的测量设备；独立的、周期性的质量体系外部评估。Quality assurance measure

10、sThe confidence of the quality assurance comes from recognition and confirm the customer and regulatory requirements,product design and development,high quality sourcing,fine production,strict inspection and testing,delivery and after-sales service of thoughtful process control;Quality consciousness

11、 raises throughout all the staff;Implementing international,national and industry standards;Objective internal quality system evaluation;Adopting international advanced production and testing equipment,high precision measuring equipment;Independent,periodic external quality system evaluation.一、质量管理体

12、系Quality management system质量管理体系文件控制层次质量管理体系文件控制层次质量手册程序文件作业指导书 表单记录职责、任务要求由谁何时去做什么如何去做用什么去证明Quality management system document control levelQuality manualProgram filesOperation instructionRecordResponsibilities、Mission requirementsWho,when and what to doHow to doWhat to prove二、产品实现过程Product realiza

13、tion process产品实现过程流程图产品实现过程流程图Product realization process flow chart二、产品实现过程-合同签订过程 Contract signing质量质量控制要求控制要求Quality control requirements 投标文件满足招标文件和投标评审的要求；The bid documents to meet the requirements of The bid documents to meet the requirements of the tender documents and bid evaluationthe tende

14、r documents and bid evaluation；合同条款与投标文件的偏差得到澄清；Clarify the deviation of the terms of the Clarify the deviation of the terms of the contract and bid documentscontract and bid documents；合同条款、技术协议满足用户要求并能完全履行。The terms of the contract,the technical The terms of the contract,the technical agreement can

15、 meet user requirements and be agreement can meet user requirements and be able to completely fulfill.able to completely fulfill.质量保证措施质量保证措施Quality assurance measures 投标文件递交前对所有条款进行评审；Review all terms before bidding documents submitted；合同签订前对所有合同条款进行评审。Review all the terms of the contract before th

16、e contract signing.质量控制要点质量控制要点Quality control points 检查投标的技术参数、原材料及组部件采购周期、工艺条件、试验要求、产品交货期、付款方式、投标保证金和履约保证金回收、质保期、违约金等条款是否符合公司和用户要求；Check whether the clauses of the technical data of the bidding,raw material and parts purchasing cycle,process conditions,testing requirements,product delivery time,pa

17、yment terms,bid bond and performance bond,quality assurance period,the penalty due to breach of contract are accordance with the requirements of the companies and users；检查合同条款与投标条款的偏差。Check the deviation of the terms of the contract and tender clause.质量检验记录质量检验记录Quality inspection records 投标评审表；合同评审

18、表（销售类）。Bid evaluation table；The contract review form(sales)招标文件Bid documents投标评审Bid evaluation投标Bidding中标后合同评审After winning the contract review签订合同Sign the contract二、产品实现过程-设计和开发过程 Design and development质量质量控制要求控制要求Quality control requirements设计图样、技术条件符合订货合同（合同转交单）、技术协议、与产品有关的技术标准及相关的法律和法规的要求。Design

19、 drawings,technical conditions comply Design drawings,technical conditions comply with the order contract(contract transfer list),with the order contract(contract transfer list),the technical agreement,related to the product the technical agreement,related to the product with the requirements of tec

20、hnical standard and with the requirements of technical standard and related laws and regulations.related laws and regulations.质量保证措施质量保证措施Quality assurance measures 产品设计编制设计任务书及设计计划；Prepare the design specification and design plan；设计过程应用潜在失效模式及后果分析工具（FMEA）；Design course application potential failure

21、 modes and effects analysis tool(FMEA)；设计文件100经过校核、会签、审核、批准；100%design documents will be checked，signed,reviewed and approved；重点项目、重大产品、新产品组织技术专家评审。Organize technical expert review for the key projects,major products and new product.质量控制要点质量控制要点Quality control points 设计初步评审；设计技术评审；产品图纸评审；工艺会签；设计验证；设

22、计确认；设计更改。Preliminary design review；Technology design review；Product drawing review；Sign of process；Design verification；Design confirmation；Design change.质量检验记录质量检验记录Quality inspection records 设计评审记录；Design review record；设计验证记录；Design verification record；设计确认记录。Design confirmation record.合同协议Contract

23、 agreement初步设计Preliminary design设计评审Design review技术设计Technical design评审和审批Review and approval设计验证Design verification绘图Drawing审核批准Approval发放Issue二、产品实现过程-采购过程 Procurement质量质量控制要求控制要求Quality control requirements 按技术文件及合同要求组织采购；Organize procurement according to the technical documents and contract requ

24、irements；物资满足相应标准要求；Goods meet the requirements of relevant standards；供方为合格供方；The supplier is qualified supplier；按相关要求进行物资贮存和标识。Storage and identify goods according to the requirements of the relevant.质量保证措施质量保证措施Quality assurance measures 进厂物资（按批次）100%进行检查或验证；Goods into the factory(in batches)100%w

25、ill be inspected or certificated;绝缘成型件利用X光检测仪逐件进行检测；Insulation parts test using X-ray detector one by one；重点材料、组部件派监造人员现场监造；Arrange supervision personnel on-site supervision for the key materials and parts；开展供方选择、评价和重新评价工作；Develop the supplier selection,evaluation and reappraisal.质量控制要点质量控制要点Quality

26、 control points 开展供方评价，选择合格供方；Carry out the supplier evaluation,select the qualified supplier；组织采购合同评审；Organize purchase order review；采购物资外观和性能检查；Goods appearance check and performance tests；物资贮存条件及标识检查。Material storage conditions and identity check.质量检验记录质量检验记录Quality inspection records 材料、组部件采购计划；

27、Purchase plan；原材料进厂检验记录；Inspection record；供应商基本状况调查表；Suppliers basic status questionnaire；供方业绩内部评价汇总表。The supplier performance internal evaluation summary table.材料购买单Material purchase order选择供方Supplier selection合同评审Contract review进货检验Incoming inspection入库Entering warehouse贮存Storage发放Issue二、产品实现过程铁心生

28、产过程 Core production质量质量控制要求控制要求Quality control requirements产品尺寸、毛刺、锈蚀、波浪度及绝缘电阻符合图纸、技术标准和合同协议要求；Product size,burr,rust,waves and insulation resistance in accordance with the drawings,technical standards and the contract requirements；产品清洁度。Product cleanliness.质量保证措施质量保证措施Quality assurance measures 铁芯片

29、按GB2828方法抽样检验；Core lamination is sampling inspected according to GB2828 method；铁芯叠装100检查；Lamination 100%will be inspected；纵剪、横剪采用德国进口乔格线加工，硅钢片存贮采用立体库；Silicon steel sheet cut by German import brendon DE jonge line，and storage using three-dimensional library；日降尘量控制在20mg/以下。The daily heavy control unde

30、r 20 mg/.质量控制要点质量控制要点Quality control points 铁芯片尺寸，铁芯直径、窗口尺寸检查；Core lamination size,core diameter,and the size of the window inspection；铁芯垂直度检查；Core verticality inspection；铁芯叠积缝检查；Core pile joint inspection；铁芯绝缘电阻测量；Core insulation resistance measurements；铁芯清洁度检查。Core cleanliness inspection.质量检验记录质量检

31、验记录Quality inspection records 铁芯片纵剪操作检查记录；Longitudinal shear operation and inspection record；铁芯片横剪操作检查记录；Transverse shear operation and inspection record；铁芯叠装操作、检查记录。Lamination operation and inspection record.作业计划、图纸、技术要求Work plans,drawings,technical requirements硅钢片验收Silicon steel sheet acceptance纵向

32、剪切Longitudinal shear横向剪切Transverse shear检查Inspection铁芯叠装Lamination试验Testing最后检查Final inspection二、产品实现过程绝缘件生产过程 Insulation parts production质量质量控制要求控制要求Quality control requirements 绝缘件尺寸和外观要求；Insulation parts size and appearance requirements；地屏、静电板引线焊接圆滑过渡，无尖角毛刺；Earthing screen，electrostatic plate wir

33、e welding smooth transition，nsharp corners burr；绝缘件清洁度。Insulation parts cleanliness.质量保证措施质量保证措施Quality assurance measures 绝缘件100%检查；Insulation parts 100%will be inspected；粉尘区和绝缘件粘合区进行隔离；Isolation dust area and insulation adhesive area；绝缘车间为全封闭厂房，日降尘量控制在20mg/以下，温度控制在2528、湿度控制在35%RH。Insulation is ful

34、ly enclosed workshop,workshop daily heavy control under 20 mg/,the temperature control in 25 to 28,humidity control at 35%RH.质量控制要点质量控制要点Quality control points 绝缘件尺寸（长、宽、厚、孔距等）测量；Insulation parts size(length,width,thickness,pitch,etc.)inspection；静电板引线焊接、绝缘包扎检查；Electrostatic plate wire welding，insula

35、tion bandaging inspection；地屏引线焊接和电阻测量；Earthing screen wire welding and resistance measurement；外观及清洁度检查。Appearance and cleanliness inspection.质量检验记录质量检验记录Quality inspection records 地屏制造操作检查记录；Earthing screen operation and inspection record；静电板制造操作检查记录；Electrostatic plate operation and inspection reco

36、rd；铁轭垫块制造操作检查记录；Yoke spacer operation and inspection record；纸板筒制造操作检查记录。Cylinder operation and inspection record.作业计划、图纸、技术要求Work plans,drawings,technical requirements绝缘材料验收Insulation materials acceptance下料Input material绝缘件加工Insulation parts processing绝缘件检查Insulation parts inspection二、产品实现过程线圈生产过程 W

37、inding production质量质量控制要求控制要求Quality control requirements 线圈绕制、组装符合图纸及技术条件要求；Winding rolling,assembling conform to the requirements of the drawings and technical conditions;线圈出头屏蔽符合图纸、技术条件要求；Winding head shielding conform to the requirements of the drawings and technical conditions；线圈无断路、短路；Winding

38、without open circuit and short circuit；产品清洁。Product cleanliness.质量保证措施质量保证措施Quality assurance measures 线圈卷制、组装100%检查；Winding rolling,assembly 100%will be inspected；重点部位及关键尺寸组织技术人员现场鉴定；Key parts of the organization technical personnel on-site identification and critical dimensions；全封闭线圈生产车间日降尘量在20mg/

39、以下，湿度低于40%，温度在25-28之间。Fully enclosed winding workshop,heavy under 20 mg/,humidity below 40%,the temperature is between 25 to 28.质量控制要点质量控制要点Quality control points 导线线规、绝缘厚度检查；Wire gauge,the thickness of insulation inspection；线圈匝数、幅向尺寸检查及线圈短路、断路测量；Winding circle number,the size of the picture to chec

40、k and coil short circuit,open circuit measurement；组装后高度检查；After assembly height measurement；线圈出头屏蔽检查；Winding exit shield inspection；产品清洁度检查。Product cleanliness inspection.质量检验记录质量检验记录Quality inspection records 线圈卷制操作、检查记录；Winding rolling operation and inspection record；线圈组装操作、检查记录。Winding assembly o

41、peration and inspection record.作业计划、图纸、技术要求Work plans,drawings,technical requirements导线、绝缘件验收Wire,insulation parts acceptance线圈绕制Winding rolling检查Inspection线圈组装Winding assembly短路、断路检查Short circuit,open circuit inspection最终检查Final inspection二、产品实现过程油箱生产过程 Tank production质量质量控制要求控制要求Quality control re

42、quirements 油箱及附件焊线质量符合图纸和工艺要求；Tank and accessories welding line quality conform to the drawings and technical requirements；油箱尺寸、机械强度符合图纸和工艺要求；Tank size,mechanical strength in accordance with the drawings and process requirements;油箱表面无锈迹、油迹、灰尘；Tank surface is no rust,oil stains,dust;油箱涂漆质量符合图纸和工艺要求。T

43、ank paint quality conform to the drawings and technical requirements.质量保证措施质量保证措施Quality assurance measures 油箱尺寸、正压试验、真空试验、预装100%检查；Tank size,positive pressure test,vacuum test，preassemble 100%will be inspected；油箱焊线检测采用无损探伤；Tank welding line detection using nondestructive flaw detection。质量控制要点质量控制要点

44、Quality control points 油箱对装、焊装尺寸及焊线质量检查；Tank to the pack size,welding and welding line quality inspection；油箱整体试漏，抽真空试验、正压试验检查；Whole tank leakage,vacuum test,positive pressure test;油箱及附件预装检查；Preassemble inspection；油箱吹砂、涂漆及清洁度质量检查。Tank of blown sand,paint and cleanliness quality inspection.质量检验记录质量检验记

45、录Quality inspection records 油箱焊接操作、检查记录；Tank welding operation and inspection record；油箱及附件预装操作、检查记录；Tank and accessories preassemble operation and inspection record；油箱清理、喷漆操作、检查记录。Tank cleaning,painting operation and inspection record.作业计划、图纸、技术要求Work plans,drawings,technical requirements钢板预处理Steel

46、plate pretreatment油箱焊装Tank welding检查Inspection预装Preassemble试漏检查Leak check吹砂Blowing sand涂漆Painting最终检查Final inspection二、产品实现过程产品装配、试验过程 Assembly and testing二、产品实现过程产品装配、试验过程 Assembly and testing二、产品实现过程产品装配、试验过程Assembly and testing质量质量控制要求控制要求Quality control requirements 产品绝缘装配、引线装配、器身干燥处理、真空处理、总装配符合

47、图纸、工艺标准及技术条件要求；Product insulation,wire assembly,assembly body drying treatment,vacuum treatment and final assembly drawings,process standards and technical requirements；产品试验结果满足技术条件、合同及技术协议要求；Product test results meet the technical conditions,contract and technical agreement requirements；产品清洁。Produc

48、t cleanliness.质量保证措施质量保证措施Quality assurance measures 产品绝缘装配、引线装配、器身干燥处理、真空处理、总装配100%检查；Insulation assembly,lead assembly,active part drying,vacuum processing ,final assembly 100%will be inspected.器身整理在全封闭、可调控温湿度的整理间内完成；Active part collation carry out in a fully enclosed room,where temperature and hu

49、midity can be adjusted.产品试验按合同协议和技术条件逐项试验；Product test item by item according to the contract agreement and the technical conditions of test.质量控制要点质量控制要点Quality control points 铁芯接缝、波浪度、垂直度、松紧度检查；Core seam,wave degree,vertical degree,firmness inspection；器身绝缘距离、引线连接、出头屏蔽检查；Active part insulation dista

50、nce,lead connection,exit shield inspection；器身干燥处理检查；Active part drying inspection；安装尺寸及绝缘距离检查；Installation size,and insulation distance inspection；产品真空处理检查；Vacuum processing inspection；产品最终试验；Final testing。质量检验记录质量检验记录Quality inspection records 绝缘装配操作、检查记录；Insulation assembly operation and inspectio