成品不合格处理 Handling of non-conforming finished products

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标识与隔离

• 标识：一旦发现不合格成品，应立即采用醒目的标识牌、标签或涂色等方式，清晰地标明其不合格状态，确保在后续的处理过程中不会与合格产品混淆。
• 隔离：将不合格成品转移至专门的隔离区域进行存放，该区域应具有明确的界限和标识，防止不合格产品在未经授权的情况下被移动或使用
  

Identification and isolation
Identification: Once non-conforming products are found, they should be immediately marked with prominent signs, labels, or colors to clearly indicate their non-conforming status, ensuring that they will not be confused with qualified products in subsequent processing.
Isolation: Transfer non-conforming products to a dedicated isolation area for storage, which should have clear boundaries and markings to prevent unauthorized movement or use of non-conforming products

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原因调查

• 组建调查小组：由质量控制部门牵头，组织涉及生产、研发、采购等多个部门的专业人员，共同组成不合格原因调查小组。
• 收集相关数据：调查小组应全面收集与不合格成品相关的各种数据，如生产批次记录、原材料检验报告、生产过程中的工艺参数记录、成品检验报告等。
• 分析调查数据：运用适当的质量分析工具和方法，如鱼骨图、排列图、因果矩阵分析等，对收集到的数据进行深入细致的分析，从人、机、料、法、环、测等多个方面逐一排查可能导致成品不合格的原因。
  

Cause investigation

Establish an investigation team: Led by the quality control department, organize professionals from multiple departments including production, research and development, and procurement to jointly form a non conformance investigation team.
Collect relevant data: The investigation team should comprehensively collect various data related to non-conforming finished products, such as production batch records, raw material inspection reports, process parameter records during the production process, and finished product inspection reports.
Analyze survey data: Use appropriate quality analysis tools and methods, such as fishbone diagrams, Pareto charts, causal matrix analysis, etc., to conduct in-depth and detailed analysis of the collected data. From multiple aspects such as human, machine, material, method, environment, and measurement, investigate the possible reasons that may cause the finished product to be non-conforming one by one.

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处理决策

• 返工：对于一些通过重新加工或调整能够达到合格标准的不合格成品，可以考虑采取返工的处理方式。在确定返工方案时，需要充分评估返工过程对产品质量的潜在影响，确保返工后的产品能够满足规定的质量要求。
• 返修：当不合格成品存在某些缺陷，但通过修复能够使其满足预期的使用要求时，可以选择返修的处理方式。与返工不同，返修后的产品可能无法完全达到原有的质量标准，但只要其能够满足特定的使用目的和要求，就可以被接受。
• 报废：对于那些严重不符合质量标准，且无法通过返工、返修等方式使其达到合格状态或满足预期使用要求的不合格成品，应果断采取报废的处理方式，以防止这些不合格产品流入市场，对企业的声誉和消费者的权益造成损害。
• 让步接收：在某些特殊情况下，当不合格成品的缺陷对产品的性能、功能、安全性等方面的影响较小，且经过评估认为在不影响产品正常使用和满足客户基本需求的前提下，可以考虑采取让步接收的处理方式。
  

Handling decisions

Rework: For some non-conforming products that can meet the qualified standards through reprocessing or adjustment, rework can be considered as a processing method. When determining the rework plan, it is necessary to fully evaluate the potential impact of the rework process on product quality to ensure that the reworked product can meet the specified quality requirements.
Repair: When there are certain defects in the non-conforming product, but it can be repaired to meet the expected usage requirements, the repair method can be chosen. Unlike rework, the repaired product may not fully meet the original quality standards, but as long as it can meet specific usage purposes and requirements, it can be accepted.
Scrap: For non-conforming products that seriously do not meet quality standards and cannot be reworked, repaired, or meet expected usage requirements, a decisive scrap disposal method should be adopted to prevent these non-conforming products from entering the market and causing damage to the reputation of the enterprise and the rights and interests of consumers.
Concession acceptance: In certain special circumstances, when the defects of non-conforming products have a minor impact on the performance, functionality, safety, and other aspects of the product, and after evaluation, it is considered that concession acceptance can be adopted without affecting the normal use of the product and meeting the basic needs of customers.

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实施处理措施

• 制定处理计划：根据处理决策，制定详细的处理计划。计划应包括处理流程、责任部门和人员、时间安排以及所需的资源等。
• 执行处理措施：责任部门和人员按照处理计划，认真执行各项处理措施。在处理过程中，应严格遵守相关的操作规程和质量标准，确保处理效果。
• 监控处理过程：质量控制部门应对处理过程进行全程监控，定期检查处理进度和质量情况。如发现问题，应及时通知责任部门进行整改，确保处理过程顺利进行。
  

Implement handling measures

Develop a processing plan: Based on the processing decision, develop a detailed processing plan. The plan should include processing procedures, responsible departments and personnel, schedule, and required resources.
Execution of handling measures: Responsible departments and personnel shall conscientiously implement various handling measures according to the handling plan. During the processing, relevant operating procedures and quality standards should be strictly followed to ensure the effectiveness of the treatment.
Monitoring and processing process: The quality control department should monitor the entire processing process and regularly check the progress and quality of the processing. If any problems are found, the responsible department should be notified in a timely manner for rectification to ensure the smooth progress of the handling process

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效果验证

• 重新检验：对于经过返工、返修或其他处理措施的成品，应按照规定的检验标准和方法进行重新检验。检验项目应包括外观、尺寸、性能、功能等方面，确保成品质量符合要求。
• 稳定性测试：为验证处理后的成品在实际使用过程中的稳定性和可靠性，有必要进行稳定性测试。测试内容可以包括模拟实际使用环境、加速老化试验、耐久性测试等，通过对测试结果的分析和评估，确定成品是否能够满足长期稳定使用的要求。
  

Effect verification

Re inspection: For finished products that have undergone rework, repair, or other processing measures, they should be re inspected according to the prescribed inspection standards and methods. The inspection items should include aspects such as appearance, size, performance, and functionality to ensure that the quality of the finished product meets the requirements.
Stability testing: It is necessary to conduct stability testing to verify the stability and reliability of the processed finished product during actual use. The testing content can include simulating actual usage environments, accelerated aging tests, durability tests, etc. By analyzing and evaluating the test results, it is determined whether the finished product can meet the requirements for long-term stable use.

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预防措施

• 制定预防措施：针对不合格原因调查分析的结果，制定切实可行的预防措施，以避免类似不合格问题在今后的生产过程中再次发生。预防措施应具有针对性、可操作性和有效性，明确责任部门、人员和时间节点，确保措施能够得到有效落实。
• 实施预防措施：责任部门和人员按照预防措施计划的要求，认真组织实施各项预防措施。在实施过程中，应加强对措施执行情况的监督和检查，及时发现并解决遇到的问题，确保预防措施能够顺利推进并取得预期效果。
  

preventive measure

Develop preventive measures: Based on the investigation and analysis of the causes of non conformities, develop practical and feasible preventive measures to avoid similar non conformities from happening again in future production processes. Preventive measures should be targeted, operable, and effective, with clear responsibilities for departments, personnel, and timelines to ensure effective implementation.
Implementing preventive measures: Responsible departments and personnel shall conscientiously organize and implement various preventive measures in accordance with the requirements of the preventive measures plan. In the implementation process, it is necessary to strengthen the supervision and inspection of the implementation of measures, timely discover and solve problems encountered, and ensure that preventive measures can be smoothly promoted and achieve expected results.

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记录存档

• 记录内容：对成品不合格处理的全过程进行详细记录，内容应包括不合格成品的基本信息（如产品名称、型号规格、生产批次、数量等）、标识与隔离情况、原因调查分析过程及结果、处理决策内容、处理措施实施过程及相关数据、效果验证结果、预防措施制定与实施情况等。
• 存档管理：将记录资料进行分类整理，按照规定的存档要求和期限进行妥善保存。存档记录应便于查询和追溯，为企业在后续的生产经营活动中进行质量改进、风险管理、客户投诉处理等提供有力的证据支持和决策依据
  

Record and archive

Record content: Detailed records should be made of the entire process of handling non-conforming finished products, including basic information of the non-conforming products (such as product name, model specifications, production batch, quantity, etc.), identification and isolation situation, cause investigation and analysis process and results, handling decision content, implementation process of handling measures and related data, effectiveness verification results, and development and implementation of preventive measures.
Archive management: Classify and organize recorded materials, and properly store them according to the prescribed archive requirements and deadlines. Archival records should be easy to query and trace, providing strong evidence support and decision-making basis for enterprises to carry out quality improvement, risk management, customer complaint handling, etc. in subsequent production and operation activities