This document outlines the metrics used to define and track defect levels during production, ensuring a standardized approach for assessing product quality at various stages of the manufacturing process.
Leading Through Quality Control
Strict Quality Control
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PairGears always prioritizes product quality, understanding that high-quality products are key to earning customer trust. Therefore, PairGears implements strict quality control measures at every stage to ensure that each product meets or even exceeds customer expectations.
Quality Management Documents
This diagram visually represents the relationship between defect levels and the development goals for production processes, providing clear targets for reducing defects and improving quality.
Diagram of Defect Level and Aims for Development
This report discusses the impact of operator performance on production quality, highlighting the need for consistent training and monitoring to ensure that human factors do not contribute to defects.
Dependence on Operator
This document details the process of tracking failures and discrepancies in production, with a focus on implementing corrective actions to prevent recurring issues and maintain high-quality standards.
Tracking Failures and Discrepencies Leads to Corrective Actions
This report explains the methods used for built-in gauging during the manufacturing process, ensuring real-time detection and correction of defects, and improving the overall process efficiency.
Gauging Built-In the Process
This document outlines the procedure for granting deviation permits when there are deviations in the manufacturing process or product specifications, ensuring that corrective actions are taken while maintaining product quality.
Deviation Permit for Manufacturing Process and Product Deviations
This document presents the Design Failure Mode and Effects Analysis (DFMEA) for identifying potential design flaws and assessing their impact on product performance, guiding improvements before production.
DFMEA
This document provides the Process Failure Mode and Effects Analysis (PFMEA) for evaluating potential risks in the manufacturing process, helping to mitigate failure modes and improve production quality.
PFMEA
This report includes the results from bench life tests conducted on prototypes and serial production units, assessing the durability and performance of the products over time to ensure reliability.
Bench Life Tests of Prototypes and Serial Production
This document presents the results of the Measurement Systems Analysis (MSA), evaluating the accuracy and precision of the measurement systems used in production, ensuring that they meet quality standards.
MSA Report
This inspection plan outlines the approved methods for measuring and testing equipment, ensuring that all tools used in production are calibrated and maintain accuracy for quality control.
Approved Inspection Plan of Equipments Measurement Ans Test Equipments
This plan defines the steps for maintaining quality control throughout the production process, detailing inspection, testing, and monitoring procedures to ensure consistent product quality.
Process Quality Control Plan
This form is used to document approved corrective actions following identified quality issues, ensuring proper tracking and resolution of defects to prevent recurrence.
Approved Form of Corrective Actions Report
This document outlines the company’s commitment to maintaining high-quality standards, detailing the principles and objectives for quality management and continuous improvement.
Quality Policy
This plan outlines the strategy for implementing and developing the Quality Management System (QMS), focusing on ensuring compliance with industry standards and enhancing operational efficiency.
Plan of Implementation and Development of QMS
This list includes all the testing and inspection equipment used in production, detailing the tools required for ensuring product quality and meeting regulatory standards.
Testing and Inspection Equipment List
This document contains the approved form for assessing suppliers of raw materials and components, ensuring they meet the required quality standards before being used in production.
Approved Form of Supplier(Raw materials and components) Assessment
This plan details the Advanced Product Quality Planning (APQP) process for new production development, outlining the steps for ensuring quality from the design phase through to production.
New Production Development Plan (APQP)
This document outlines the strategy for purchasing new equipment, ensuring that all equipment meets the requirements for improving production capabilities and maintaining high-quality standards.
Purchase of New Equipment Plan
Comprehensive Quality Management System
IATF 16949 Quality Management Standard
PairGears relies on the IATF 16949 quality management system, covering every stage from raw material procurement to production processing, process inspection, and final product inspection. Through comprehensive quality management, every step is ensured to meet stringent quality standards.
Advanced gear and test equipment
High-Precision Testing Equipment
PairGears is equipped with advanced gear and material testing equipment, including three-coordinate measuring machines, gear testing centers, material hardness testers, metallographic analyzers, and material spectrometers. These devices enable high-precision testing of products and materials, ensuring that every detail meets quality requirements.
Detailed Process Management
Strict Process Control
During production, PairGears implements strict process controls, with each process step meticulously recorded and closely monitored. By optimizing the process flow, production efficiency is improved while ensuring product consistency and stability.
Strict Perpendicularity testing standards
Shaft Perpendicularity Testing
After heat treatment, shafts may experience some bending deformation. Perpendicularity testing can promptly identify and correct bending phenomena, ensuring the accuracy and stability of transmission and extending the lifespan of gearboxes.
Strict hardness testing standards
Gear Hardness Testing
The gear is finished after the tooth shape machining, heat treatment is required to increase the surface hardness of the gears. The surface hardness must meet design requirements to ensure that the gears can withstand high loads and high-speed operation without deformation or surface wear. Hardness testing also helps optimize the heat treatment process, improving gear hardness and wear resistance, thus extending the service life of the gears.
Ensure quality meets design requirements
Metallographic Analysis of Gear Internal Materials
Metallographic analysis detects the uniformity of the internal structure of gears, identifying any defects or foreign materials, and evaluates the manufacturing process's conformity to ensure quality meets design requirements.
The results also provide reference data for gear design and heat treatment process optimization, aiding in the selection of materials, heat treatment parameters, and process flows to enhance gear performance and longevity.
Adhere to the principle of continuous improvement
Continuous Improvement and Optimization
PairGears adheres to the principle of continuous improvement, enhancing product quality through ongoing technological innovation and process optimization. Employees are encouraged to actively participate in quality improvement activities, collectively advancing the company's quality standards.
PairGears' quality control standards not only comply with the IATF 16949 international standard but also exceed the industry's general requirements. A detailed quality control manual has been established, which all employees must strictly follow, ensuring that every stage from design to production meets the highest standards.
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