As we all know, heat treatment is an important part of mechanical manufacturing engineering by changing the material organization to obtain the required performance of mechanical parts or products and ensure the use of safe and reliable processes. Because the quality characteristics of heat treatment are that the results cannot be fully verified by subsequent inspections and tests, and the negative effects and economic losses caused by quality problems in heat treatment are great, in the GB/T19000 series of standards, heat treatment is To be recognized as a “special process”, special measures need to be taken to implement a full, comprehensive, and full-process quality control.
Due to the differences in heat treatment equipment, personnel quality, parts technical requirements, production guidelines, process technology and production management levels of domestic enterprises, there are differences in the special measures adopted to control the quality of parts or products, and heat treatment has continuous production. The characteristics of the operation, therefore, it is very important to seek a quality control method in the production process to meet and improve the quality of heat-treated parts, especially mass-produced parts.
2 The main content of the quality control method of the production process
2.1 Change the ideas and concepts of quality assurance model
In the past, our thoughts and concepts on the quality assurance model and quality management focus of heat-treated parts remained in the tradition of relying solely on the final inspection, focusing only on quality results, and not focusing on the control of quality formation and eliminating heat treatment defects. In the process of quality formation, there have been parts defects or missed inspections, causing certain quality losses.
All kinds of personnel are busy processing the results of the parts every day, the result is that the busier the more chaotic, repetitive and low-level errors occur repeatedly, and the work is abnormally passive. We learned from the pain, calmly summarized and learned the lessons of failure, looked for and explored successful methods, and re-understood and positioned the key tasks of quality management. Through learning the relevant content of heat treatment standards and learning from the experience of successful heat treatment management companies, it is clear that improving the quality of heat treatment must first change the thinking and concepts of various personnel on the quality assurance mode.
That is to say, the traditional passive check by the final inspection is transformed into a prevention Mainly, the quality assurance model of active control that combines prevention and inspection has established clear responsibilities, standardized management, strict rewards and punishments, and unified professional technology, management technology, and scientific methods, as well as full participation, full process control, and comprehensive management. Three-pronged approach” process quality control management ideas and concepts. The results of several years of implementation show that the change of thinking and concept is the core and key to the comprehensive and effective implementation of process quality control.
2.2 Strengthen the “Four Managements”
(1) Strengthen the implementation of heat treatment standards and regulatory management of control elements
As a special process in the production process, heat treatment is a special process in the production process. What are the factors to be controlled in the whole production process, what employees should do, how to do it, and the code of conduct to do better is to sincerely implement and implement the heat treatment standard.
As an enterprise that produces military products and foreign trade civilian products, we first organized all kinds of heat treatment personnel in stages, and learned basic heat treatment standards, quality control and inspection standards, process method standards, process material standards, safety, energy consumption and environmental protection according to standard categories. Standard related content.
During the learning process, special emphasis was placed on the control elements of intention and responsibility integrity performance standards, and “hard power” was used to permeate the control elements through every link in the implementation of the heat treatment production process, infiltrating every detail, and comparing the heat treatment standards, from people Regulate the whole process of production in terms of equipment, machine, material, law, environment, etc., use “soft power” to cultivate staff’s sense of integrity and detail style in implementing standards, so that all kinds of personnel can consciously control all quality factors in the production process.
The element content implements comprehensive, effective and standardized control. This not only reflects the effectiveness of the implementation of standards, but more importantly is the standardized management of control elements, enabling employees to understand and clarify process requirements, identify and understand process characteristics, use and master process methods, and form an orderly and standardized Production order. Therefore, strengthening the implementation of heat treatment standards and standardized management of control elements are the basis and important measures for achieving process quality control methods.
(2) Strengthen the integrity and detail management of various personnel in the production process
In addition to the different quality characteristics of the heat treatment industry, it also shows that the production characteristics are collective operations. Therefore, we have re-understood and positioned the role of integrity and details in improving the quality assurance ability of the production process, in order to overcome the simple and extensive management model in the past or avoid the lack of integrity and a small thing done by one person to affect the team’s mood and products. Quality,
we use “Emotional Quotient” to enhance the loyalty and integrity of employees in the production process, use “IQ” to stimulate employees’ enthusiasm and potential to pay attention to the details of the production process, and cultivate employees to improve the cohesion and cohesion of the production process team with the spirit of integrity and detailed style. The execution of the system guides employees to learn to tolerate and respect individual differences when acknowledging and appreciating the advantages of others, and eliminate misunderstandings and differences through communication.
At the same time, we have introduced the quality concept of “pursuing excellence and creating high-quality products”, the post concept of “supervising the upper process, doing this process well, and serving the next process”, “for ourselves, for others, against violation of regulations, except The construction of corporate culture such as the safety concept of “hidden danger” and the concept of ideological and political work of “spring wind and rain, moisturizing things silently” has introduced an incentive mechanism mainly based on “positive incentives” and a distribution mechanism of “the capable and meritorious”.
Conducted speech contests on the themes of “Integrity is in my heart”, “Details determine success or failure”, and “If there is no execution, there is no combat effectiveness”, and launched a job training and skill contest, and selected “integrity employees” and “technical experts” in stages. .
This not only reflects the standardization of management and a strong harmonious atmosphere, but also unites the team, wins the understanding and support of employees for the requirements of standardized management and integrity details, and enables employees to pass the various systems from the beginning under supervision during the production process. Execution has gradually become the conscious behavior of employees, which has improved the execution of production process discipline and various management systems. In the production process, we give you more guidance on the control elements and know-how, give you more explanations of possible problems and treatment methods, and remind you more when there is paralysis, and show you more consequences for the violation of the process. Explain a little.
All of our sincere, patient and meticulous dedication to employees has been rewarded by employees for their honest performance and attention to detail in the production process. Therefore, to maintain the normal order of the production process and strengthen the basic management, it is necessary to use honesty as the cornerstone and details as guarantees. Honesty and details are the boosters for realizing the quality control method of the production process.
(3) Strengthen production personnel and inspection personnel to be jointly responsible for the monitoring and management of the production process
To implement the monitoring and management of the production process is to monitor and measure the quality assurance ability of the production process. We adjust the monitoring and management of the production process from the responsibility of the past professionals to the joint participation and responsibility of production personnel and inspection personnel, and implement the inspection and follow-up production system.
The four aspects of technology, production, inspection, and quality personnel jointly conduct process confirmation for the proposed process plan and process regulations. Fill in the confirmation parameters and results in the “Heat Treatment Process Confirmation Sheet”; organize the key processes by four personnel to conduct process reviews, clarify the key process quality control points, control elements, control methods, inspection results and monitoring responsible persons.
Realize the first “three inspections” and batch parts first batch appraisal system; on the basis of process review for critical parts and mass-produced parts, the “four determinations” principle is implemented, that is, “design process, personnel, equipment, and Process quality control methods” guide production personnel and inspectors to analyze the production process using statistical techniques such as control charts, histograms, and cause-effect diagrams to determine the quality of parts and production conditions in a timely manner.
Inspectors are given the review of the training results and qualifications of the production personnel, the confirmation of the uniformity of the heating equipment furnace temperature and the verification results of the temperature control instrument, the temperature control measurement system, whether the process materials are supplied at a fixed point, whether they have the original certificate and The inspection and acceptance of the factory and the confirmation of the inspection results are carried out in accordance with the requirements during the production process.
It is clear that the inspectors have the right to stop all behaviors that violate the process discipline. The production personnel and the inspection personnel jointly sign the monitoring results of the process parameters of the production process and the measurement conclusions of the parts, and the parts can be transferred to the next channel after confirming that they meet the process regulations. The implemented production personnel and inspectors are jointly responsible for the monitoring and management of the production process, which greatly improves the sense of responsibility and work quality of the producers and inspectors.
As the main body of the monitoring and management of the production process, they are effective in improving parts, especially mass-produced parts. Quality assurance capabilities have played a positive role in promoting.
(4) Strengthen the implementation record management of various quality raw data
The original records of the process implementation of the heat treatment production process, the equipment operation status and the conformity of the production parts are the source of information to ensure, improve and improve the quality, and are the main basis for improving the sense of responsibility of various personnel, determining the quality of work and quality traceability.
In addition to adopting automatic paperless records for new and retrofitted equipment, we have designed a “process material entry acceptance and production process cycle inspection result table” according to the requirements of the standard, combined with production conditions and characteristics, and “furnace temperature uniformity and measurement System Cycle Appraisal Form “,
Metallographic Inspection Conclusion Form before High Speed Steel Furnace”, “Tools and Tooling Production Process Original Record Form”, “Product Parts Production Process Original Record Form”, “Quality Inspection Results Original Record Form”, “Heat Treatment Production Process Forms such as “Confirmation Sheet”, “Customer Satisfaction Survey Form” and other forms. Intensified training for various types of personnel to implement normative records, formulated management and assessment methods for normative records of production processes, and clarified the requirements of normative records, responsible persons and various records Retention period. Emphasis has been placed on the authenticity, standardization, completeness and timeliness of various parameter monitoring and measurement records that affect process capabilities.
Process technology, production management and quality management personnel randomly check and confirm compliance with various original results Corrective measures are proposed to improve the irregularities and untimely phenomena in the records, and strictly assessed in accordance with the management methods.
For those who are not serious, irregular and untimely recorded repeatedly, they are recommended to be transferred from the heat treatment work position. The real-time management of various quality original records provides real and effective data support for the formulation of corrective and preventive measures, quality problem analysis, quality improvement decisions and quality system audits.
3 implementation effect
In recent years, the heat treatment production process quality control methods that we have applied have achieved significant economic benefits in terms of quality, safety, site management, corporate culture construction, improvement of staff quality, skill level and teamwork ability, and product competitiveness. Social benefits. Heat treatment passed the IS09000 series standard certification and passed the re-examination for six consecutive years; the process yield rate has reached 99.99% for four consecutive years, which is 4.9% higher than the company’s assessment index;
32 technological innovation and quality improvement projects have been completed, of which 7 key research projects are large This greatly improved product quality and opened a “green channel” for products to enter the international market. Five key research projects were awarded first prizes for outstanding achievements at the provincial and ministerial levels, saving and reducing waste losses totaled 3.64 million yuan, and were repeatedly evaluated It is an outstanding team, and was named “National Quality Management Excellent Team” by the National Federation of Trade Unions, the Central Committee of the Communist Youth League, China Association for Science and Technology, and China Quality Management Association. It was awarded the “May 1st Labor Award” by the Shanxi Provincial Labor Competition Committee.
The quality control method of the heat treatment process explored and summarized is based on the relevant standards of heat treatment, based on the principles of prevention, standardized management, both symptoms and root causes, and overall improvement. It affects the quality of the production process from human, machine, material, method, and environment. Starting with the control, it has stimulated all kinds of personnel’s sense of integrity and detail style, enhanced team spirit and cooperation ability, improved the quality assurance ability of the production process, and achieved obvious quality effects and economic benefits.