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PCBA Nonconforming Product Control Procedure
1. Incoming Materials (Including Semi-Finished Goods) & RoHS Nonconformance Handling
1.1 IQC Rejection Procedure
When Incoming Quality Control (IQC) identifies nonconforming materials and rejects them, an Incoming Material Nonconforming Report must be completed.
Approval flow: Department Supervisor → Quality Manager → IQC issuance.
Distribution: One copy to PMC for warehouse return processing; one copy to Purchasing to notify the supplier, request root cause analysis, and corrective action.
Follow-up: Purchasing returns the supplier’s reply to IQC for record; IQC verifies quality in the next batch.
1.2 Conditional Acceptance (Deviation Approval)
If urgent production requires acceptance of nonconforming materials:
Purchasing applies for special acceptance within the nonconformance report.
Decision-making authority:
Appearance defects – Quality Department decides if standard relaxation or selective use is possible, with limit samples if needed.
Structural or performance defects – Engineering Department evaluates usage precautions or special treatments. If uncertain, the R&D Project Engineer makes the final call.
Approval: Joint signature from R&D, Engineering, Purchasing, and Quality; final approval by General Manager.
Labeling: IQC applies “Selected/Special Acceptance” tags with reasons noted; warehouse segregates accordingly.
1.3 Standard Rejection
Nonconforming items without special acceptance are returned to suppliers via Purchasing.
2. In-Process Nonconformance Handling
2.1 Immediate Isolation
Production lines must isolate and clearly label nonconforming items upon discovery.
2.2 Appearance Defects
If defect rate > 5%, IQC is notified; Quality Manager assesses severity, arranges material replacement or selective use, and checks warehouse stock.
Quality Abnormality Report is sent to suppliers for action.
If defect rate > 10% within one hour, QC may stop the line until corrective actions are validated.
2.3 Functional or Performance Defects
If defect rate > 3%, Engineering and R&D must confirm the issue, notify Quality, and arrange warehouse verification.
If defect rate > 5% within one hour, QC can stop production until corrective actions are approved.
2.4 Nonconforming Material from SMT, THT, Assembly, or Packaging
Production sends items to IQC for verification.
If confirmed as incoming defects, items are labeled, Return Material Form is completed, and defective stock is replaced after Quality approval.
Purchasing contacts suppliers for return/replacement.
3. In-Process Inspection Nonconformance
Nonconforming items are stored in designated areas; repair and test records are maintained.
IPQC issues Quality Abnormality Reports for process deviations, led by Engineering.
Rework follows the Rework Operation Procedure, with QC re-inspection and reporting.
Measurement instrument anomalies require product traceability, re-testing, and instrument calibration.
4. Finished Product Nonconformance Handling
Products failing Final Quality Control (FQC) are labeled, and Quality Abnormality Reports are issued for root cause analysis.
Overdue stock re-inspection failures are reworked until compliant.
Deviation Shipments:
Requires special release request with model, quantity, defect details, and risk assessment by Engineering/R&D.
Final approval by Quality Manager; customer consent needed if outside agreed standards.
5. Recurring Issues
Quality Department periodically convenes Production, Engineering, and R&D to review recurring defects, analyze from multiple dimensions (materials, design, tooling, process methods), and implement root cause corrective measures under the Recurring Issue Identification and Improvement Procedure.
6. Reliability Test Failures
If aging, environmental, drop, or vibration tests reveal > 3 identical failures or batch-level defects, production halts until validated corrective measures are implemented.
7. Customer Returns
Quality coordinates with relevant departments to handle nonconforming returned products per the Customer-Related Process Control Procedure.
8. HSF Nonconforming Product Recall
Triggers: Test agency noncompliance, or HSF-related safety/property damage.
Actions: Stop production, notify distributors, inform customers of affected products, and execute recall plans within set timelines.
9. Scrap Management
Material Scrap: Applied by Purchasing when confirmed unusable by R&D, expired and failed re-inspection, or defective from workshops. Requires GM approval.
Semi-Finished/Finished Scrap: Applied by Production due to design immaturity or operational/equipment failures. Approval by GM is mandatory.
10. CCC Nonconforming Product Control
Marking, isolation, and re-inspection after rework.
Collect data from audits, inspections, and complaints; analyze causes and prevent recurrence.
Notify certification bodies of any certified product quality issues.
11. Issuance of Quality Abnormality Reports
Based on nonconformance thresholds in incoming, in-process, or finished products, IPQC/FQC/Engineering issues reports for QE-led cause analysis and improvement tracking.
All reports are archived in the Quality Department.
12. Environmental & Audit Nonconformance
Nonconformance in environmental management is handled per laws, standards, and system documentation.
Internal/external audit findings must be corrected within defined timelines.
All corrective actions follow the Corrective and Preventive Action Procedure and Continuous Improvement Procedure.
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