Molds Management Operation Procedure
Rev.A Follow chart
Responsible Process Description
To provide reasonable control for operations such as mold development, purchasing, contract review, inspection/acceptance, payment application, safekeeping, maintenance, inventory check, transfer, scrapping.
2.1 Applies to all molds used in components designed and developed by the Company.
2.2 ODM molds.
4.1 Engineering department: Responsible for mold development, purchasing request and inspection/acceptance.
4.2 Injection department: Responsible for setting up file and managing molds.
Engineer dept. Managing director
New mold development Engineer dept.
Establishment of purchasing requirement Engineer dept. Supplier
Contact implementation Engineer dept.
Mold trial Tooling team
Injection dept. Mold preservation & maintenance Mold modification
Refer to 5.1 Refer to 5.2 Refer to 5.3 Refer to 5.4 Refer to 5.5
Refer to 5.6
Tooling team Supplier
5.1 New mold development
5.1.1 Engineer responsible for development of the production draws the product component diagram, fills in purchasing request, searches for qualified mold/fixture manufacturer if not appointed by customer and obtains quotation from at least two manufacturers.
5.1.2 Engineer-in-charge fills in content of quotation form in the “Purchasing Request” in accordance with “Purchasing Operation Procedure”, and submit to higher-ranking supervisor for review and approval.
5.1.3 The reopening of mold after the old mold becomes obsolete is carried out by purchasing in accordance with new mold opening process.
5.2 Establishment of purchasing requirement
5.2.1 To open a mold, a “Transaction Contract ”must be signed with a c ontract manufacturer. In accordance with contract content and other items agreed between both parties, and contract is then sent to manufacturer for official contract signing. The transaction contract is preserved by administration department.
5.2.2 Guaranteed life span of molds must be documented on the transaction contract.
5.3 Contact implementation
5.3.1 Supplier supply mold drwas to engineer dept. to confirm, engineer dept. manager review and approve of mold opening and require supplier returning complete date.
5.4 Mold trial
5.4.1 After completing mold, Engineering dept. and injection dept., which are responsible for mold trial.
5.4.2 After mold acceptance by engineering dept., engineering dept. sufills in "Mold Approve Form"with managing director signer and provides a duplicate copy to accounting, purchasing and supplier, at the same time obtains at least three signed samples to be placed separately with quality assurance department, injection department, supplier.
5.4.3 Engineer dept. is responsible for the management of "List of Molds".
5.5 Mold preservation & maintenance
5.5.1 Purchasing is responsible for supervising manufacturer in maintenance, repair and management of molds.
5.5.2 Purchasing and engineer dept. is responsible for the manage ment of “List of Molds”
5.5.3 With regards to repair of non-conformity during guaranteed life span of molds, manufacturer should notify purchasing, confirm the party responsible for such
non-conformity, and the party responsible will be in charge of completing the repair
5.5.4 When a mold reaches its guaranteed life span, or is no longer usable or produced, purchasing shall submit the “Fixed Asset Depreciation Form” to apply for scrapping before applying for new mold opening.
5.6 Mold modification
5.6.1 When asking to modify mold, sales unit shall coordinate with engineering, purchasing and quality assurance to verify its feasibility and sharing of repair cost. 5.6.2 During mold engineering change and other engineering changes, engineering department shall issue “Engineering Change Request”. If there is a need for modification or reopening of mold, engineering department shall first inform purchasing, then notify manufacturer to carry out mold modification or reopening. Acceptance, safekeeping and payment application are in accordance with 5.3, 5.4 and 5.6.3 Stipulations in 5.2 are followed if there is a need to re-establish transaction contract.
5.6.4 When there is a need to modify mold due to requirements of production efficiency or qualit y factors, the “Engineering Changes Operation Procedure” is followed.
Equipment Maintenance/Repair Operation Procedure
Responsible Process Description
To ensure that internal production equipment are functioning normally at all times so as to increase productivity and product quality.
Applies to regular maintenance and repair of production-related equipment in the Company’s factory. Includes all equipment listed in the list of equipment.
4. Authority/Responsibility ：
4.1 Administration dept. & Tooling team: Responsible for regular maintenance and repair of manufacturing unit’s equipment.
4.2 Using dept.: Responsible for executing daily maintenance for production-related equipment and responding to any abnormality in production equipment. Support Administration dept. & Tooling team in implementing regular maintenance when necessary.
5.1 Purchasing request, evaluation, purchasing and acceptance of machinery equipment are in accordance with “Purchasing Operation Procedure”.
5.2 Equipment purchasing and establishing maintenance record Within a month of completing equipment installation and test-run, Administration dept. & Tooling team should prepare “Machinery Equipment/Repair Record Card” according to equipment name, property number and main specification, and register in the “List of Machinery Equipment” for control purpose. Using dept. Daily maintenance Refer to 5.4
Repair maintenance Administration dept. Tooling team Equipment management regulations Administration dept. Tooling team Refer to 5.5 Refer to 5.6
5.3 Establishment of equipment operating specification and maintenance manual
5.3.1 Administration dept. & Tooling team should establish machine operation specification and maintenance manual in accordance with machinery equipment user manual or instruction.
5.3.2.The various levels of maintenance items must be established in the “Equipment's Maintenance Plan/Accomplish Record”.
5.4 Preventive maintenance (daily maintenance)
5.4.1 Maintenance content: Includes routine simple maintenance prior to use of machinery equipment, wiping and cleaning after use, and tidying of peripheral hardware.
5.4.2 Executing personnel: Operator fills in the"Equipment's Maintenance
Plan/Accomplish Record" and department supervises the execution status.
5.4.3 Maintenance cycle: Before/after machine use; or before/after work each day. 5.4.4 Maintenance procedure: Operator should conduct maintenance according to items listed in preventive maintenance. If an abnormality is found, repair should proceed according to equipment repair process.
5.5 Equipment repair
5.5.1 Operation content: Repair of accessories and parts of all listed machinery equipment.
5.5.2 Executing personnel:
(1) Operators should pay attention to any abnormal signs or sounds during work process. If any abnormality is found, shut off power supply and stop operation immediately, and request line leader to check.
(2) If equipment problem is verified, and production cannot be continued, immediately inform tooling team & administration dept., who then repairs or changes parts depending on actual situation. After repair, tooling team & administration dept. informs production department to continue operation, and fills in"Equipment Repair Record".
(3) If tooling team & administration dept. is unable to repair the equipment problem, external vendor may be contracted to carry out repair and the "Equipment Repair Record"should be filled in for filing purpose.
5.6 Machinery equipment management regulations
5.6.1 Whenever use of machinery equipment is stopped, it must be labeled with “Stop Use Status Chart” for identificat ion purpose. Stop-use equipment must be registered in the “List of Stop-use Equipment” for control purpose.
5.6.2 If machinery equipment that have reached end of life span or have not been used for more than a year fail to meet required precision level or damage cannot be repaired, upon assessment by Administration dept. & Tooling team, the machinery equipment is scrapped according to fixed assets management regulation and submitted for approval by the highest management.
5.6.3 To restore use of machinery equipment, it must first be maintained and its performance checked to confirm that it meets specification for normal use. Then, upon approval of Administration dept. & Tooling team, it may return to normal operation.
Fixtures/Tools Check Out Operation Procedure
Responsible Process Description
1.Purpose To provide effective control for fixtures/facilities used in the manufacturing process to ensure good management and maintenance in order to stabilize product quality, prolong life span of fixtures/facilities and maintain their accuracy.
Applies to all fixtures/facilities that self designed & developed or made outside.
Function testers for inspection or test fixtures and semi-manufactured/final products or assistant fixtures/facilities that assembled by quality-related parts are all included.
4.1 Engineer dept: Responsible for considering storage, inspecting function, resolving abnormality, delivering for repair and establishing recording cycle of regular check for fixtures/facilities that self designed and developed or made outside.
4.2 Using unit: Responsible for maintenance and reservation of fixtures/facilities
4.3 Quality assurance unit: Responsible for on-site audit for correct usage of test fixtures/facilities.
5.1 Management of fixtures/facilities(Making & List in“list of fixtures/tools”)
5.1.1 Fixtures/facilities using procedure shall be discussed with responsible unit and Using dept. Need of new fixtures/facilities
M aking & List in“list of fixtures/tools” Engineer dept. Regular maintenance inspection Using dept. Engineer dept. Refer to 5.1 Refer to 5.2 Repair of abnormal
problem Engineer dept. Refer to 5.3