Incoming Material Check in Electronic Manufacturer

Single Sampling Plan MIL-STD-105D. Our material can be grouped into 3 groups : - Plastic resin, ink and paint for plastic injection process - Packaging Material - Electrical Parts We do to method for incoming materials check. - Skip lot material. Material that is grouped into this category do not need to be checked. The decision to group into skip lot is determined by QA Manager, based on Product Engineering Manager’s opinion. - Random Check We randomly check incoming material according to MIL-STD-105D Single Sampling Plan Level II, with AQL (Acceptance Quality Level): critical= 0, major= 1.0, minor= 2.5. AQL is determined by customer. Critical is related with safety. Critical= 0 mean all incoming materials must not have even single piece material defect in safety related matter. Major is related with functional and minor is related with cosmetic aspect. To determine sample size, please use Sample Size Code Letter, as follow :

Lets say our incoming material quantity is 3000 pieces. Because we use single plan level II, according to above table, sampling size code is K. According to below table, sampling size for K is 125 pieces.

Because AQL for major defect is 1.0, its mean that if we found maximum 3 pieces has major defect, this lot still can be accepted. But, if we found 4 pieces or more has major defect, this lot have to be rejected.

Quality Assurance Concept

In tough competition like these days, quality assurance is the main concern – beside price – in manufacturing business. Maintaining relationship with existing customer is the goal of quality, and it will be a best selling point for marketing team to find new customer. We must deliver more than expected products to maintain the relationship. Even though, do not make it over. Both sides must get benefit from the relation. Customer is a partner, not a king.

Our main current product is universal remote control, beside surge suppressor and wireless phone jack. In our top order period, we made more than 1.2M sets a month. Since our average manufacturing capability is around 5000 sets per production line per day, we have to run 12 ~ 13 lines to catch up the target. To maintain the quality of such quantity is not an easy process, but we do. We never had product returned sets since the beginning of factory operation (about 1992).

From beginning of operation we already implemented quality assurance process to ensure that our products always meet customer expectation, and if possible try to exceed. MIL-STD-105D is used for quality assurance process. Since 1996 we implemented. ISO9001:1994. This standard enhance in controlling product quality.

There are 3 stages quality check :
- Incoming Material Check :
After unloading raw material from container and before recorded as “ready to be used” material
- Inline Quality Check
Quality inspection in production line
- Outgoing Quality Check
Before shipping the products to customer.

We provide total solution for consumer electronic manufacturer. We provide plastic injection mould, surface part mounting and production line assembly. We are unique in raw material cycle. Raw material is supplied by customer and finished product is send to same customer. Business mapping for raw material process follows:

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Inline Quality Check is performed only for new product or if necessary

Quality Leadership Process – Fundamental Concept

• We must make Quality the number one priority in our business

• Top Management must totally commit to the process

• We must exceed our customer expectation for every product and service we provide • Quality is everyone’s responsibility

• We must build trust among ourselves, with our customer and with our suppliers

• We must change from problem reaction to problem prevention by doing every job right the first time

• We must create empowered organization that allows each of us the opportunity and freedom to constantly improve our work environment

• Training, resources and support must be provided to get the job done

• This is an on going process, not “just another program”

BUILDING TRUST THROUGH QUALITY