Quality Assurance System
LONG WAY ENTERPRISE CO., LTD is a typical family business owns by five (5) brothers established on 1975. It started by producting textile, gloves, shoes, cloth and some accessories for knitting cuff, elastic strap, belts and webbing which service thru Taiwan local supplier company. In 1977, as skateboard business begins to grows, Long way becomes interested to produce safety protective gear equipment wherein most of webbing is utilize. We import Velcro from Japan and USA as part for its components and design plastic parts for needs of the markers. As the demands for Velcro increase, Longway has become interested in the technology wherein research and development department was created for this purpose. In 1982, it was success and become the pioneer industry in Taiwan. In 1983, Velcro hook and loop) manufacturing was built up not only for our own safety gear used but as well the demand for both local and export worldwide market. In 1985-1988, high demands was turn into a completed “TURN KEY PROJECT” wherein machines and technology were sold to eight (8)companies. In 1983, Long way added another project to the manufacturing lines of Soccer Shin pads, vollyball, football pads and other related pads using most components of knitting materials, elastic webbing,hook and loop. In 1987, as a good results of Velcro Turn Key Projects, Long Way also invested in Real Estate business till 1990 with main projects on apartments and housing construction which is successful till the present. For Sports industry, due to high demand and its growing business, Taiwan manufacturing operation can’t fully service the demands due to high rate of labor shortage during year 1988-1989. In order to cope up the marker demand, Long Way has decided to make investment of operation in Shenzhen, China for advantage of low rate labor cost for pricing competitive for the market, Long Way was the first Taiwan company to set up for manufacturing operation of sporting gear products plant in China in 1989 by the same of Deyork limited and rental basis for 2 years till 1990. As sporting industry continues to grows, we then decided to design and construct our own factory and started operation of 1st plant in 1992 with service employees of 800. The 2nd plant was then decided to construct which started operation on 1993 and can accommodate 1,500 maximun employees. The Quality Assurance Plan was created in 1993 spring when the new plant started fully operation on manufacturing the complete sporting gear pads and protectors lines with applied patent accordingly. The company has also added another manufacturing lines in November,1992 producing Gummy Candies for China domestic market and has been successful too on this venture. Long Way had have been able to deal honestly and established long term relationships with well-known sporting companies worldwide and will still continues to grow. Our Research and Development team is working hand on hand with client’s high support for its quality design by producing good quality and competitive products. 1.1 Research & Development Department Introduction 1)Design Graphic Center Computer available if MAC and PC With well experience designers of more than 5 years and also with ability of prototype making Our China factory has also the same facilities 2)Pattern Maker Designer From this pattern computer, we’re able to: - Grade sizing - Calculate material yield consumption - BOM 3)Prototype Shop By sculptor type, we’re able to service any 2D or 3D drawing to model type within 4 to 14 days We have 4 sets of CNC machine at our shop in suburb about 15km from Long Way office. 4)Management Information System (MIS)) We created all datas based for our internal use both at office and for China factory 5)Graphic Film Developer Machine We create and develop graphic in our MAC and PC Computer stations. The film can be develop within an hour and explore the film for 1st sample discussion in house within 48 hours. We also use the same machine system in our China factory. 6)Film Explorer Machine and Color Spray Exploring the silk screen for first sample processing, color idea spray develop for first color proposal. We can change to any color with 1/2 to 1 1/2 hours. 7)Last Machines For servicing samples of our Skates Liner, shoes skate and shores lines. Our China factory also use the same equipments. 8)Shoes Pattern Maker Designer Most of samples required, we’re able to supply within 1 to 10 days for the first article 9)Sales Samples Assembling Line We have a sample assembling line for sales samples requirement located at Keelung, Taiwan (40 km from the office). Or processed the sales samples at China factory with our R&D teams heading the direction. Once sales samples approved, a guide book be established for the manufacturing and Q/C manual for guidelines which follows our quality assurance plan book established accordingly. 1.2 CNC Center Introduction 1)Location Located at Taipei suburb approximately 15 km from office ( 25 minutes by car) 2)Prototype Shop Possible to service any 2D drawing and converse to 3D model. 3)Facilities ?At present, has 4 sets of CNC specifications as follows: X Y Z A) 800 500 500 B) 800 450 500 C) 1000 500 700 D) 1400 700 700 E) Prototype copy mold of Japan made machine with European and Japanese materials. One prototype mold can produce 18 to 20 pcs with leadtime of: 1 – 3 pcs = 5 to 7 days 4 – 10 pcs = 7 to 12 days 11 - 18 pcs = 7 to 15 days ?At future by 1998, will add another machine of SCAN Digital. 4)Services We’re able to service the 3D model with CNC milling parts or SLA parts. SLA is not available in this facility but have the capacity to sub-contract it. For most clients software, we’re able to used the following: -Pro E, Cimatron, Master Cam, Cam Max and any IGES file for PC can be converse. Delivery leadtime with 3D file will take 3 to 7 days, with 2D file, will take 7-12 days. 2.0 PURPOSE 1)This quality Assurance Plan is based on “ISO 9003” Quality Assurance system 2)To describe the system, administration and process 3)How to control quality 4)To achieve customer’s expectations, etc…… 2.1 Incoming material control To get the vendors parts and semi-assembly to meet the needs of products ’ specification . Selecting the qualified materials to ensured consumer’s satisfaction at Longway’s products. 2.2 Purchase control Due to the purchased material, the quality, price and delivery has direct and indirect influences on the plant. So Longway should have a vendor’s QA. And inspection system for material purchasing. 2.2.1 Control Points To analyze the function of product’s components, materials and find ways to solve concerned problems . To coordinate with the vendors regarding their product quality, price and delivery . 2.2.2 Purpose Process 1)Survey – The purpose of survey is to see whether the vendor’s process capability and product quality meet Longway’s product specification. 2)Check – The results of survey are discussed and decided by the concerned section to select the vendors. 3)Sample approval – the production developer section provides the converned specification and engineering drawing to vendors for pilot run. After approved by Longway, materials will be ordered with same specification. 4)Coordination – It includes the purchase contract, negotiating process and other terms. 5)Incoming Material Control – To make data from incoming product quality and delivery for vendor’s evaluation. 6)Audit for source of material – To audit whether the material purchased by materials section and accepted by the I.Q.C are supplied by approved vendors. 2.3 Vendor’s Control and Assistance 2.3.1 Vendor’s Data Concentration and Management . 1) Longway’s Vendor Survey table 2) Sample Specification Sheet 2.3.2 For the purpose of assistance to vendors, Longway provides them with various necessary support for quality control system be established. 2.3.3 If product quality and delivery date are changed, the surveyor must take immediate actions. Every coordination record should be kept for follow-ups quality control survey table and must be submitted to QA manager. On the other hand, it can be regarded as a criteria of encouraging to select other vendors. 2.4 Vendor Quality Survey 2.4.1 Objective of Vendor Survey 1) To find our sources of supply of parts and materials 2) To evaluate and select vendors 3) To assist vendors on their product’s quality control 2.4.2 Object of Survey The major object of survey is the domestic direct vendors who supply mostly fabric, EVA foam, plastic parts, elastic knitting, Velcro, etc… 2.4.3 Surveyor – consists of engineer, quality controller and purchaser 2.4.4 Frequency of survey 1)First survey must be taken for new vendors 2)A survey must be taken at random of every 6 months or a year. Every new vendors must be surveyed at the beginning 3)If vendor’s product quality and delivery varies, immediate action is needed 2.4.5 Survey items 1) Quality Plan and Practice 2) Manufacturing Flow and Process Control 3) Transmission and Reservation for materials 4) Inspection and Operation Standard 5) Engineering Drawing and Data Processing 6) Incoming Material Control 7) Process Quality Control 8) Quality Assurance and Reliability 2.5 INSPECTION SPECIFICATION 2.5.1 Incoming Inspection Instruction According to the formal engineering drawing, int’l standard and other concerned specification. 2.5.2 Sampling Inspection Switching Procedure Standard 1)Inspection Level: MIL-STD-105D Level II, Sampling Plan 2)AQL: Per components quality plan, unless otherwise specified 0 Defect Safety / Reliability items 0.4 Measurement / Function items 1.5 Mechanic / Non-Function items 2.5 Appearance items Switching Procedure 1)Normal to tighten – when 2 out of 5 consecutive normal inspected lots has been rejected 2)Tighten to normal – when 5 consecutive normal inspected lots have been accepted 3)Normal to reduce – when 10 consecutive normal inspected lots have been accepted 4)Reduce to normal – any lot has been rejected during reduce inspection period or over 3% of major defects have been found out at in-process line 5)Reduce to non-audit – quality guarantee granted from vendor and approved by QA manager and keeping good records without any rejection as long as 6 months and total receiving of over 15 lots with no major defects at in-process lines 2.6 VENDOR RATING SYSTEM 2.6.1 Longway must evaluate each vendors monthly for their product quality and delivery. If they fail as required, Longway must assist them. 2.6.2 In order to encourage vendors to develop their product quality and delivery, rating and encouragement regulation has been made by Longway. The evaluation method regulation can be deveded into quality and delivery with respect to percentage as follows: 1) Quality: Percent defective 70% 2) Delivery: Accuracy 80% Vendors inspection record 20% Coordination 20% Coordination 10% 2.7 REVIE PRICEDURE In order to settle the unqualified incoming materials and to avoid loss from wrong review, the sample board had been established. The manager decides whether the lot is acceptable, sorting our or need re-work. Then, to submit the decision to plant manager for review . 2.8 DATE PROCESSING AND UTILIZATION Date processing consists of monthly report, vendor data card and inferior material report, etc… 2.8.1 Monthly Report: (1)Vendor Quality Situation Report According to their daily delivery and product quality situation, monthly statistical report is made and submitted to purchase section as criteria for vendors evaluation. (2)Vendor Rating Report According to the vendor rating and encouragement regulation, monthly evaluation is required. To calculate their satisfactory results, good vendors will be offer with short payment terms. 2.8.2 Vendor Quality History Card It is the card on which the lot inspected parts are recorded by the inspector for future Reference. 2.8.3 Inferior Material Report For the purpose of getting material improvement in future, an inferior material report Copy is sent to vendor to check its causes for necessary improvements. 3.0 IN-PROCESS CONTROL To control the product quality during manufacturing process with purpose to manufacture products in accordance with specification and to prevent any occurrence of defect products. The product quality can be assured as well can meet the need of consumers functional specification. 3.1 IN PROCESS CONTROL PROGRAM 3.1.1 Control Station According to carious steps of operation and inspection, Long way sets different department such as cutting, assembling, trimming, packaging on line and appoints inspectors to inspect during manufacturing process as well the sample. The main jobs of inspectors as follows: 1)Mechanical function test 2)Appearance and safety inspection 3)To make reasonable judgment and feedback 4)To make inspection record for process capability analysis 5)To assist manufacturing line for developing self-assurance work 3.1.2 Sampling Method – in order to assure quality of product assemble, we use the MIL-STD-105D sampling inspection Inspection Content – Visual and mechanical function inspection To consider the lot per day products as sampling lot The inspection standard is to use lever 2, AQL for QC sampling as follows: AQL CRITICAL MAJOR MINOR 0% 2.5% 4.0% Quantity to Quantity to be Maximum umber of Be shipped: checked at random: defect allowed: Major Minor 151 - 280 32 3 5 281 - 500 50 5 7 501 - 1,200 80 7 10 1,201- 3,200 126 10 14 3,201- 10,000 200 14 21 10,001- 35,000 315 21 21 35,001- 150,000 500 A)Regular standard quantity control B)For new products and quantity based – major quantity control 3.2 STANDARD OPERATING PROCEDURE Operation instruction is developed by technical section and finished by production section in accordance to the process and method, It also includes operating process and records. The necessary instrument must be hung up before every operator for standard operating procedures. 3.3 PATROL INSPECTION 1)Frequency – 2 times a day 2)Person in charge – QA Manager 3)Job content – to perform patrol inspection by focusing on quality key points of production process. To keep records according to check list. 3.4 DATE RECORDING AND UTILIZATION In order to make feedback system efficiently, every engineering station has inspection And test data classified and analysis by production and quality control section for improvement methods. The process control forms as follows: 1)Process Quality Report 2)Failure Analysis, corrected action and follow-ups 3)Sampling Inspection Report 4)History Card 5)Final Inspection Report 6)Patrol Inspection Record With the above methods, the products quality can be maintained as expected. 4.0 FINISHED GOODS CONTROL In order to expand international market and obtain continuous development, Long way controls the quality of finished goods to meet every customer’s specification and requirement. 4.1 INSPECTION PROCEDURE To assure the finished goods quality, their have three inspection methods to follow: 4.1.1 Total Inspection Long way takes 100% inspection of finished goods to assure quality before packing. All defective quantity must be returned to manufacturing section for re-checking. 4.1.2 Sampling Inspection For finished goods to be judged on it’s quality, inspectors must takes several test such as impact, tensile, peel and shear test, etc… 4.1.3 Detailed Inspection This inspection is applied to new develop items taken from production line. After judging the quality, the inspection result shall be transferred to concern section. 4.1.4 Out-Going Inspection Unless otherwise specified, the sample size which was accepted or any rejected quantity are selected in accordance with specification MIL-STD-105D, single sampling plan for normal inspection or general level-II. AQL CRITICAL MAJOR MINOR 0% 2.5% 4.0% Quantity to Quantity to be Maximum umber of Be shipped: checked at random: defect allowed: A B A B 151 - 280 32 64 2 3 281 - 500 50 100 2 3 501 - 1,200 80 160 3 4 1,201- 3,200 126 252 4 5 3,201- 10,000 200 400 6 8 10,001- 35,000 315 630 8 12 35,001- 150,000 500 1,000 11 18 4.2 INSPECTION SPECIFICATION According to the customer’s engineering and design specification and safety standard, Long way sets the finished goods inspection. 4.2.1 Inspection items 1) Mechanical function test 2) Visual inspection 3) Packing inspection 4.2.2 The practice and regulation before goods delivery: When finished goods are not qualified, it should be submitted to plant for decision. After re-work or re-inspection by manufacturing section, it is returned to QA for sampling inspection. 4.3 INSPECTION AND TEST RECORDS 4.3.1 Daily Report The inspector analyses the inspection record daily. This should use the final inspection to make statistics of defect rate and circumstances daily. This should be submitted for attention of the next day. 4.3.2 Monthly Report To arrange date and submit them to the concerned section monthly, Then to make options and prevention method for the last month’s product Quality. The date includes the followings: 1) Process Quality Situation 2) Finished Goods Quality 3) Test Report 4.3.3 Records are to be retained for a period of one year 1) Vendor Quality History Card 2) Final Inspection Record 3) Detailed Inspection Record 4) Sampling Inspection Record 5) Test Record 5.0 STORAGE AND SHIPPING CINTROL To provide secure storage and proper delivery, Longway arranges every quality product protection and proper identification after inspection. 5.1 STORAGE FINISHED GOODS IDENTIFICATION CARD 1) white card for 1-3 months storage goods 2) yellow card for 4-6 months storage goods 3) Red card for over 6 months storage goods 5.2 STORAGE FINISHED GOODS AUDIT In order to avoid any defective on storage goods, Longway sets storage finished goods regulations. 5.2.1 Storage Finished Goods Re-inspection 1)If finished goods have been stored for over3 months, the Qasection must be re-inspect master carton before shipping. 2)If finished goods have been stored for over 6 months, the QA section must be re-inspect them as a brand new lot before shipping. 5.2.2 Re0inspection Method 1)According to out-going inspection (AQL) 2)If product quality is regarded as defected as defect, the goods must be arranged for total re-inspection and re-work by production section. 5.3 STORAGE SECURITY INSPECTION To audit whether the anti-rob or anti-fire equipments are workable, all combustible goods are well stored in a safety place. 5.4 LOADING AUDIT To avoid product damaging in loading process and keep them in good condition, the warehouse personnel must put goods into container properly.

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