1 Introduction
As we all know, heat treatment is an important part of the mechanical manufacturing engineering by changing the material structure so that the mechanical parts or products obtain the required performance and ensure the safe and reliable use of the process. Because the quality characteristics of the heat treatment are not fully verified by subsequent inspections and tests, and the negative effects and economic losses caused by quality problems in the heat treatment are very large. Therefore, in the GB/T 19000 series of standards, the heat treatment is Being identified as a "special process", special measures need to be taken to implement quality control of all personnel, all-round, and entire processes. As the heat treatment equipment, personnel quality, parts technical requirements, production program, process technology and production management levels of various domestic companies vary, the special measures adopted to control the quality of parts or products also vary, and heat treatment has continuous production. The characteristics of the operation, therefore, to seek a quality control method in the production process, to meet and improve the quality of heat treatment parts, especially the mass production of parts quality is particularly important.
2. The main content of the quality control method of the production process
2.1 Transform the idea and concept of quality assurance model
In the past, our thoughts and concepts on quality assurance models and quality management priorities for heat-treated parts stayed in the traditional purely final inspections. We only focused on the quality results, did not put the key work on the control of quality formation, and eliminated heat treatment defects. In the process of quality formation, parts defects or missing inspections have occurred continuously, resulting in a certain quality loss. All kinds of personnel are busy with the processing of the parts' results every day. The result is that the busier and chaotic, the repetitive and low-level errors occur repeatedly, and the work is abnormally passive. We made painstaking efforts, summed up and learned lessons from failures, looked for and explored successful methods, and reconsidered and positioned the key tasks of quality management. By studying the relevant content of heat treatment standards and drawing lessons from successful heat treatment management company experience, it is clear that improving the quality of heat treatment must first change the ideas and concepts of various types of personnel on the quality assurance model. That is to say, the traditional passive inspection solely based on the final test will be transformed into prevention. Based on the quality assurance model of active control combined with prevention, inspection and inspection, we have established a clear responsibility, standardized management, strict rewards and penalties, and integrated professional technology, management technology, and scientific methods, as well as full participation, full process control, and overall management.†Three-pronged approach to process quality control management ideas and concepts. The results of several years of implementation show that the change of ideas and concepts is the core and key to the full and effective implementation of process quality control.
2.2 Strengthen "Four Managements"
(1) Implementation of enhanced heat treatment standards and regulatory management of control elements
Heat treatment is a special process of the production process. What are the elements of control in the whole process of production, what the employees should do, the specifications of what to do and the guidelines for doing better are the implementation and implementation of heat treatment standards in good faith. As a company that produces military products and foreign trade civilian products, we first organized heat treatment personnel in various stages to learn basic standards for heat treatment, quality control and inspection standards, process method standards, process material standards, safety, energy consumption, and environmental protection Standard related content. In the learning process, special emphasis and emphasis are placed on the control elements of the standards for the implementation of the standards of care and responsibility and the use of “hard power†to permeate control elements throughout every link of the heat treatment production process, permeate every detail, compare heat treatment standards, and The entire process of production is standardized in terms of machines, materials, materials, methods, and rings, and employees use “soft power†to train employees to implement the standards of integrity awareness and details, so that all types of personnel consciously and proactively control all factors affecting quality in the production process. Elements of the implementation of comprehensive, effective and standardized control. This not only reflects the effectiveness of the implementation of standards, but more importantly, the standardized management of control elements, enabling employees to understand and clarify the process requirements, identify and understand the characteristics of the process, use and master the process methods, and form an orderly and standardized Production order. Therefore, the implementation of intensified heat treatment standards and the standardized management of control elements are the basis and important measures for achieving process quality control methods.
(2) Strengthen the integrity and detailed management of various personnel in the production process
In addition to having different quality characteristics from their industries, heat treatment is also characterized by collective operations. Therefore, we re-recognized and positioned the role of integrity and detail in improving the quality assurance ability of the production process, to overcome the past simple and extensive management model or to avoid the ineffectiveness of a person due to lack of integrity and a small thing affect the team mood and product Quality, we use “Emotional Intelligence†to enhance employees’ loyalty and integrity in the production process, use “IQ†to stimulate employees' enthusiasm and potential to focus on the details of the production process, and cultivate employees to use the spirit of integrity and details to improve the cohesiveness of the production process team. The executive power of the system guides employees in learning to recognize and appreciate the merits of others, learn to respect and respect individual differences, and eliminate misunderstandings and disagreements through communication. At the same time, we studied and carried out the quality concept of “pursuit of excellence and qualityâ€, the concept of “supervising the processes, doing the process, and the process of serviceâ€. “For ourselves, for others, against the law, in addition to The concept of safety of hidden dangers and the ideological and political work concepts such as “Breathing in the rain, moistening things and keeping silent†and other corporate culture constructions have introduced the incentive mechanism based on “positive incentives†and the distribution mechanism of “enjoyable positions for talents and meritorious deedsâ€. Conducted speech contests with the theme of "Integrity in My Heart," "Details Determine Success or Failure", and "Without Execution, There is No Battle Ability". We conducted post training and skill contests, and selected "integrity employees" and "technical experts" in stages. . This not only reflects the normative management and rich and harmonious atmosphere of the management, but also embodies the team, has won the employees' understanding and support for the specification management and the detail requirements of integrity, and enables the employees to passively monitor various systems in the production process. Implementation has gradually become the conscious behavior of employees, and has increased the execution of process discipline and various management systems in the production process. In the production process, we will give you more guidance and control points and give us more explanations of possible problems and treatment methods. We will remind you more when there is a paralysis phenomenon, and we will be more concerned about the consequences of violating the process. Explain one point. All this we have done sincerely, patiently and meticulously to the employees, and we have got the employee's generous return on honest performance and attention to detail in the production process. Therefore, maintaining the normal order of the production process and strengthening the basic management requires the use of good faith as the cornerstone and details as the guarantee. Integrity and detail are the boosters to achieve quality control methods in the production process.
(3) Strengthen the production personnel and inspection personnel to jointly take charge of the monitoring and management of the production process
The implementation of the monitoring and management of the production process means monitoring and measuring the quality assurance capability of the production process. We will monitor and manage the production process by the past professionals responsible for the adjustment of production personnel and inspection personnel to jointly participate in and jointly responsible for the implementation of inspection and follow-up production system. For the proposed process plan and process specification, the process is confirmed by the technicians, production, inspection, and quality. The confirmation parameters and results are entered in the “Confirmation Sheet for Heat Treatment Processesâ€; the four-member personnel are assigned to the process review for the key-off process, and the process quality control points, control elements, control methods, inspection results, and monitoring responsibility are clarified. Achieve the first “three inspections†and the first batch of appraisal systems for batch parts; on the basis of process assessment for the parts with heavy parts and mass production, implement the principle of “Four Sets,†namely, “determining process, setting staff, setting equipment, setting "Process Quality Control Method", which instructs production personnel and inspectors to apply control charts, histograms, causality charts and other statistical techniques to analyze the production process and determine the quality of parts and production conditions in a timely manner. Give the inspectors an examination of the production staff training results and qualifications, confirm the uniformity of the furnace temperature of the heating equipment and the identification results of the temperature control instruments and the temperature control measurement system, and determine whether the process materials are subject to fixed-point supply, and whether they have the original certificate and The inspection of the incoming plant and the production process are carried out according to the requirements of the periodic inspection and the confirmation of the inspection results, clarifying that the inspectors have the right to stop all violations of the process discipline. The production personnel and inspectors jointly sign the monitoring results of the process parameters of the production process and the measurement results of the parts, and confirm that the parts are transferred to the next lane after confirming that they comply with the process specification. The implementation of production personnel and inspectors jointly responsible for the monitoring and management of the production process has greatly improved the responsibility and quality of work of producers and inspectors. As the main body of the production process monitoring and management, they improve the quality of parts, especially large batches of continuous production parts. Quality assurance ability has played a positive role in promoting.
(4) Strengthen the implementation record management of various quality raw data
The original records of process execution, equipment operation and conformity of production parts in the heat treatment production process are the sources of information for guaranteeing, improving and improving the quality, and the main basis for improving the responsibility of various personnel and determining the quality of work and quality traceability. In addition to adopting automatic paperless records for new and reconstructed equipment, we have designed the “Process Material Acceptance and Production Process Cycle Test Results Table†in accordance with the requirements of the standard, combined with production conditions and characteristics, “Temperature uniformity and measurement of furnaces. System cycle identification table ", high-speed steel metallurgical check conclusion table", "tool tooling production process of the original record", "product parts production process of the original record", "quality inspection results of the original record form", "heat treatment production process "Confirmation Form", "Customer Satisfaction Questionnaire Form", etc. Formal records of all types of personnel are carried out for intensive training, management evaluation methods for the production process specification records are formulated, and the requirements for standardization records, responsible persons, and various records are defined. Years of preservation, emphasis was placed on enhancing the authenticity, standardization, completeness, and timeliness of various parameter monitoring and measurement records that affect process capability.Process technology, production management, and quality management personnel randomly check and confirm compliance with various raw results. Sexuality, to propose corrective actions to correct non-standard, untimely phenomena in records , According to the management measures, strict assessment, the personnel who are not serious, unstandard, and untimely in the records of repeated records are recommended to transfer from the heat treatment jobs, implement the real-time management of various quality raw records, develop corrective and preventive measures, and analyze quality problems. Quality improvement decision-making and quality system auditing provide real and effective data support.
3. Effect of implementation
In recent years, the heat treatment production process quality control methods we applied have achieved significant economic benefits in terms of quality, safety, on-site management, corporate culture construction, promotion of employee quality, skill level, teamwork, and product competitiveness. Social benefits. The heat treatment passed IS09000 series standard certification and passed six consecutive years of review; the process yield has reached 99.99% for four consecutive years, 4.9% higher than the company's assessment index; 32 technical innovation and quality improvement projects have been completed, including 7 major projects The scope has improved the quality of products, opened a “green channel†for products to enter the international market, five projects have been awarded the first prize for outstanding achievements at provincial and ministerial levels, and a total of 3.64 million yuan has been saved and reduced for waste products. It is an excellent team and was named “National Outstanding Quality Management Team†by the All-China Federation of Trade Unions, the Central Committee of the Communist Youth League, the China Association for Science and Technology, and the China Quality Management Association, and was awarded the “May 1 Labor Certificate†by the Shanxi Provincial Labor Competition Committee.
4. Conclusion
The method of quality control of heat treatment process based on groping and summarizing is based on the criteria of heat treatment related standards, based on the principle of prevention, standard management, tackling from both the root causes and the overall improvement, from the person, machine, material, method, ring and other factors affecting the quality of the production process. The start of control, inspired the integrity of various types of personnel awareness and details of style, and enhance the team spirit and cooperation capabilities, improve the quality of production process assurance, and achieved significant quality and economic benefits.
As we all know, heat treatment is an important part of the mechanical manufacturing engineering by changing the material structure so that the mechanical parts or products obtain the required performance and ensure the safe and reliable use of the process. Because the quality characteristics of the heat treatment are not fully verified by subsequent inspections and tests, and the negative effects and economic losses caused by quality problems in the heat treatment are very large. Therefore, in the GB/T 19000 series of standards, the heat treatment is Being identified as a "special process", special measures need to be taken to implement quality control of all personnel, all-round, and entire processes. As the heat treatment equipment, personnel quality, parts technical requirements, production program, process technology and production management levels of various domestic companies vary, the special measures adopted to control the quality of parts or products also vary, and heat treatment has continuous production. The characteristics of the operation, therefore, to seek a quality control method in the production process, to meet and improve the quality of heat treatment parts, especially the mass production of parts quality is particularly important.
2. The main content of the quality control method of the production process
2.1 Transform the idea and concept of quality assurance model
In the past, our thoughts and concepts on quality assurance models and quality management priorities for heat-treated parts stayed in the traditional purely final inspections. We only focused on the quality results, did not put the key work on the control of quality formation, and eliminated heat treatment defects. In the process of quality formation, parts defects or missing inspections have occurred continuously, resulting in a certain quality loss. All kinds of personnel are busy with the processing of the parts' results every day. The result is that the busier and chaotic, the repetitive and low-level errors occur repeatedly, and the work is abnormally passive. We made painstaking efforts, summed up and learned lessons from failures, looked for and explored successful methods, and reconsidered and positioned the key tasks of quality management. By studying the relevant content of heat treatment standards and drawing lessons from successful heat treatment management company experience, it is clear that improving the quality of heat treatment must first change the ideas and concepts of various types of personnel on the quality assurance model. That is to say, the traditional passive inspection solely based on the final test will be transformed into prevention. Based on the quality assurance model of active control combined with prevention, inspection and inspection, we have established a clear responsibility, standardized management, strict rewards and penalties, and integrated professional technology, management technology, and scientific methods, as well as full participation, full process control, and overall management.†Three-pronged approach to process quality control management ideas and concepts. The results of several years of implementation show that the change of ideas and concepts is the core and key to the full and effective implementation of process quality control.
2.2 Strengthen "Four Managements"
(1) Implementation of enhanced heat treatment standards and regulatory management of control elements
Heat treatment is a special process of the production process. What are the elements of control in the whole process of production, what the employees should do, the specifications of what to do and the guidelines for doing better are the implementation and implementation of heat treatment standards in good faith. As a company that produces military products and foreign trade civilian products, we first organized heat treatment personnel in various stages to learn basic standards for heat treatment, quality control and inspection standards, process method standards, process material standards, safety, energy consumption, and environmental protection Standard related content. In the learning process, special emphasis and emphasis are placed on the control elements of the standards for the implementation of the standards of care and responsibility and the use of “hard power†to permeate control elements throughout every link of the heat treatment production process, permeate every detail, compare heat treatment standards, and The entire process of production is standardized in terms of machines, materials, materials, methods, and rings, and employees use “soft power†to train employees to implement the standards of integrity awareness and details, so that all types of personnel consciously and proactively control all factors affecting quality in the production process. Elements of the implementation of comprehensive, effective and standardized control. This not only reflects the effectiveness of the implementation of standards, but more importantly, the standardized management of control elements, enabling employees to understand and clarify the process requirements, identify and understand the characteristics of the process, use and master the process methods, and form an orderly and standardized Production order. Therefore, the implementation of intensified heat treatment standards and the standardized management of control elements are the basis and important measures for achieving process quality control methods.
(2) Strengthen the integrity and detailed management of various personnel in the production process
In addition to having different quality characteristics from their industries, heat treatment is also characterized by collective operations. Therefore, we re-recognized and positioned the role of integrity and detail in improving the quality assurance ability of the production process, to overcome the past simple and extensive management model or to avoid the ineffectiveness of a person due to lack of integrity and a small thing affect the team mood and product Quality, we use “Emotional Intelligence†to enhance employees’ loyalty and integrity in the production process, use “IQ†to stimulate employees' enthusiasm and potential to focus on the details of the production process, and cultivate employees to use the spirit of integrity and details to improve the cohesiveness of the production process team. The executive power of the system guides employees in learning to recognize and appreciate the merits of others, learn to respect and respect individual differences, and eliminate misunderstandings and disagreements through communication. At the same time, we studied and carried out the quality concept of “pursuit of excellence and qualityâ€, the concept of “supervising the processes, doing the process, and the process of serviceâ€. “For ourselves, for others, against the law, in addition to The concept of safety of hidden dangers and the ideological and political work concepts such as “Breathing in the rain, moistening things and keeping silent†and other corporate culture constructions have introduced the incentive mechanism based on “positive incentives†and the distribution mechanism of “enjoyable positions for talents and meritorious deedsâ€. Conducted speech contests with the theme of "Integrity in My Heart," "Details Determine Success or Failure", and "Without Execution, There is No Battle Ability". We conducted post training and skill contests, and selected "integrity employees" and "technical experts" in stages. . This not only reflects the normative management and rich and harmonious atmosphere of the management, but also embodies the team, has won the employees' understanding and support for the specification management and the detail requirements of integrity, and enables the employees to passively monitor various systems in the production process. Implementation has gradually become the conscious behavior of employees, and has increased the execution of process discipline and various management systems in the production process. In the production process, we will give you more guidance and control points and give us more explanations of possible problems and treatment methods. We will remind you more when there is a paralysis phenomenon, and we will be more concerned about the consequences of violating the process. Explain one point. All this we have done sincerely, patiently and meticulously to the employees, and we have got the employee's generous return on honest performance and attention to detail in the production process. Therefore, maintaining the normal order of the production process and strengthening the basic management requires the use of good faith as the cornerstone and details as the guarantee. Integrity and detail are the boosters to achieve quality control methods in the production process.
(3) Strengthen the production personnel and inspection personnel to jointly take charge of the monitoring and management of the production process
The implementation of the monitoring and management of the production process means monitoring and measuring the quality assurance capability of the production process. We will monitor and manage the production process by the past professionals responsible for the adjustment of production personnel and inspection personnel to jointly participate in and jointly responsible for the implementation of inspection and follow-up production system. For the proposed process plan and process specification, the process is confirmed by the technicians, production, inspection, and quality. The confirmation parameters and results are entered in the “Confirmation Sheet for Heat Treatment Processesâ€; the four-member personnel are assigned to the process review for the key-off process, and the process quality control points, control elements, control methods, inspection results, and monitoring responsibility are clarified. Achieve the first “three inspections†and the first batch of appraisal systems for batch parts; on the basis of process assessment for the parts with heavy parts and mass production, implement the principle of “Four Sets,†namely, “determining process, setting staff, setting equipment, setting "Process Quality Control Method", which instructs production personnel and inspectors to apply control charts, histograms, causality charts and other statistical techniques to analyze the production process and determine the quality of parts and production conditions in a timely manner. Give the inspectors an examination of the production staff training results and qualifications, confirm the uniformity of the furnace temperature of the heating equipment and the identification results of the temperature control instruments and the temperature control measurement system, and determine whether the process materials are subject to fixed-point supply, and whether they have the original certificate and The inspection of the incoming plant and the production process are carried out according to the requirements of the periodic inspection and the confirmation of the inspection results, clarifying that the inspectors have the right to stop all violations of the process discipline. The production personnel and inspectors jointly sign the monitoring results of the process parameters of the production process and the measurement results of the parts, and confirm that the parts are transferred to the next lane after confirming that they comply with the process specification. The implementation of production personnel and inspectors jointly responsible for the monitoring and management of the production process has greatly improved the responsibility and quality of work of producers and inspectors. As the main body of the production process monitoring and management, they improve the quality of parts, especially large batches of continuous production parts. Quality assurance ability has played a positive role in promoting.
(4) Strengthen the implementation record management of various quality raw data
The original records of process execution, equipment operation and conformity of production parts in the heat treatment production process are the sources of information for guaranteeing, improving and improving the quality, and the main basis for improving the responsibility of various personnel and determining the quality of work and quality traceability. In addition to adopting automatic paperless records for new and reconstructed equipment, we have designed the “Process Material Acceptance and Production Process Cycle Test Results Table†in accordance with the requirements of the standard, combined with production conditions and characteristics, “Temperature uniformity and measurement of furnaces. System cycle identification table ", high-speed steel metallurgical check conclusion table", "tool tooling production process of the original record", "product parts production process of the original record", "quality inspection results of the original record form", "heat treatment production process "Confirmation Form", "Customer Satisfaction Questionnaire Form", etc. Formal records of all types of personnel are carried out for intensive training, management evaluation methods for the production process specification records are formulated, and the requirements for standardization records, responsible persons, and various records are defined. Years of preservation, emphasis was placed on enhancing the authenticity, standardization, completeness, and timeliness of various parameter monitoring and measurement records that affect process capability.Process technology, production management, and quality management personnel randomly check and confirm compliance with various raw results. Sexuality, to propose corrective actions to correct non-standard, untimely phenomena in records , According to the management measures, strict assessment, the personnel who are not serious, unstandard, and untimely in the records of repeated records are recommended to transfer from the heat treatment jobs, implement the real-time management of various quality raw records, develop corrective and preventive measures, and analyze quality problems. Quality improvement decision-making and quality system auditing provide real and effective data support.
3. Effect of implementation
In recent years, the heat treatment production process quality control methods we applied have achieved significant economic benefits in terms of quality, safety, on-site management, corporate culture construction, promotion of employee quality, skill level, teamwork, and product competitiveness. Social benefits. The heat treatment passed IS09000 series standard certification and passed six consecutive years of review; the process yield has reached 99.99% for four consecutive years, 4.9% higher than the company's assessment index; 32 technical innovation and quality improvement projects have been completed, including 7 major projects The scope has improved the quality of products, opened a “green channel†for products to enter the international market, five projects have been awarded the first prize for outstanding achievements at provincial and ministerial levels, and a total of 3.64 million yuan has been saved and reduced for waste products. It is an excellent team and was named “National Outstanding Quality Management Team†by the All-China Federation of Trade Unions, the Central Committee of the Communist Youth League, the China Association for Science and Technology, and the China Quality Management Association, and was awarded the “May 1 Labor Certificate†by the Shanxi Provincial Labor Competition Committee.
4. Conclusion
The method of quality control of heat treatment process based on groping and summarizing is based on the criteria of heat treatment related standards, based on the principle of prevention, standard management, tackling from both the root causes and the overall improvement, from the person, machine, material, method, ring and other factors affecting the quality of the production process. The start of control, inspired the integrity of various types of personnel awareness and details of style, and enhance the team spirit and cooperation capabilities, improve the quality of production process assurance, and achieved significant quality and economic benefits.