Comments on the production and quality control of

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Abstract: This paper introduces some details of implementing ISO, 5S and EPR to control powder production and quality, and the necessity of environmental protection control, as well as examples of production and quality control, in order to promote the healthy development of the industry

01 preface

powder coating, a new environmental protection coating project, has developed for more than 40 years since its birth in China in 1965

because of its "four e" (efficiency, energy saving, environmental friendly, excellent finishing) effects, coatings have developed very rapidly. The annual sales volume reached 910000 tons in 2010

there are numerous powder coating enterprises. However, the production and quality control capabilities of enterprises are uneven, especially small and medium-sized enterprises are relatively weak

this paper discusses the production and quality control of powder coatings based on the production habits and quality control characteristics of the powder industry

02 implementation of ISO management system

iso (International Organization for Standardization) is a World Federation composed of national standardization groups (ISO member groups)

iso9000 family and ISO14000 family standards are a series of standards on quality and environmental management issued by ISO. They are universal quality and environmental management system standards

it can select and combine several system elements according to the characteristics of the enterprise, and strengthen the quality management activities in the whole process of procurement, design and development, production, inspection, sales and use, And strengthen "green environmental protection" "Management activities. Institutionalization and standardization have become the requirements and activity procedures of the internal quality and environmental work of the enterprise.

among the powder coating production enterprises, many small and medium-sized enterprises have obtained ISO9001:2008 quality management system certification and ISO14001:2004 environmental management system certification.

however, a considerable number of enterprise certification is just a kind of business development needs, dealing with customers, and only staying in one At the level of formalism, it is not really implemented in the operation, and it does not benefit from the added value generated by the ISO management system in an all-round way. In fact, such certification has no practical significance

of course, many small and medium-sized enterprises have obtained ISO management system certification and fully implemented ISO management. For example, after the implementation of ISO management, the internal operation is standardized and the business continues to develop. So that enterprises in aluminum, electrical appliances, auto parts and other special fields to establish a specific customer base

in order to realize the sharing of resources and data throughout the city and improve enterprise management, it is also common for enterprises that have successively carried out the European "QUALICOAT" aluminum certification and the global green partner certification of Sony electric appliance. Our company has developed more special powders for auto parts, so the original ISO management system has been upgraded to iso/ts16949:2009

iso/ts16949:2009 "quality system - automotive suppliers - special requirements for the application of ISO9001:2008" was jointly drafted by the automotive industry departments of the United States, France, Germany and Britain, and jointly formulated by the National Automotive Federations (ANFIA, AIAG, CCFA, FIEV, SMMT and VDA) under the international automotive task force (IATF)

since iso/ts16949:2009 has included all the contents of ISO9001:2008, it is certified by iso/ts16949:2009, which also marks compliance with the ISO9001:2008 standard

iso standard is an internationally recognized conformity assessment system and a sign that enterprises meet the requirements of the quality management system. The implementation of ISO is the premise for enterprise management to be in line with international standards

03 the implementation of 5S on-site management method

5s originated in Japan, namely, sorting (Seiri), rectification (Seiton), cleaning (Seiso), cleaning (Seiketsu), and quality (Shitsuke), also known as the "five standing rules" or "five standing laws"

refers to the effective management of personnel, machines, materials, methods and other production factors at the production site, which is a unique management method of Japanese enterprises. The principle is as follows:

according to the needs of further development of enterprises, some enterprises have added safety on the basis of the original 5S, That is, "6S;

some enterprises have increased saving, forming" 7S "; some enterprises have added shiukanka, service and Shikoku, forming" 10s.

but everything changes, all from "Derived from 5S, such as sorting and recycling powder and cleaning up useless waste in sorting.

in some sense, this can involve saving and safety. More specifically, for example, the cleaning solvent discarded in the safety channel, which is the content that safety should pay attention to.

5s is the basis of on-site management, the premise of total production management (TPM), and total quality management (TQM) The first step is also the guarantee of the effective implementation of ISO

the effect of implementing ISO, TQM, TPM and other activities is hidden and long-term, and it is difficult to see significant effects at the moment, while the effect of 5S management activities is immediate

if 5S management is introduced in the implementation of ISO, TQM, TPM and other activities, significant results can be achieved in a short time. For example, by sorting and rectifying the sample materials and foundation materials, and making rational use of them in recent orders, we can see the benefits immediately

the details of management determine success or failure. Our logo is very clear. Even the sample material recycling in the laboratory is divided into five recycling barrels: "non recyclable", "indoor dark proofing material recycling", "indoor light proofing material recycling", "outdoor dark proofing material recycling" and "outdoor light proofing material recycling". The implementation of 5S site management method is the basis for the perfect integration of ISO and ERP

04 implementation of EPR

erp is the abbreviation of enterprise resource planning in English, that is, enterprise resource planning. It refers to a comprehensive and systematic management platform based on information technology and using the advanced management ideas of modern enterprises at the end of February this year, which comprehensively integrates all resource information of enterprises and provides enterprises with decision-making, planning, control and business performance evaluation

ERP system is not only a software management tool, but also a management idea and a management culture, which has become the operation mode of modern enterprises

Most of the contents of IS0 can be integrated into ERP system. ERP not only provides a scientific and efficient operation platform for IS0 quality system, but also can effectively solidify the implementation results of IS0, so that enterprises can fully enjoy the convenience and efficiency brought by informatization. The combination of the two can complement each other and multiply the effect

in the early stage of EPR implementation, a part of the existing procedure documents, work instructions or records certified by ISO can be incorporated into the corresponding constraints and controls to promote the implementation of EPR

according to the characteristics of powder enterprises, the inspection records, production formula, cost and loss accounting, finished products and raw materials in and out of the warehouse control

the processes and activities that can be completed by computer are integrated into the EPR system, and the report output format of each module of EPR is unified into the quality records required by ISO, forming an organic whole with mutual penetration at a certain range and level

when the engineer reviews the production formula sheet, he can know the batch number and inspection results of the inventory incoming materials through the company's ERP management platform, and can refer to the production formula of each batch in the formula database

after reviewing the incoming batch number and formula proportion of the production standard formula, enter the production order quantity, and the software system will automatically generate the production formula sheet, material issuance sheet, material staging sheet, quality control sheet and product labels, and print them out

then, the warehouse keeper can issue materials to the production workshop one by one according to the material issuance sheet according to the number of mixing tanks required for feeding according to the order quantity of this batch, and the engineer can modify the color according to the production formula sheet

after production, the system will automatically calculate the total feeding quantity, qualified products, unqualified products, loss rate and qualified rate of the order through the entry of relevant data

managers can clearly understand the stock in and stock out of raw materials and finished products on the software management platform, the production and quality of each order, as well as the product receipt rate of each machine. It can effectively control people, machines, materials, methods, environment and measurement in an all-round way

ERP is an advanced information technology of enterprises and a systematic management tool. The implementation of ERP is the logical link of the perfect integration of iso/5s/erp

05 environmental protection control

environmental protection control is a systematic project. It is far from enough to rely on the strength of an enterprise alone. We must require our supply chain to control together, so that environmental protection can be guaranteed

powder coating is a kind of chemical, so it is difficult to achieve food grade "environmental protection" in the full sense. It can only be "environmental protection" in the narrow sense, that is, it meets the requirements of environmental friendly regulations in relevant application fields

the common regulations for the environmental protection requirements of powder coatings are "ROHS standard", "toy standard", and for fiber core steel wire rope, if the jacketing method is used, remove the fiber core at the jacketing place, fill this section with steel core with the same strand diameter, and then jacketing "reach regulation", etc. it is worth noting that some customers leave room, and the requirements of enterprise standards are higher than these EU standards

rohs (restriction on the use of hazardous substances) is the EU Directive on the restriction of the use of certain hazardous substances in electrical and electronic equipment

regulations requiring powder coatings for electrical decoration and insulation protection to restrict the use of lead, mercury, cadmium, hexavalent chromium and PBB (polybrominated biphenyls) and PBDE (polybrominated diphenyl ethers) containing bromine compounds. The specific limit standards of harmful substances are shown in the table below:

regulations on the use of special powder coatings for the coating of toys and baby products to limit the content of eight heavy metals. That is, en formulated by the European Union: 1994+ A1:2000 toy safety standard -- Part 3: safety of toys - Part 3: migration of certain elements

it is similar to the American toy safety standard ASTM F. The specific limit standards for hazardous substances are shown in the table below:

reach (focusing on the registration, evaluation, authorization and restriction of chemicals), that is, the draft of the new chemical policies and regulations of the chemical registration, evaluation, authorization and restriction system launched by the European chemical Administration (ECHA)

as of December 19, 2011, the latest number of SVHC is 73. The European Chemicals Management Agency said that it would officially release the 7th batch of 13 SVHC at the official meeting in due time, and the SVHC list of reach regulation would reach 86 SVHC at that time. The list of SVHC is shown in the following table:

powder coating enterprises engaged in international trade business should be more rigorous in environmental protection control, because environmental protection laws and regulations vary in different countries and regions, and enterprises cannot bear the losses involved in environmental protection compensation

in terms of all the processes of product design, order receiving, production, shipment and quality management, relying solely on testing is not enough to ensure that the shipped products will never have problems

our control of environmental protection should be "three noes". That is, "no entry, no use, no issue". That is, the whole process control

first of all, "no entry" means that when purchasing raw materials, it is necessary to control the incoming materials containing harmful substances from entering the factory, that is, to grasp the environmental protection incoming materials

Copyright © 2011 JIN SHI