Recently, the company has been busy with customers in Japan about 3528 Blackboard 12V60led / m, 0.3m/pcs lights with related matters.Related members of the company benefit a lot, all aspects of the ability are obtained certain improvement.Because this product is not our normal standard,it should be paid more attention in all aspects of the production process.There are mainly two aspect problems about this series of products.One:the product appearance and packaging issues,such as lamps`local position is not flat after the lamp with a glue,glue omissions, light tape glue off late, terminal deviation, 3M glue wrinkling, omissions paste 3M adhesive and 3M adhesive tape bias, etc.Two:written documentation rigor and effective implementation issues .
Growing process
Phase I: Process Descriptions
After entering welding process, in the sub-plate process, after the separation of the FPC board,put each 0.5m long FPC board butt weld ends together and then cut the FPC board as 0.3m/pcs, good welding ends terminal, then go to the next step of gluing process,put every 0.3m light bar into a certain length (4.5m is that 15pcs0.3m lights are connected together with pins and sockets ),and then epoxy.In the process of packaging, we initially adopted black reel-static bag way to make light bar (4.5m) involved a black reel, and finally packing.
Phase II: continuous improvement
Compared with the first phase, it is mainly the welding process and packaging process improvements.After entering the welding process to separate FPC board, we connected the lamp into 4.8 m/PCS,processed terminals at both ends, and then into the test, the aging , injecting step.After glue curing is completed, the 4.8m/pcs lights will be cut into each 0.3m/pcs with a fixture ,then cut the 0.3m light both ends of the strip off 3.5 mm + / - 0.3 mm,and then welded on both ends of the corresponding terminal in the light `s both side.In the end, the ends of the terminal portion and ripped plastic parts covered with heat shrink tube, and finally into the packaging process.We have mainly adopted the dispersed packing way,tiled the light on the workbench,then smooth paste 3M adhesive tape on the back position of the soft light strip,and then draw off the tape with a blade,put each 1 PCS good light bar on a cardboard.Notice that between each light bar placed lights parallelly,avoid stacked between adjacent article lamp, there are 25PCS lights on each partition,a total of 8PCS partition (200PCS / box).After each film ,it required thin film with lights surfaces,protective colloid, and protection with pearl cotton inside the surround of the carton to avoid extrusion article lamp,and finally packing. As shown in figure:
Phase III: Continuous Improvement
Compared with the second phase, we mainly improve the packaging process,and use the pearl cotton to protect the terminal box, packaging as shown below:
Net Weught = 1.32kg / carton Gross Weight = 1.92kg / carton
Carton Size = 340mm * 240mm* 200mm
Phase IV : Mature
We mainly conduct a comprehensive improvement on the FPC board. Since before the FPC board is 8mm in width and length of each one is 0.5m, in the manufacturing process FPC board needs to be cut, and the terminal (pin Row) width is 10mm, and the row needle row mother is a four-fight, so we redesigned the FPC board.We change the FPC board into 10 mm wide and the length of 0.3 m,change the FPC welding plate into the four welding points, so that, in the welding process, welding directly to the ends of the FPC terminal, and when processing row needle row mother,we don't have to cut off all both sides of the needle into the potting process.In the potting process, it is no need to connect epoxy light bar,just tidy the flat strip into the fixture shop on glue.It can enter the packing process, The packing method is same with the third period, only the lights numbers are different in each box.
Through customer complaints case and process improvement we can accumulate some comments:
Carefully treat any problems feedback from customers:Details determine success or failure, even trivial things, we must treat and confirm carefully and patiently.
Follow-up and improvement: we should follow-up timely,listen to the views of others Open-mindedly ,treat and implement timely;
Solve the problem: all customers prefer a straight written report reply.Having clear simple and feasible solution will be ok. When customers have questions, we answer and fix it,just ensure the correctness of the content.If you need to verify the problem, we can tell them directly that the situation need to be verified before giving the reply;
The written documents:things through customers written acknowledgment information repeatedly and accurately shows the importance of written information .In a design or process changes, it must be rigorous and should inform the customer timely, we must make a written confirmation job with the customers! The expression of written document must be accurate, effective, practical operability and withstand scrutiny verification.