品质管理 - 华客精密科技

Quality Control Process

Strictly enforce 6S standards for end-to-end quality control, from injection molding to part machining.

Plastic Mold Quality Control Process

Design Review

Use Moldflow for mold flow analysis to optimize gate location, runner balancing, and cooling line design. Evaluate risks of sink marks, warpage, and weld lines; confirm parting line, core-pull mechanisms, and ejection system. Generate a DFM report for customer approval to prevent design defects.

Material Inspection

Mold steel (P20, 718H, S136, NAK80) undergoes hardness testing (HRC 30-54), ultrasonic flaw detection for internal defects, and spectrometer verification of material composition prior to warehousing. All materials must comply with DIN/ASSAB standards; non-conforming stock is immediately returned to the supplier.

Process Monitoring

Verify stock uniformity after CNC rough machining. Measure cavity dimensions using a CMM for precision (±0.01mm). Monitor EDM electrode wear (inspect every 1mm of machining). Ensure wire-cut EDM accuracy within ±0.003mm and surface roughness Ra0.2-0.8.

Injection Molding Production Quality Control Process

Incoming Quality Inspection

Strictly inspect batches of raw materials such as ABS, PC, PP, and PA. Test melt flow index for fluidity and moisture content using a moisture analyzer. Verify that material grade and physical properties comply with ISO standards. Immediately quarantine and return any non-conforming batches.

First Article Inspection

Perform first-article inspection before each production batch. Measure critical dimensions using a coordinate measuring machine (CMM) with accuracy ±0.01mm, visually inspect for cosmetic defects (sink marks, flash, weld lines), and conduct assembly testing to verify fitment. Mass production may commence only after passing all checks.

Process Inspection

Every 2 hours, quality inspectors perform spot checks on critical dimensions and surface finish. Injection molding parameters (temperature, pressure, cycle time) are monitored in real-time, with SPC control charts recorded. Any anomalies trigger immediate machine stoppage and adjustment to ensure a process capability index (CPK) of ≥1.33.

Part Manufacturing Quality Control Process

Drawing Review

The engineering team performs DFM analysis on customer drawings, evaluating tolerance grades (IT6-IT7), surface roughness (Ra 0.8-3.2), and material machinability. Using UG/CAD software for process simulation, they confirm manufacturability and issue a review report.

Process Orchestration

The process engineer defines a detailed machining route (roughing → semi-finishing → finishing), selects appropriate tooling (carbide, ceramic inserts), sets cutting parameters (spindle speed, feed rate, depth of cut), generates CNC programs using CAM software, and performs simulation to prevent collisions.

First Article Trial Cut

After completing the first article, measure critical dimensions using a CMM (tolerance ±0.005mm), check profile with a projector, assess surface quality with a roughness tester, and verify material properties with a hardness tester. Mass production may only proceed after all checks pass. Retain the first article as a reference standard.