Talent promotes enterprise, quality wins, quality is life, products represent character, and quality is the key factor of enterprise life and death. Establishing, implementing and maintaining an effective quality management system in strict accordance with the ISO900 1:2008 standard and continuous improvement are the keys for enterprises to maintain long-term prosperity. Focusing on the six elements of "human, machine, material, law, environment and measurement", we will continue to promote enterprise quality management, strengthen the inspection and monitoring mechanism, and strengthen the education of quality management awareness of all employees in the enterprise, so that the enterprise can move forward to a modern enterprise with higher management level, higher work efficiency, higher high-tech content, higher added value, low consumption, no pollution and information construction.
I. Basic policies and requirements
(a) the performance of enterprise products can meet the satisfaction and requirements of customers in a short time, and the products returned by customers due to quality problems must be solved within this year.
(2) Adhere to the quality tenet and quality direction of "profit on both sides, responsibility in the middle, quality is life and customers are God".
Second, establish a complete quality assurance system.
1, compile and improve various welding quality management systems (methods)
(1) operator training assessment and qualification examination methods.
(2) Welding process preparation and approval methods.
(4) Acceptance, storage, drying and delivery system of welding materials.
(5) Welding equipment management system.
⑥ Measures for the management of product sample making.
⑦ Management system of welding heat treatment.
⑧ Welding repair management system.
Pet-name ruby welding inspection system.
Third, the quality assurance system construction and operation mode
1. Organization: set up a quality management office (total quality office for short) and appoint management representatives.
2. Design control: The correct design of welded structure is one of the most basic conditions for obtaining high-quality structure, so special attention should be paid to design review. Special attention should be paid to material selection, material matching, joint position and overall size, groove shape and size, and requirements for joints.
3. Purchasing documents: The purchasing department must purchase in strict accordance with the purchasing technical documents.
4. Control of purchased parts: All purchased welding materials and welding equipment must have qualified certificates, quality certificates and quality inspection reports.
5, material identification and control:
(1) structural materials must be marked and transplanted according to specified procedures after being cut;
(2) Welding materials shall clearly indicate the brand or model and its specifications;
(3) Strictly abide by the sending and receiving system to ensure that the physical objects are consistent with the identification.
6. Control of special technological process: The machining process which has an important influence on welding quality, many technological parameters and complicated changes is taken as the control of special technological process.
7. Control and treatment of nonconforming products: minimize and recover economic losses, and carry out three levels of treatment: direct recovery, repair recovery and scrapping.
8. Quality cost: According to the annual plan and the quality problems existing in the previous year, make a quality improvement plan and take quality improvement measures to reach the quality target within a time limit. When making improvement measures, we should follow the principle of economy, that is, under the condition that the quality meets the contract requirements or the corresponding national standards, starting from the actual situation of the enterprise, taking the principle of reducing production costs and improving economic benefits as the principle, adopting the most economical manufacturing method.
Four, the establishment and improvement of quality assurance system
1, all levels of quality assurance institutions and quality control personnel engaged in quality control are complete.
① Quality assurance engineer (one person). Entrusted and authorized by the general manager, the highest person in charge of quality assurance is the highest administrative leader of the Total Quality Office. In addition to the direct leadership of the organization and management personnel, the quality leaders scattered in other departments should also be under the jurisdiction of the quality assurance engineer.
② Person in charge of material quality (one person).
③ Process quality supervisor (1 person).
④ Welding quality supervisor (1 person).
⑤ Quality inspector (1 person).
⑥ Inspector (two persons)
2, the symbol of the normal operation of the quality assurance system
(1) Personnel at all levels must work normally at their posts and have continuous work records.
② The original records of technical quality control in the product manufacturing process are complete, the signing procedures are complete, and the contents are true and reliable.
(3) The quality information circulation channels are smooth, the quality problems are handled in time, and the handling methods and procedures meet the requirements.
(4) the quality inspection department timely reports quality information and quality problems to the top management or management representative, and transmits them to relevant functional departments.
⑤ Implement the quality responsibility system. Keep your promise, and those who win for a long time will be rewarded.
⑥ Hold regular quality analysis meetings to continuously improve product quality.
⑦ Make the operation chart of quality management organization.
3, product maintenance and scrap
(1) If the user returns the goods, it is necessary to distinguish the responsibilities and make original records, including the reasons for the parts, the required expenses and the implementation methods.
② On-site maintenance: whoever builds it will repair it, and make records and signatures, and the required expenses.
(3) Scrapping: Scrapped products can only take effect after being signed by the quality assurance engineer and sent to the scrap place for storage.
Raw material acceptance system
First, understand the credibility of material suppliers and cooperative manufacturers, and whether the product quality is reliable and credible.
Second, materials inspection reports must be collected and kept, and whether the single products of cooperative manufacturers are qualified or not must be strictly inspected and controlled, and records should be made.
Third, raw materials related to assembly size must be strictly controlled according to the drawing and the national standard system should be implemented. Unqualified materials will never be accepted.
Four, when necessary, sampling material test.
5. Do not accept products without three certificates: material brand, specification, quantity, surface quality and batch number, which can only be put into storage after acceptance.
Welding process compilation, evaluation and testing system
A, compiled by welding technicians at corresponding levels, and evaluated and tested by engineers or relevant experts and experienced operators.
Second, the whole test process must be tracked and recorded in detail, and operated according to the process parameters.
Three, test operators must have the corresponding welding level, and the corresponding welding equipment.
4. Verify in the implementation process according to the process documents, and constantly modify and improve in the information feedback.
Welding quality responsibility system
Firstly, it is determined whether the riveted assembly parts meet the technological requirements.
Second, determine whether the riveted products meet the welding requirements.
Third, check whether the plate material and welding material meet the requirements, and check whether the welding process parameters meet the technical requirements at any time.
Four, check the weld formation at any time, whether there are welding defects.
Five, strict control, according to the process requirements.
Six, process parameters do not meet the requirements of welding, the scene at any time to correct.
Process quality assurance system
First of all, according to the product requirements, prepare the technical documents needed in the production process. Including some widely used and commonly involved technical requirements of some manufacturing processes. Such as bending, stamping, bending, etc.
Second, for some special processes, it is necessary to compile special processes and strictly review the pattern templates to see if they meet the process requirements.
Third, estimate the processing time according to each process card or process, and put it into production through certification.
Product inspection system
1. Self-inspection: Operators inspect their own products and mark the words "self-inspection".
Second, the inspector's first inspection: the unqualified parts should be marked with the words "this part is unqualified", and the treatment method should be put forward, and then sent to the plastic surgery team after inspection.
Three, the second inspection after plastic shot blasting, qualified should be marked "can be painted".
Four, the factory inspection qualified and marked "qualified".
Welding quality inspection
Welding quality inspection is an important measure to ensure the quality of welding products and prevent waste products from leaving the factory. Through inspection, we can find out the quality problems in the manufacturing process, find out the reasons, eliminate the defects, make new products or new processes applied and ensure the quality; In normal production, through the perfect quality inspection system, the defects in the production process can be eliminated in time to prevent the recurrence of similar defects, reduce the number of repairs, save working hours and materials and reduce costs. Therefore, welding quality inspection is an indispensable and important link in welding production.
7. 1 Contents and methods of quality inspection of welded joints
Welding quality inspection runs through the whole welding process, including three stages: before, during and after welding.
7. 1. 1 Contents and requirements of welding quality inspection
(1) Pre-welding inspection
Pre-welding inspection refers to the inspection work that should be carried out before the weldment is put into production. It is the first stage of welding inspection, and its purpose is to prevent and reduce the possibility of defects in welding in advance. The items included are:
(1) check whether the model and material of welding base material, welding wire and covered electrode meet the design or specified requirements;
(2) Check whether other welding materials, such as the brand of automatic flux for submerged arc welding, and the purity and proportion of shielding gas for gas shielded welding meet the requirements of process regulations.
(3) Check the welding process measures to ensure the smooth welding;
(4) check whether the welding groove processing quality and welding joint assembly quality meet the requirements of the drawings;
⑤ Check whether the welding equipment and its auxiliary tools are in good condition, and whether the wiring and pipeline connection meet the requirements;
⑥ Check whether the welding materials are rusted, dried and preheated according to the process requirements;
⑦ Identify the operating technical level of welders;
⑧ Check whether the welding product drawings, welding process regulations and other technical documents are complete.
(2) Inspection in welding production process
Inspection in welding process is the second stage of welding inspection. In the process of operation, the welder aims to prevent welding defects caused by operation reasons or other special cables, so as to find problems and solve them in time. Including:
① Check whether the welding equipment operates normally during welding;
(2) the implementation of welding process rules and regulations;
(3) Whether the clamping condition of welding fixture is firm during welding;
④ Welding defects such as incomplete penetration, slag inclusion, blowhole and burn-through that may occur during operation;
⑤ Intermediate inspection of welding joint quality, such as intermediate inspection of thick-walled weldments.
Pre-welding inspection and in-welding inspection are important links to prevent defects and repair. Although most welding defects can be eliminated by repairing, repairing will consume materials, energy and working hours and increase product cost. Usually, more strict technical measures are needed for repair, which brings trouble to the work, and the repair site may produce more complicated stress state, which becomes a new hidden danger affecting the safe operation of the structure.
(3) finished product inspection
Finished product inspection is the last stage of welding inspection, which needs to be inspected item by item according to the design requirements of products. The items included mainly include: checking whether the weld size, appearance and flaw detection are qualified; Whether the product appearance size meets the design requirements; Whether the deformation is controlled within the allowable range; Whether the product has been heat-treated within the specified time, etc. There are two kinds of inspection methods for finished products, destructive and nondestructive, and there are many methods and means. The specific methods adopted are mainly determined according to product standards, relevant technical conditions and user requirements.
7. 1.2 welding quality inspection method
Inspection methods of welding quality can be divided into nondestructive and destructive methods, as shown in Figure 7- 1.
Figure 7- 1 welding inspection method
1.
By correctly defining the inspection standard of welding quality, employees are guaranteed to produce qualified products during welding and inspection.
2. Scope
Suitable for welding workshop.
3. Working procedures
According to the actual situation of manufacturing process, the visualization of boundary samples can be used to clearly distinguish whether the welding quality meets the requirements.
3. 1 Definition of unqualified solder joints in resistance spot welding and unqualified solder joints and welds in CO2 gas shielded welding.
Eight kinds of resistance solder joints below 3. 1. 1 are considered unqualified and defined as unqualified quality:
3. 1. 1. 1 virtual welding (no nugget or nugget size less than 4mm) solder joint, code L.
3. 1. 1.2 The code of the solder joint with cracks around the solder joint is C.
3. 1. 1.3 burn-through, code b.