Manufacturing Process Changes and Defects

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Questions and Answers

What is the appropriate contact person for a change in the process window range?

Nissha Japan(Kameoka)

Asri (IMD senior executive) (correct)

Faiskandar (QA Engineer)

Pathmanathan (Factory Manager)

Which of the following activities are considered an intentional change?

Adjustment(Within the process window range)

Personnel transfers without training

Replacement of the cavity (CAV) inserts (correct)

Maintenance

In which scenario would contact with "Nissha Japan(Kameoka)" be necessary?

A change in the type of resin used in the production process.

A repair of the measuring equipment used in the production process.

A change in the foil lot used for the product. (correct)

An adjustment to the molding process within the process window range.

What is the appropriate contact person for a change in the production setup?

Pathmanathan (Factory Manager) (A) Signup and view all the answers

Which of these changes would likely require a check of the "Check Details" column in the table?

Mold polishing (A) Signup and view all the answers

Which of the following would be considered an incidental change in the "Man" category?

Personnel transfers without training (B) Signup and view all the answers

What is the appropriate contact for a change in the cylinder?

Faiskandar (B) Signup and view all the answers

Which of the following changes is NOT mentioned in the content as impacting the "Visual inspection/Product dimensions" aspect?

Mold breakdown (A) Signup and view all the answers

What is primarily measured during the production sampling inspection for control points?

Visual inspection (A) Signup and view all the answers

Which measurement is not typically assessed in the inspection process outlined?

Labor costs (B) Signup and view all the answers

In which aspect is boss pin height assessed during inspections?

Measurement of control points (A) Signup and view all the answers

What type of inspection is used to validate the suitability of the process window?

Visual inspection (D) Signup and view all the answers

Which option is least likely to be included in the overall measurement inspections?

Boss pin adjustment (A) Signup and view all the answers

What is emphasized in the first stage of production sampling inspection?

Dimension accuracy (B) Signup and view all the answers

Which element is consistently involved in the control points measurements?

Visual inspection (D) Signup and view all the answers

In the overall measurement category, which of the following is typically not performed?

Longevity testing (C) Signup and view all the answers

Study Notes

Incidental and Intentional Changes

Impacted areas require confirmation and contact based on a list of incidental/intentional changes.

Defect List

Includes numerous defects in products, including variations in color, white marks, dryness, uneven coloration, lines (black and white), fading, bleeding, color tone shifts, anti-glare issues, moiré patterns, cloudy areas, polarized visibility issues, ink flow problems, air bubbles, weld lines, foil cracks, sink wrinkles, and sink marks.

Process Changes

Resin Lot Change, Foil Lot Change, Mold Changes (includes no touch idle conditions; maintenance, spare parts replacements, mold polishing, mold corrections, Cavity (CAV) insert replacements, mold grain insert replacements, mold breakdowns, setup changes).
Process Window Adjustments (both within and outside the process window). Improved cylinder versions noted, as well as design changes to foils.
Personnel Transfers: Transfers can be with or without training.

Measurement and Inspections

Overall Measurement, Measurement of Replacement Parts, Visual Inspection, Production Sampling Inspections, Measurement of Control Points, and details on boss pin heights and replacement area dimensions are required. Validation of process window suitability is also mentioned.
Measuring equipment repair and updates are mentioned.
Product dimensions are assessed after relevant process changes.

General Notes

Parts should be replaced rather than repaired whenever possible.
Construction/repairs without permission from Kameoka Factory are not allowed
Contact the Factory Manager and Kameoka Factory for cases not listed.
Contact information for Kameoka Factory is provided.

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Description

This quiz delves into incidental and intentional changes in manufacturing processes, along with a comprehensive defect list that affects product quality. Participants will explore various process adjustments, lot changes, and the impact of personnel transfers on production. Test your knowledge on identifying defects and understanding the implications of process changes.