GE Shirley 的万佳访厂报告
1．跟 [万佳的技术管理] 谈过后了解现况如下：[万佳] 正完成一些毛管样办，是有较厚的 [ALON涂层] （保护层），用了 [日雅] 灯粉。于12月8日将会有100小时的数据，12月12日会有200小时数据可作大约计算 [光衰的改善]。
1．After talked to Wanjia's tech. leader, the current situation is:> Wanjia has finsihed some samples with thicker Alon coating, use NICHIA phosphor, on Dec-8, they can get the 100hrs test data, and Dec-12, can get the 200hrs test data to get a roughly evaluation on lumen maintenance improvement.
2．无论测试成绩如何他们都会开始造余下型号。将会在12月14日完成。全部送交 [Super Trend] 这样安排是比原来的时间表迟了2天。是否可以接受？请通知 [Super Trend]。
2．no matter the test result is OK or not, they will start producing all the samples we needed for testing consider with our suggestion according to today's process check. and all the samples will send to Supertrend on Dec-14(two days delay compare with the original schedule?? is it acceptable or not? please confirm with the team and call Supertrend if the timing is not acceptable)>
3．今天他们造了一些样办，让我们检查由第一个工作站开始的生产程序。但发现了一些问题，请跟进下列事项：
3．Today, they build some samples for our process check from the first station, there is some problems with their process control, below items please follow up:
1．[TCP] 是他们的大客户，他们是从 [TCP] 买灯粉的。[TCP] 做完了试产（根据TCP的生产流程）之后就把灯粉送去 [万佳] 使用。 但 [万佳] 是没有再做试产（基于万佳的流程），亦没有 [万佳] 的 [混制灯粉记录]。所以我们监管不了 [DVP/PVP/第一次生产] 是否用了同样的灯粉。 但 [万佳] 的人说三次都是用了 [日雅粉]。12月12日的生产，他们答应了会做一次 [试产] 及 [灯粉来料试产] 及 [混制灯粉的试检]，若OK，则开始做其余型号的样办，亦答应了做 [样办生产记录]。
a. TCP is one of their big customer, they bought the NICHIA phospher from TCP and after TCP finished the trial run test based on their own products/process, the phospher will sent to Wanjia to produce without wanjia's own trial run based on wanjia's process/products.No phospher/powder preparation record can check, can not know the DVP/PVP/1st production used same phospher or not(wanjia told me they used NICHIA phospher for the all three times); For the samples making on Dec-12, they will do a trial run for the phospher incoming check and phospher preparation check, if OK, then, start to produce all samles, the related record will be setup;
2． [ALON保护层] 的控制：他们增加 [AL2O3的浓度]（由4% ==> 5%）使 [光衰表现] 较好。涂 [保护膜] 之前, 用 [纯水] 清洗 [玻管] 在同一机器上做 [样办]，[玻管] 没有干时, 水滴回去 [AL203回收液] 里。我检查过有 [保护涂层] 的 [玻管]， 发现有些 [玻管] 是 [几乎透明] 的，这说明了可能 [漏涂] 或可能 [AL2O3浓度太低]。在12月12日的生产是, 要先 [干管] 后 [涂保护膜]，更加上 [100%检查]，更需要提供 [已涂好的样办]，给 [工人] 做 [对照]。
b. Alon coating(precoating) control: they has increased the Al2O3 concentration from 4% to 5% to get better lumen maintenance. But, they use hot DI water to clean the tube before pre-coating on the same machine without drying the tube, the water dropped into the recycle Al2O3 liquor directly, which keep the Al2O3 liquor being diluted during pre-coating. We checked the pre-coated tubes after precoating and before phoshor coating, can found some tubes are almost transparent, maybe did not pre-coating because of the operators carelessness, maybe because the Al2O3 concentration is too low. For the samples making on Dec-12, will dry tubes after cleaning offline and then do the precoating; 100% precoating inspection need to be done before phosphor coating, and the limit samples for the inspection will be prepared to help the inspectors inspection;
3．[涂粉后烤管] 的机器在05年中已换过，以前是比较 [平直的烤管机]，但现在是如图中的机（不一样）。机中只有一个 [温度计] 放于中间的 [加热区]，而在 [两边斜波区] 是没有 [发热器] 的。机内有[2米予热区]，[2米加热区] 及 [2米冷却区]。 展示热区的温度是480℃, 但机器是没有 [温度分布数据表]的。据他们的 [现有流程], 2-3只 [变形灯管] 是可以接受的。我检查过 [生产线] 上的 [记录] 发现有2只 [变形灯]。我觉得 [烤管线入口区] 温度不对，用手 [试温] 发觉温度跟 [室温] 差不多。至于 [变形灯] 我怀疑是 [加热区] 温度太高这会影响 [灯粉] 的质量。他们答应了测试 [机器各程序的温度]，取得 [温度分布数据] 请把这些 [数据] 给 [匈牙利] 参考。
c. Tube baking after phosphor coating machine changed from mid of last year(the PVP use new baking machine), the original is flat and straight, the new machine is like this shape> << OLE Object: Picture (Enhanced Metafile) >> , there is only 1 temp tester in the middle of the top heating area( the two slope area has no heating tube), 2 meters long for the heating area and 2m for entrance preheating area, 2m for the cooling area, the displayed heating area temp is around 480C, no temp. profile for this baking machine. according to their current process, 2 to 3 pcs deforming lamps is acceptable(I checked one of their inspection record online, there are 2pcs deforming lamps), I feel the entrance part temp. by my hand, it is much cool like the environment temp in the room. from the deforming lamps, maybe some place temp. in the heating area is very high, that might affect the phosphor quality. They will test the baking machine/process to get the temp. profile, please get the temp. profile and send to hungary for suggestion.
4．月12日做的灯 [Ar氩气] 的 [压力] 会由3加至3.5 (Colums) 增加 [改善光衰的表现]。而在 [排气] 前的 [加热时间] 可以用 [软件] 来控制到 [中级加热时间]。
d. For the samples making on Dec-12, the Ar fill preasure will be increased from 3 to 3.5 columns to improve the lumen maintenance. the heating before exhausting time will be controled by the software to make sure the minmun heating time.
5．[平封] 程序是要操作员用手去改正（芯柱）的方向。这样 [手接触到芯柱阴极] 部分，是会影响到 [排气质量] 及 [灯的寿命]，所以这样 [程序] 要用一些 [工具] 来代替 [手指操作], [避免碰到阴极] 部分。
e. Sealing process need correct the stem direction by hand before close the tube on the stem, and the operators finger may touch the cathod, that will effect the exausting quality and may effect lamp life, some tooling need to use to avoid finger touch the cathod.
6．[涂保护层] 及 [涂灯粉] 的 [操作指导] 上，没有 [注明温度]、[公差] 及[气压] 的要求，这些 [工艺] 上的要求是一定要在 [操作指导] 上显示，而每次 [进行生产] 之前一定要 [检查正确] 的。
f. precoating/ phosphor coating, no temp. requirement/tolerance and air blow pressure defined in the WIs, all process parameters need to be defined in the WIs and be checked before production;
7．这工厂是 [ISO001认证] 的工厂，但多年来都没有按 [ISO制度] 控制好工厂的运作，[追逆性]，[品质记录] 及 [仪器校对] 需要改善。
g. this plant got ISO9001 certificate years ago, but not control according to the system for many years...the trancibility and quality record and calibration need enhance.> << File: supertrend exhausting current setting.xls
第二篇：CCC验厂之前的内审报告
内 审 计 划
审核组组长： 组员：
1审核目的：确认本公司建立并实施的3C认证工厂质量保证体系的符合性、有效性、充分性，确认公司生产产品与型式试验合格样品的一致性。
2审核依据：《强制性产品认证工厂质量保证能力要求》和本公司的质量手册、程序文件、工艺文件、产品描述。
3审核覆盖产品：GSM手机
4审核时间：20xx年11月 日至20xx年11月 日
首次会议时间：11月 日 9 时
首次会议时间：11月 日19时
5现场审核期间请被审核方有关人员参加下列活动：
首、末次会议：最高管理者或其代表及与审核有关的管理要员参加。
审核活动：按审核日程安排，被审核方有关人员在本岗位。
6审核安排：
内 审 检 查 表
内 审 检 查 表
内 审 检 查 表
内 审 检 查 表
内部质量体系审核报告(可附页)
