生产试产程序

PURPOSE

To define the procedure used to assure process issues are identified and resolved and to assure process controls are in place to support production of finished good products produced by factories in Asia.

SCOPE

2.1 This procedure applies to all factories in Asia currently supplying Finished Goods to

Char-Broil.

2.2 This procedure applies to any products developed by CB New Product Development

Teams (NPDT) and produced by factories in Asia.

2.3 This procedure is applicable to the following conditions, but not limited to:

2.3.1 New design models / concepts

2.3.2 Existing models that are moved to a different manufacturing location. 2.3.3 Existing models with major design changes.

2.3.4 Product not produced within a 12-month period. REFERENCES

 Engineering / Product Specification  Assembly Manual  Bills of Material

 Workmanship Standards / Criteria for Rejection – CFR  Prints and Metrology

 Graphic Art / Carton Art / Point of Purchased labels.  Tooling First Shots (T1) – CP 0001  Engineering Pilot – CP 0003

 Completed EP Compliance Report  Cross Build Procedure – CP 0004

RESPONSIBILITIES

4.1 Operations Team – Asia Operations – Lead Organization for Production Pilot:

4.1.1 Assign responsibility to appropriate Operations Manager to coordinate,

schedule and complete the Production Pilot Run.

4.1.2 Manufacturing Pilot Plan to produce 30 units or greater of each model number. 4.1.3 Document and Issue Product Quality Plans – OQC.

4.1.4 Review and Approve Product Quality Plans prepared by Factory / Supplier –

IQC and IPQC.

2.0

3.0

4.0

Issued by Department/Section: Effective Date: CP Number: Operations, Asia Operations Title: Production Pilot Standard Operating Procedure May 1, 2006 Issued by: 0002 Page: Buck Zachry Supersedes: 2 of 4 New 4.1.5 Complete, review and close all outstanding issues as part of Production Pilot

Report. Issue report to CB – NPDT, Factory Supplier and Product Engineering Team – Asia Operations via PDMLink.

4.1.6 Work with Factory and Product Engineers to identify and resolve all critical

relationship of processes to product.

4.1.7 Implement the Product Workmanship Standards and Criteria for product

rejections. Obtain input from New Product Development Team as required for clarification. Communicate these standards and criteria to the Factory Supplier.

4.1.8 Select and assemble product units in accordance with the product instruction

manual the planned quantity of production units to confirm fit and function and proper assembly capability.

4.1.9 Complete and Issue First Article report for specific Product being piloted. 4.1.10 First Article Report is authorization to the factory to produce product in

accordance with purchase order releases.

4.1.11 Confirm Warranty Parts – Release of Minimum Order Documentation is

conducted and accurate.

4.1.12 Confirm successful completion of all certification and third party testing.

4.2

Product Engineering – Asia Operations

4.2.1 Assign Engineering Pilot responsibilities by Product Engineering Manager – Asia

Operations.

4.2.2 To participate in internal review of model and provide comments to Operations

Team – Asia Operations in support of Production Pilot Report.

4.2.3 Complete all required actions identified as open issues during the Engineering

Pilot.

4.2.4 Confirm that all design issues are closed prior to production pilot run.

Factory/Supplier

4.3.1 To provide Product Engineering – Asia Operations with documentation

(drawings) referencing completed tooling / process plan relating to the model being reviewed.

4.3.2 To participate in internal review of model and provide comments to Operations

Team – Asia Operations in support of Production Pilot Report.

4.3.3 Document and issue Product Quality Plans – IQC and IPQC.

4.3.4 For all off tool components complete metrology reports and provide First piece

Inspection (FPI) documentation to Product Engineering and Operations Team –

4.3

Issued by Department/Section: Effective Date: CP Number: Operations, Asia Operations Title: Production Pilot Standard Operating Procedure May 1, 2006 Issued by: 0002 Page: Buck Zachry Supersedes: 3 of 4 New 4.4

Asia Operations. Note – This requirement should be achieved as part of the T1 process – Reference CP 0001.

4.3.5 To have available off tool parts and components needed to support the build of

production pilot plan number of units.

Product Data System

4.4.1 To complete the product BOM’s and any revisions prior to the Production Pilot

Run.

4.4.2 To complete any revisions to product instruction manuals prior to the

Production Pilot Run. NPD Team - Provide the following in support of MP. 4.5.1 Product Description Statement (PDS) 4.5.2 Product Specification Document (PSD)

4.5.3 Review and comments regarding Final Prototype Models

4.5.4 Complete Product Specifications and General Workmanship Standards.

4.5

5.0

Procedure

5.1 All parts for production pilot should be 100% manufactured off final tooling. 5.2 Review tooling to check repeatability of the parts.

5.3 Randomly select parts to assemble selected units per the Instruction Manual. 5.4 Check fit and function of the assembled units.

5.5 Compare ALL artwork to required standards, including, but not limited to the following:

5.5.1 Graphic and carton art; POP; carton, rating and warning labels. 5.5.2 Instruction Manuals

5.6 Note any discrepancies between the Product Specification, BOM, Instruction Manual

and unit on PP Report.

5.7 Compare units to CFR / Workmanship Standards. 5.8 Perform functional test. (Use as consumer would)

5.9 Review final packaging and communicate any identified issues or concerns. This item

should be completed at EP.

5.10 Operations Team to work with Product Engineering Team – Asia Operations and

supplier factory to determine understanding of critical relationship of processes required to manufacture product.

5.11 If requested, send samples to US product development team.

5.12 Issue Production Pilot (PP) report to respective departments via PDMLink.

Issued by Department/Section: Effective Date: CP Number: Operations, Asia Operations Title: Production Pilot Standard Operating Procedure May 1, 2006 Issued by: 0002 Page: Buck Zachry Supersedes: 4 of 4 New 5.13 Process after Production Pilot and before First Production.

5.13.1 Supplier shall provide schedule for implementation of required improvements as

per the Production Pilot report.

5.13.2 Operations Team shall perform or arrange to have performed required product

transit testing and provide test report / results to respective departments via PDM Link.

5.13.3 If required, supplier shall send graphic samples to NPD Team and Product

Engineering – Asia Operations for review.

5.13.4 NPD Team Quality Manager shall provide finalized Workmanship Standards

and Criteria for Rejection (CFR) documentation.

5.13.5 NPD Team to finalize Product Specification. 5.13.6 Supplier to provide final factory quality plan.

5.13.7 Supplier to provide sample of unit with all required improvements from

production pilot and close all issues related to the factory as noted in the Production Pilot Report.

5.13.8 Product Data Systems Team to complete BOM, instruction manuals and any

revisions prior to Production Run.

5.13.9 Supplier to complete updated drawings prior to first production run.

5.13.10Product Data Systems Team to release final drawings prior to first production

run.

5.13.11Operations Team – Asia Operations to issue First Article and authorize the

Factory Supplier to produce specific new model grill.