Quality Management
Since 2003, Tanyun has started to construct its quality management system following the requirements of ISO9001 and initially formed the quality control management system, which emphasized on documentation, routinization and process. In 2005, in order to develop and produce military weapon equipment, Tanyun built the national military-standard quality management system based on the GJB9001A-2001: Quality Management System Requirement and submitted the certification application. Regarding the annual examination of quality management system as the way of making continuous improvement on quality management, Tanyun regularly organizes internal examination of quality management system. Through the internal examination, the company can find the problems and insufficiency from the current QM system. The company also raises requirement in the annual management examination meeting and follows the execution situation of requirements and advice collected in the meeting, the latter of which can guarantee the effectiveness of the advice. In the routine production activities, Tanyun strictly follows the requirements of national military-standard quality management system and controls the development of production and service of the products to meet the legal requirement and to satisfy customers’ needs. By evaluation, Tanyun identifies customers’ needs, analyze the execution risks, take effective action to avoid or to lower the risks. To track the quality and the using status of delivered products, the company regularly visits customers and studies market development, product development and customers’ expectations on products and services. Also, by conducting the satisfaction survey, Tanyun collects customers’ feedback, pays great attention to their user experience to helps them improve products and services continuously. According to the production needs, the company adopts the monthly purchasing plans and temporary purchasing plan (if necessary) and conducts annual evaluation on suppliers to guarantee the quality of the raw material. The production process strictly sticks to the ideas of “Strict, Specialized, Specific and Stable”, and organizes self-examination, crossed-examination and special examination. The qualified products will be delivered to the warehouse and examined regularly during storage period. The products will be checked again before delivered to the customers.
Procurement
According to factors of experiment and transportation, Tanyun divides materials into significant materials (Type A materials) and ordinary materials (Type B material).
Monthly, the Planning Department presents Purchase Application From to confirm the requirement of necessary materials (types, specification, amount, good arrival time, etc.). The Purchasing Department will base on the Purchase Application Form or temporary Purchase Application Form to prepare Purchase Order to purchase materials. Procurement will conducted after the Planning Department gain supervisor’s approval. For the raw materials purchased from the third party, The Purchasing Department is required to select suppliers from The List of Qualified Suppliers before purchasing. When purchasing important materials from suppliers, the Planning Department will sign Order Contract to confirm the material type, specification, amount, quality requirement, technological standard, verification condition responsibility for breach of contract, delivery time and other relevant information. When the materials are delivered to the company, the warehouse keeper should check the types and amounts of the materials based on the supplier’s list and fill the Material Arrival Record Book. Together with the Material Arrival Record Book, the warehouse keeper will send the quality verification documents of A materials and Delivered Goods Inspection Declaration Notice to the Quality Management Department and contact the Purchasing Department when in emergency. The activities of quality verification will be conducted according to Quality Inspection Control Procedure: Q/TY?14.06-2015. When the materials have problems, the Purchasing Department will immediately contact suppliers for feedback and solutions( including replacement and return). The Purchasing Department will conduct a Supplier Qualification Evaluation once a year.
Sale
Before receiving contracts and orders, Tanyun will evaluate them ( including contacts in oral forms). The requirement of the contract evaluation are as follows: The terms of the contracts should be specific and reasonable; Tanyun is able to meet the contract’s requirements; for contracts in oral form ( including contracts dealt in telephone), and other situation without written requirement, Tanyun should confirm that the order’s requirement is approved by relevant people before the order is accepted. Tanyun should also fill the TANYUN Order Form. If the change of product requirement influences the customers, customers’ approval should be gained before certain adjustment is about to be made. For the amendment of the contract, the sale representative of Tanyun should report the situation to customers and company’s related departments immediately.
Tanyun drafts Annual Service Plan and organizes after-sale activities to collect product quality information and customers’ opinions (including complaints and handling method of unqualified products) . The sales department will organize service activities according to schedules and fill Service Execution Inspection Report. The department will collect customers’ feedback about quality information and requirement in different channels, fill the Quality Information Report, and conclude the results and send the reports to the Associate General Manager and relevant departments. Relevant departments will analyze the problems, find solutions and deliver Quality Information Process and Feedback Report. The sales representatives regularly visit customers (usually half a year) to understand their requirements and expectations on the products and finish the activity by filling Service Execution Inspection Report and Customer Satisfaction Report. For customers’ telephone calls, letters, sales representatives will fill Customers Phone Calls and Letters Visit Registration Report and organize internal communication based on Quality Information Report and Service Execution Inspection Report. For major accidents about quality, the General Manager should call relevant research departments to organize a meeting to analyze the reasons, get related deparments to assume the responsibility, provide solutions and take prevention measures. After filling out the Service Execution Inspection Report, related department should follow the service to provide proofs for internal examination and managerial evaluation.
Production Management and Control
The Product Department will draft Product Commencement Notice five days before production based on the monthly production plan. The notice will be delivered to production workshops, Quality Management Department, Technology Department, Purchasing Department, Equipment Department and other departments to help them understand information about production mission, time, technology requirement, standards, etc, which can guarantee the success of the production. Based on the Product Commencement Notice, the Product Department will deliver technological documents, technology instructions to relevant workshops. The workshops receive Product Commencement Notice and Work Instruction, which are used for preparation before production.
A. Inspect production equipment and infrastructure including water gas and electricity, the operation condition of valves. The department should carry out the work of operation debugging and Three-level maintenance.
B. Check operation conditions of measuring equipment and monitoring equipment
C. Provide pre-production training to relevant staffs. Staffs should pass specialized exams before participating in production. In key work process, it is necessary to arrange specialized staffs to particular positions.
D. The documents used in production site, including Work Instruction, Quality Control Instruction, etc., should be the newest and effective version. The documents should be accurate, comprehensive, coordinated, unified and clear.
E. Raw Materials should be collected according to the explanation of matching ratio written in the technology documents. The product marking and batch number should be kept clear and complete.
F. The safety identifiers, clear area lines and Material Identifiers should be clear and complete in work site.
G. Materials should be brought to fixed location management in specific areas, and should be put in alignment. The label of Production equipment and Monitoring equipment should be kept clear and effective.
H. The workshop should be kept well ventilated, and equipped with fire protection equipment. The equipment should be placed in specific locations, and kept intact and effective.
The process mentioned above should be reported to Product Department after the production is finished. The Product Department should organize Quality Management Department, Technology Department, Equipment Department and other departments to check debugging before production. If they find out the insufficiency, related departments should rectify and draft process check record before commencing production.
Management measures during production:
Only when all the equipment pass the examination can the product begin.
The first batch of products should be examined under the following situations,:
A. If the product is made by several processes, the examination for the first batch of products will begin based on each process. If the first batch of process will be regarded as a rejected process, the process will be considered a failure, but will not affect productions of other processes.
B. If the production can not be examined in a form of process, the final products will be the first batch for examination. The examination for the first batch of products should be conducted unless interval time between consecutive production and production halt lasts more than a month
C. The first batch of product whose raw material and technology procedure ( including methods, equipment and other significant change) are changed. The production record of the first batch products should be stamped with a red mark of ‘ First Batch’, and be regarded as acceptable products if passing the examination.. The workshop will provide continuous monitoring on operational parameters of each process according to Process Instruction and keep production record according to the Control Process Record. The staffs in charge in the workshop is required o check daily production record, and to keep record according to Control Process Record. Production record with uniform numbers should be used in production site and staffs in charge should write down the contents with a black ink pen and according to regulations. The written contents should be complete, clear and easy to be identified. False and fake record is prohibited. Advance or delay recording are also prohibited. According to the confirmed results, practitioner will take charge of control and labeling work for key (special) process according to regulations. According to Three Forms’ requirement, the department should arrange specific staffs for specialized positions and continue to monitor and control the checkpoints during the work process. Tanyun adopt batch management during production process and materials including raw materials, intermediate products, semi-finished products and the recycles should be marked with names, types, models, amounts, batches and other necessary information according to the requirement 4.10 of Product Label and Traceable Control Procedure. According to the control point set by Technology Instructions, the Product Inspection Report should include information such as product name, workshop name, date, product batch, weight, and etc.
The workshop will establish accounts of production equipment and monitoring equipment to conduct dynamic management to keep consistency between account books and labels. The workshop should keep maintenance of product equipment and fill Daily Maintenance Record of Production Equipment. The workshop should also deliver the monitoring and measuring equipment to Quality Management Department for inspection according the scheduled time required by Inspection Plan of Monitoring and Measuring Equipment Cycle. If production operators discover problems during production, they should immediately report to relevant supervisor, and relevant staffs should deliver the message to relevant departments in the form of Quality Information Delivery Form, suggesting specific requirement of information feedback. Departments responsible solving the problems should finish the Quality Information Delivery Form as required, which built a closed loop for the problem. When there are problems of changing technology documents, relevant department should deliver Document Change Application/Approval Notice Form to Technology Quality Department. According to regulations of handling rejected products, relevant departments should carry out work of labeling marks and isolated storage. According to disposal opinions on rejected products, rejected products should be reworked or repaired, and QC staffs should be informed to check the products again.
Management after production: the qualified products should be packaged and sent to the warehouse according to relevant regulations. Workshops will collect and organize product process records and deliver them to Product Department after classification. Product Monitor should return the left raw material to the raw material warehouse, pack the acceptable products, deliver them to the finished products and clean work site. For the cleaning and maintenance of production equipment, workshops should fill Daily Cleaning Record of Production Equipment, close water, electricity, gas and other facilities. The workshop staffs should calculate the failure cost of rejected products and report it to the Financial Department. They should also fill the Rejected Products Scrapping Form to report the scrapped, rejected products and delivered the report to Financial Department after supervisors’ approval. Those rejected and scrapped products that can not dealt with should marked with clear labels, sent to scrapped products warehouse and stored in isolation.
