Targeted at new QC employees, IQC/IPQC/FQC/OQC inspectors, team leaders, and Quality Department trainers.
4 chapters, 18 pages: ① Overview of inspection and preparation for starting work (three-inspection system, internal calibration of gauges, four don'ts for inspection records); ② Incoming material inspection IQC (GB/T 2828.1 sampling guidelines, four-step unpacking judgment, four-color labeling); ③ Process inspection IPQC (five triggers for first article, patrol inspection of personnel, machinery, materials, methods, and environment, Cpk and control chart anomaly judgment); ④ Finished product inspection and nonconforming product closed-loop handling (five inspections for FQC/OQC, three checks for release, marking → isolation → review → disposition).
Case studies are based on a glass deep-processing production line, methods are applicable to all discrete manufacturing industries.
Complementary article: id=95 "IQC/IPQC/FQC/OQC — Four 'Goalkeepers' in Manufacturing Enterprise Inspection Processes"; use in conjunction with the 'First Article Inspection (FAI) Practical Training' and IQC/IPQC/FQC/OQC inspection checklist templates in the same directory.
Knowledge Code 11.1.1 (IQC/IPQC/FQC/OQC Planning).
Suggested agenda: Overview of inspection and the three essentials for starting work (20 minutes) → IQC sampling and judgment (20 minutes) → IPQC first article/patrol inspection/Cpk (25 minutes) → FQC/OQC and nonconforming product closed-loop handling (20 minutes) → on-site practice.
Before the meeting, bring the current 'Inspection Standards Manual', 'Sampling Standards', limit samples, and a set of gauges within the calibration period to the site; after the meeting, arrange for new employees to independently complete one IQC sampling judgment and one first article confirmation, to be signed off by the mentor for confirmation of starting work.
Values for AQL, frequency, and Cpk thresholds within the slides are for teaching purposes; before internal training, please replace them with actual values from the factory's controlled documents.
Judging by feel and not referring to the current controlled standards is the most common source of nonconformities for new employees.
Using expired gauges invalidates all inspection conclusions — check the calibration label before starting work.
Focusing only on the conforming rate and not on Cpk can mask processes that are drifting towards specification limits.
Closing cases after nonconforming product disposal without identifying root causes and solidifying SOPs will lead to recurring issues; 'employee carelessness' is not a root cause.