這是我在中質盟兩個月左右的講課內容，將其匯編整理成冊。分為課文和知識點，便于大家查閱润梯。這是課文的Unit 1。

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Lesson 1

Part 1 Incoming Quality Control 來料質量控制

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Word Service Station 詞語加油站

quality['kw?liti] n. 質量 ｜ control[k?n'tr??l] n. 控制

procedure[pr?'si?d??] n. 程序 ｜ director[dai?r?kt?] n. 總監(jiān)

headquarter[,h?d'kw?rt?] n. 總部 ｜ supervisor ['sup?va?z?] n. 主管

responsible [ri'spɑns?b(?)l] adj. 負責的 ｜ non-restriction [ri'strik?(?)n] n. 非限制

antenna[?n't?n?] n. 天線 ｜ assembly[?'s?mbli] n. 組裝件

instruction[in'str?k??n] n. 指導書 ｜ regulation[?r?ɡj??lei??n] n. 規(guī)定

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Conversion: Brief introduction of Incoming Inspection Procedure簡要介紹來料檢驗程序

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Scene: In the incoming inspection office
A = Tony, B = Jennifer, C= Mr. Acker

A: Mr. Acker. This is our Incoming Quality Control Department (質量控制部門). Jennifer, I’d like you to meet Mr. Acker. He is the Plant Director（工廠總監(jiān)）from the headquarters (總部)in Nuremberg, Germany.

B: I’m very delighted to meet you, Mr.Acker. I am supervisor(主管) of incoming inspection team.

C: Nice to meet you, Miss Jennifer.How many inspectors in incoming quality team?

B: 3 inspectors, and they are responsible (負責) for incoming quality control of cable, cable harness (線束), trading goods (貿易商品) and so on.

C: Could you kindly introduce (介紹) your incoming inspection procedure（程序）, Miss Jennifer?

B: Certainly. After receiving the raw material(原材料) by warehouse, the warehouse keeper(倉庫管理員) will post it to inspection stock and mark label on it. Firstly, I check the free inspection list to see it needs inspection or not. I will post it to non-restriction stock（非限制庫） in SAP when it is in the list.

A: Mr. Acker. The free inspection list is updated by our SQE monthly.

**C: ** Sounds good (看起來不錯）.

B: The next step, we inspect the material according to the incoming working instruction basing on different types. For instance, jumper cable, connector and antenna（天線）.

C: How about your finding non-conformity material（不合格材料）?

B: It is the third step. We start the reviewing procedure（評審過程） after I send NCR report （不合格報告） via E-mail. The Production Engineer（產(chǎn)品工程師）,Assembling Engineer（裝配工程師） and Quality Engineer（質量工程師） will check this material after receiving the E-mail

A: According to the regulation（規(guī)定） in company, they should make decision in 2 working days.

C: That’s fine. Miss Jennifer, thank you very much for your introduction today.

B: You are welcome.

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Part 2 Process Quality Control 過程質量控制

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Word Service Station 詞語加油站

automatic [??:t?’m?tik] adj. 自動的 ｜ production [pr?’dΛk∫n] n. 生產(chǎn)

introduce [?intr?'dju:s] v. 介紹 ｜ privilege [‘priv?lid3] adj. 榮幸的

preparation [?prep?’rei∫n] n. 準備 ｜ acceptance [?k’sept?ns] n. 接受

criterion [krai’ti?ri?n] n. 標準 ｜ approve [?'pru:v] v. 批準

refund [‘ri:fΛnd] v. 退還 ｜ specifically [sp?’sifikli] adv. 具體地

routing [‘ru:tiη] n. 路線 ｜ Furthermore [?f?:e?’m?:] adv. 此外

impress [im’pres] v. 給...印象 ｜ approach [?’pr?ut∫] n. 方法

facility [f?’cil?ti] n. 設備 ｜ efficient [I’fi∫nt] adj. 高效率的

brochure [‘br?u∫?] n. 手冊 ｜ literature [‘litr?t∫?] n. 資料

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Conversion: Brief introduction of Process Quality Control簡要介紹過程質量控制

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Scene: In the Cable System workshop
A = Peter, B = Mr. Thoma, C= Albert

A: Mr. Thoma, what you see now is our new automatic production line（自動生產(chǎn)線）, for the products Elisonstack.

B: Is the production line fully automatic?

A: Well, not fully automatic.

**B: ** What kind of quality control do you have?

A: We set up the sampling（抽樣） inspection procedure for the process control. Albert, could you introduce it to Mr. Thoma.

C: I am privileged（榮幸的） to do it. Mr. Thoma, 4 Quality Gates（質量關） are set up in the production line, Cable cutting（斷線）, End preparation（端部處理）, Soldering （焊接） and Overmolding（注塑）. In the 1st gate, acceptance criterion（接收標準） of cable after cutting is defined according to MIL-STD-1916, and also required（要求） and approved（通過） by the customer, Cisco.

B: How about the acceptance criteria?

C: 0 receive a refund（0收1退）. From the 2nd gate, we make sampling check in each gate every 2 hours per shift. Specifically（具體來講）, we check the end preparing 3pcs, PCB soldering 3pcs and Overmolding 3pcs in every 2 hours.

B: Will you record the inspection result, in the routing inspection（巡檢）?

**C: ** Yes, every inspector here writes it down as soon as they finish inspection.

**B: ** Will you make some measuring for the soldering inspection?

C: The distance from AL-foil to soldering pad, and we measure it with the microscope. Furthermore（此外）, the measuring data is recorded in X-R chart, which will be analyzed（分析） by engineers every day.

**B: ** Excellent（極好的）. I’m impressed by your approach to business. In addition（此外）, you have fine facilities（設備）and efficient（有效率的） inspectors. The product gives you an edge over your competitors（競爭對手）, I suppose.

C: Yes, No one can match us as far as quality is concerned.

B: Peter, could you give me some brochures for the products? And the price if possible.

A: Certainly. Here are our sale catalogue and literature.

B: Thank you. I think we may be able to work together in the future.

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Lesson 2

Part 1 Final Quality Control 成品質量控制

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Word Service Station 詞語加油站

Representative [?r?pr?'z?nt?t?v] n. 代表 ｜ complaint [k?m'pleint] n. 投訴

Comment ['k?m?nt] n. 評價 ｜ mount [ma?nt] v. 安裝

Correspond [,k?r?'sp?nd] v. 與...對應 ｜ lean [li:n] v. 傾斜

Cosmetic [k?z'm?t?k] n. 外觀的

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Conversion: Brief introduction of Final Quality Control簡要介紹成品質量控制

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Scene: In the conference room 2, two persons are reviewing the final quality control procedure with customer

Dylan: Quality team leader in supplier
George: SQE in customer
Michelle: Sales representative in supplier

Dylan: Thank George for coming to this conference, to discuss about the complaint (抱怨) we received last week from Simens.

George: Dylan, could I have your comments（看法） on the issue we found in our production line that, a screw missing in your assembly?

Dylan: All right. The long screw which should be ***mounted (安裝) *** in the backshell, was found missing in the assembly. After our analyzing, we consider the ***reason (原因) *** to cause the failure is, the tooth inside the backshell break, then the long screw cannot hold on inside.

Michelle: Then why the mistake escapes?

Dylan: First, no operator checked the tooth while mounting; Second, there is no check for the screw dropping after closing backshell; Third, the inspection fixtures cannot detect the failure.

Michelle: I see. Then how do we control the final quality now?

Dylan: Corresponding to (與…相對應) the root causes I listed above, we made improvements in the three following points. First, add the tooth inspection in backshell assembling to check the defects; Second, add the screw mounting check by shaking, after our Design of Experiments (實驗設計); Third, change the angles of inspection fixtures by leaning（傾斜） it, like the picture now we see.

George: Do you have any visual check for the finished-goods?

Dylan: Yes. We set up the cosmetic inspection（外觀檢驗） before packing.

**George: ** Well, increase it in your corrective actions. Furthermore, how to prevent the same mistake for other products?

Dylan: The evaluation we already carried on（開展） for the other 3 types of assemblies, and we will report to you in 3 days.

George: Great. Could I see the training record for the relevant in-service members? Training new members is also extremely necessary.

Dylan: I will call the colleagues in Training & Development department （培訓與發(fā)展部門）, to ask her to take the record here.

George: What’s your monthly output?

**Dylan: ** 10,000 sets per month.

George: What’s your usual percentage of rejects?

Dylan: Not more than one thousandth in normal operations.

George: That’s really good. Now can we have a look in line?

Dylan: Yes. Let’s go and take a look.

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Part 2 Supplier Quality Control 供應商質量控制

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Word Service Station 詞語加油站

Review /ri’vju:/ v. 回顧甥厦，檢討 ｜ discolor /dis’k?l?/ v. 變色

Originate /?’rid3neit/ v. 起源于 ｜ die cast 壓鑄件

Exceed /ik’si:d/ v. 超出 ｜ contamination /k?n’t?minei∫n/ n. 污染

Condition / k?n’di∫n/ n. 條件 ｜ evaporate /I’v?p?reit/ v. 蒸發(fā)

Detect /di’tekt/ v. 探測 ｜ specified /spes?’faid/ adj. 指定的

Warranty /’w?r?nti/ n. 保質期 ｜ Consequence /’k?nsikw?ns/ n. 后果

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Conversion: Brief introduction of Supplier Quality Control簡要介紹供應商質量控制

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Background: One batch of assemblies were found oxidization on the metal backshell, so metal part supplier in Taiwan made a review（檢討） of its product quality to Leoni via Webex meeting

Ice: Supplier Quality Engineer in Leoni
Terence: Sales in Taiwan supplier
Linda: Quality Team Leader
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Terence: Good afternoon, Ice & Linda. This is Terence.

Ice & Linda: Good afternoon.

**Ice: ** Terence, so you already see the E-mail which I sent you the day before yesterday, about the oxidized（氧化的） backshell which we found in the stock. So, what is the root cause of this oxidization failure?

Terence: After our investigation（調查）, we consider the oxidization or what we called discoloring（變色） mostly originated from（起源） acid remained the micro hole inside the backshell. The micro hole sourced from the unsuitable die casting（鑄造） parameter which exceeded（超出） original setting value. Furthermore, some contamination（污染） came from the transit trays（周轉盤） which are used for transition and recycling using.

Linda: In the case of two reasons above, what measures did you take to prevent it escaping from your factory site?

Terence: Bake the backshell before delivering to Leoni, in the conditions that 120 Celsius degree and half hour. Then acid will be evaporated（蒸發(fā)） out from the micro hole and we will make visual inspection.

Linda: If you can screen all the failures after baking, why didn’t these backshells detect in your final inspection working station?

Terence: In the end of last August, the capacity in main workshop cannot meet the fast-growing demand (快速增長的需求）, so we arrange for some products to bake in the branch of company (分公司）. Unfortunately （不幸的是）, the set-up temperature in oven in branch is a little bit different from main workshop, 35 Celsius degree lower than specified（指定的） temperature. So the lower temperature didn’t work on the backshell baking.

Ice: Could you show us the whole image about the process including the baking?

Terrence: Absolutely （完全可以）. It is the Zinc material incoming （鋅原材進料）, then go to the Die casting, then remove the runner （去飛邊）. Sand blasting （噴砂）, and tapping automatic, plating, and heating, make 100% appearance checking （外觀檢查） and packing.

Terrence: After all (畢竟), the backshell is still one kind of metal, which could be oxidized in long term storing or saved in adverse（惡劣的） environment. For the oxidization resulting from our process, the warranty is 12 months. We would say, the risk is slight minor, and isolate case discussion.

Linda: Before shipping to Leoni, did you implement any reliable test for your products in the factory?

Terrence: We made 100% heating process, and it is one kind of reliable testing. And for each batch, we made 5pcs salt-spray test.

Linda: I remember that. Now let’s see your 8D report.