Resarch & development

 

DOC. Title

Process Management Plan

DOC. No

QSSM-R/S

Version

05

Date

2015/8/16

Page

2017/1/4

Process No

Process

Step

Process Description

Controlled

Parameter

Specification

Sampling

Frequency

Equipment

Responsibility

Department

Nonconforming Model

Nonconforming

 Handling

1

Alloy Incoming  Purchase Alloy from Alloy Make Administration Department 

2

IQC  Incoming Quality Control  *Composition  According to Purchase Order  1 Time/Lot  *ICP-OES*Oxygen and Nitrogen Analyzer  R&D Department  Inspection Result
Do not Meet The Specification 
Reject 

3

Coarse Milling  Mill Alloy to Coarse Powder  *Nitrogen Purge Time  ≧5 min  100% *Coarse Milling Machine*Sieving Machine  Production Department  The Supply of Nitrogen Broke Down  Turn off the Coarse Milling Machine Immediately.
Put the Powder after Milling into Storage Tank.
Repair the Supply of Nitrogen
*Max Particle Size  ≦20# 100%

4

Fine Milling  Mill Coarse Powder to Fine PowderGrind coarse particles to find particles *Oxygen Concentration  ≦500 ppm 100% *Jet Mill*Fisher Sub-sieve SizerFisher Production Department  The Mean Particle Size Over SpecificationThe average particle size exceeds the specification Segregate and Mark the Powder After MillingAdjust Classifying Wheel Rotation SpeedContinue to Fine Mill Powder and Keep Monitoring the Mean Particle Size
*Classifying Wheel Rotation Speed  2000-4500 RPM 100%
*Mean Particle Size  1.8-5.0μm 3 Times/Lot 

5

Powder Filling  Fill Fine Powder into Rubber or Metal Mold  *Nitrogen Purge Time  ≧5 min  100% *Glove Box*Electrical Balance  Production Department  The Supply of Nitrogen Broke Down  Stop All Operation in the Glove BoxStore the Powder in Hermetically Sealed CanRepair the Supply of Nitrogen
*Powder Weight  Tap Density = 2.0-3.0 g/cm32.0-3.0 g/cm3 100%

6

Powder Aligning  Align the Easy Magnetization Axis of Each Fine Powder in the Desire Direction  *Output Voltage of Magnetizer  ≧3000V 100% *Pulse Magnetizer *Gauss Meter  Production Department  Rubber Mold Be Dropped or Shook after Powder Aligning  Re-Magnetizing the Rubber  or Metal Mold with PowderCarefully Transport to next Process 
*Strength of Magnetic Field ≧20 kOe 1 Time/3 Month 

7

Vacuum Sealing  Vacuum Seal Rubber Mold with Fine Powder in Plastic Bag  *Vacuum  ≦-70 cmHg  100% *Vacuum Sealing Machine  Production Department  The Plastic Bag is too Loose After Sealing  Cut the Plastic Bag and Take Out the Rubber Mold with Powder
Adjust the Sealing Time 
*Sealing Time  20-80 sec 100%

8

CIP Cold Isostatic Press  *Max Pressure  1500-3000 kgf/cm2 100% *Cold Isostatic Press  Production Department  Green Body Contac with Water  Discard the Green Body 
*Holding Time 0.5-10 min 100%

9

Green Body Arrangement  Take out Green Body from Mold and Arrange for Sintering *Nitrogen Purge Time  ≧5 min 100% *Glove Box  Production Department  The Supply of Nitrogen Broke Down  Stop All Operation in the Glove Box
Store the Green Body in Hermetically Sealed CanRepair the Supply of Nitrogen

10

Sintering  Vacuum Sintering  *Sintering Temperature  1000-1200℃  100% *Vacuum Furnace*Electrical BalanceElectrical balance Production Department  The Density of Magnet Block is InsufficientThe density of the blank is not enough Measure the Oxygen Content in the Magnet Block
If the Oxygen Content Is Low Then Re-Sinter the Magnet Block
If The Oxygen Content Is High Then Discard the Magnet Block
*Sintering Temperature Holding Time  3-10 Hours  100%
*Density  7.4-7.5g/cm3 100%

11

Heat Treatment  Vacuum Heat Treatment  *Heat Treatment Temperature  450-700℃  100% *Vacuum Furnace  Production Department  The iHc Value isInsufficientIHc Adjust the Temperature of Heat TreatmentHeat Treatment and Measure the iHc againIf the iHc Value is still Insufficient then Down Grade the Magnet Block
* Heat Treatment Temperature Holding Time 1-4 Hours  100%

12

IPQC In Process Quality Control  *Magnetic Properties*Density  Refer to “QC Plan”  Quality Assurance Department  Inspection Result
Do not Meet The Specification
According to ”Standard Process for Failure Product Handling” 

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