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Quality Assurance System for Welding Production

Talent thrives, quality wins, quality is life, products represent character, and quality is the key factor for the survival of an enterprise. Establishing, implementing and maintaining an effective quality management system in strict accordance with ISO9001:2008 standards and continuously improving it are the keys to the long-term survival of an enterprise. Continuously promote enterprise quality management around the six factors of "people, machines, materials, methods, environment and testing", strengthen the inspection and monitoring mechanism, and strengthen the education of quality management awareness of all employees in the enterprise, so that the enterprise can move towards a higher management level and a higher level A modern enterprise with high work efficiency, higher technology content, higher added value, low consumption, no pollution, and information construction.

1. Basic policies and requirements

(1) Make the performance of the company's products meet customer satisfaction and requirements in the short term, and resolve issues returned by customers due to quality problems within this year. product.

(2) We must adhere to the quality purpose and quality direction of "put profit on both sides, responsibility in the middle, quality is life, and customers are God".

2. Establish a complete quality assurance system

1. Develop and improve various welding quality management systems (methods)

① Operator training, assessment and qualifications Review methods.

② Methods for preparation and approval of welding procedures.

④ Welding material acceptance, storage, drying and distribution system.

⑤ Welding equipment management system.

⑥ Product style production management methods.

⑦ Welding heat treatment management system.

⑧ Weld repair management system.

⑨ Welding inspection system.

3. How to build and operate the quality assurance system

1. Organizational structure: Establish a quality management office (referred to as the Quality Management Office) and appoint management representatives.

2. Design control: The correct design of welded structures is one of the most basic conditions for obtaining high-quality structures, so special attention should be paid to design review. Pay special attention to material selection, material matching, joint location and dimensions, groove shape and size, and joint requirements.

3. Procurement documents: The procurement department must strictly follow the procurement technical documents for procurement.

4. Control of purchased parts: All purchased welding materials and welding equipment must be accompanied by certificates of conformity, quality certificates and quality inspection reports that comply with the standards.

5. Identification and control of materials:

① After the structural parts are cut, they must be marked and transplanted according to the prescribed procedures;

② Each welding material should be clearly marked Mark the brand or model and its specifications;

③ Strictly abide by the issuing system and ensure that the physical object matches the mark.

6. Control of special process: It has an important impact on welding quality and has many process parameters and complex changes as special process control.

7. Control and treatment of non-conforming products: minimize and recover economic losses, and carry out three-level treatment of direct reuse, repair and reuse and scrapping.

8. Quality cost: Carry out a quality improvement plan based on the annual plan and the existing quality problems of the previous year, take quality improvement measures, and achieve quality goals within a time limit. When formulating improvement measures, the principle of economy should be followed, that is, when the quality meets the contract requirements or corresponding national standards, the most economical manufacturing method should be adopted based on the actual situation of the enterprise, with the principle of reducing production costs and improving economic benefits.

IV. Establishment and improvement of the quality assurance system

1. Have a complete quality assurance organization and quality control personnel at all levels engaged in quality control

① Quality Guarantee engineer (one person). Entrusted and authorized by the general manager, the highest person in charge of quality assurance work is the highest administrative leader of the Quality Office. In addition to the management personnel of the organization under their direct leadership, the quality responsible persons scattered in other departments should also be under the jurisdiction of the quality assurance engineer.

② Personnel responsible for material quality (one person).

③ The person responsible for process quality (one person).

④ The person responsible for welding quality (one person).

⑤ The person responsible for quality inspection (one person).

⑥ Inspectors (two people)

2. Indicators of normal operation of the quality assurance system

① Personnel at all levels must work normally and have continuous Work records.

② The original records of various technical quality controls in the product manufacturing process are complete, the signature procedures are complete, and the content is true and reliable.

③ Quality information circulation channels are smooth, quality issues are handled in a timely manner, and the handling methods and procedures meet the requirements.

④ The quality inspection department will promptly report quality information and quality problems to the top manager or management representative, and pass them on to relevant functional departments.

⑤Promote quality responsibility system. Deliver on promises and reward long-term winners.

⑥ Regularly hold quality analysis meetings to continuously improve product quality.

⑦ Create a quality management organization operation chart.

3. Product repair and scrapping

① Users who return products must clarify their responsibilities and make original records, including the reasons for the parts, required costs, implementation methods, etc.

② On-site repair: Whoever makes the product will return it, and keep records, signatures, and required costs.

③ Scrap: scrapped products must be signed by the quality assurance engineer to be valid and sent to the scrapping place for storage.

Raw material acceptance system

1. Understand the reputation of material suppliers and collaborating manufacturers, and whether product quality is reliable and trustworthy.

2. The material inspection report must be collected and saved, and strict inspection and control of whether the cooperative manufacturer's single products are qualified and the pass rate must be kept, and records must be kept.

3. Raw materials related to assembly dimensions must be strictly controlled in size according to the drawings and implemented in accordance with national standards. Unqualified materials will not be accepted.

4. Material testing can be carried out if necessary.

5. Products without the three certificates will never be accepted: the material grade, specifications, quantity, surface quality, and batch number must be inspected and accepted before they can be put into storage.

Welding process preparation, evaluation and testing system

1. It shall be prepared by welding technicians of corresponding level, and shall be tested after evaluation by engineers or relevant experts and experienced operators. .

2. The entire test process must be tracked, detailed and true records must be made, and the process parameters must be followed.

3. The test operator must have relevant welding skills and corresponding welding equipment.

4. Verify the process documents during the implementation process, and continuously modify and improve them through information feedback.

Welding quality responsibility system

1. Determine whether the riveted assembled parts meet the process requirements.

2. Determine whether the riveted product meets the welding requirements.

3. Whether the test plate material and welding consumables meet the requirements, and check at any time whether the process parameters of the welding process comply with the process regulations.

4. Check the welding seam forming status at any time to see if there are any welding defects.

5. Strict control and operation according to process requirements.

6. If the process parameters do not meet the welding requirements, they must be corrected at any time on site.

Process Quality Assurance System

1. Prepare the process documents required in the production process according to the requirements of the product. Including some process requirements for some widely used and commonly involved manufacturing processes. Such as material bending, stamping, bending, etc.

2. For some special processes, special processes must be compiled, and the pattern templates must be strictly reviewed to see if they meet the process requirements.

3. Estimate the processing hours according to each process card or process, and put it into production through certification.

Product inspection system

1. Self-inspection: Operators inspect their own products and mark the words "self-inspection".

2. The inspector’s first inspection: The unqualified parts should be marked with the words “This part is unqualified” and a solution will be proposed. After inspection, the parts will be sent to the plastic surgery team.

3. Secondary inspection after shaping and shot blasting. If qualified, the word "can be painted" should be marked.

4. Factory inspection and marked with "qualified".

Welding quality inspection

Welding quality inspection is an important measure to ensure the high quality of welded products and prevent scrap products from leaving the factory.

Through inspection, quality problems that occur during the manufacturing process can be discovered, the causes can be found, defects can be eliminated, new products or new processes can be applied, and quality can be guaranteed; in normal production, through a complete quality inspection system, defects in the production process can be eliminated in a timely manner. defects, prevent similar defects from recurring, reduce the number of repairs, save man-hours and materials, and thereby reduce costs. Therefore, welding quality inspection is an essential and important process in welding production.

7.1 Contents and methods of quality inspection of welded joints

Welding quality inspection runs through the entire welding process, including three stages: pre-welding, during welding and post-weld finished product inspection.

7.1.1 Contents and requirements of welding quality inspection

(1) Pre-weld inspection

Pre-weld inspection refers to the inspection that should be carried out before the weldment is put into production Work is the first stage of welding inspection, and its purpose is to prevent and reduce the possibility of defects during welding. The items included are:

① Check whether the model and material of welding basic metals, welding wires and electrodes meet the design or specified requirements;

② Check other welding materials, such as submerged arc automatic Whether the flux brand, gas shielded welding shielding gas purity and ratio meet the requirements of the process regulations

③Inspect the welding process measures to ensure that the welding can proceed smoothly;

④ Check whether the processing quality of the welding groove and the assembly quality of the welded joint meet the drawing requirements;

⑤ Check whether the welding equipment and its auxiliary tools are intact, and whether the wiring and pipe connections meet the requirements;

< p>⑥ Inspect whether the welding materials are derusted, dried, preheated, etc. in accordance with the process requirements;

⑦ Appraisal of the welder's operating technical level;

⑧ Inspect the welding product drawings and Whether technical documents such as welding procedure specifications are complete.

(2) Inspection during the welding production process

Inspection during the welding process is the second stage of the welding inspection. It is performed by the welder during the operation. Its purpose is to prevent Welding defects caused by reasons or other special cable effects can facilitate timely discovery and solution of problems. Including:

① Check whether the operation of the welding equipment is normal during the welding process;

② The implementation of the welding process regulations and specifications;

③ Whether the welding fixture is clamped firmly during the welding process;

④ Welding defects such as incomplete penetration, slag inclusions, pores, and burn-through that may occur during the operation;

⑤Intermediate inspection of welded joint quality, such as intermediate inspection of thick-walled weldments, etc.

Pre-welding inspection and inspection during welding are important links to prevent defects and avoid repairs. Although most welding defects can be eliminated through rework, rework consumes materials, energy, man-hours, and increases product costs. Usually rework requires more stringent process measures, causing work trouble, and the rework area may produce more complex stress states, becoming a new hidden danger that affects the safe operation of the structure.

(3) Finished product inspection

Finished product inspection is the final stage of welding inspection and needs to be inspected item by item according to the design requirements of the product. The main items included are: checking whether the size, appearance and flaw detection of the weld are qualified; whether the appearance size of the product meets the design requirements; whether the deformation is controlled within the allowable range; whether the product has been heat treated within the specified time, etc. There are two categories of finished product inspection methods: destructive and non-destructive. There are many methods and means. The specific method to be used is mainly determined based on product standards, relevant technical conditions and user requirements.

7.1.2 Welding quality inspection methods

Welding quality inspection methods are divided into two categories: non-destructive and destructive, see Figure 7-1.

Figure 7-1 Welding inspection method

1. Purpose

By correctly defining the inspection standards for welding quality, we ensure that employees produce quality products during the welding and inspection process. Qualified products.

2. Scope

Suitable for welding workshops.

3. Work procedures

Welding quality standards According to the actual conditions of the manufacturing site process, boundary sample visualization can be used to clearly distinguish whether the welding quality meets the requirements.

3.1 The definition of unqualified quality of resistance spot welding joints and the definition of unqualified quality of CO2 gas shielded welding joints and welds.

3.1.1 The following 8 types of resistance welding joints are considered unacceptable and are defined as substandard quality:

3.1.1.1 False welding (no nugget or size of nugget) Less than 4mm) solder joint, code-named L.

3.1.1.2 The solder joint with cracks along the periphery of the solder joint is code-named C.

3.1.1.3 Burn-through, code-named B.