(I) Checking the Vehicle
1. Before and after the forklift operation, check the appearance and refill the fuel, lubricating oil and cooling water.
2. Check the starting, running and braking performance.
3. Check whether the light and sound signals are complete and effective.
4. Check whether the pressure and temperature are normal during the operation of the forklift.
5. Check for external leakage and replace seals after operation.
2. Starting
1. Before starting, look around and make sure there is no obstacle to safety.
2. pneumatic brake vehicles, brake air pressure gauge readings must reach the prescribed value before starting.
3. When starting a forklift, the driver should make sure that the load is stable and reliable.
4. Starting must be slow and smooth.
3. Driving
1. The height of the bottom of the forks from the ground should be maintained at 300-400mm, and the door frame should be tilted backwards.
2. Do not raise the fork too high when traveling. In and out of the work site or on the way, pay attention to the overhead there is no obstacle to scratch. If the forks are lifted too high, it will increase the overall center of gravity of the forklift and affect the stability of the forklift.
3. After unloading, the fork should be lowered to the normal traveling position before driving.
4. When turning, if there are pedestrians or vehicles nearby, you should signal first and prohibit high-speed sharp turns. A sharp turn at high speed will cause the vehicle to lose lateral stability and tip over.
5. It is strictly forbidden to turn off the engine when the forklift is going downhill.
6. Non-special circumstances prohibit loaded traveling brake.
7. The brake must not be used when the load is traveling up and down the slope with more than 7° and with a speed higher than the first gear, unless under special circumstances.
8. When the forklift is in operation, it should follow the traffic rules of the factory and keep a safe distance from the vehicle in front of it.
9. When the forklift is in operation, the load must be in the lowest position that does not prevent traveling, and the door frame must be properly tilted back. Do not raise the load except when stacking or loading. If the operator's view is obstructed by a large object, the forklift should be reversed.
10. The forklift is steered by the rear wheels, so it is necessary to pay attention to the swing of the rear of the vehicle to avoid the phenomenon of turning too sharply, which often occurs when beginners drive.
11. Turning on a ramp is prohibited, and you should not drive across the ramp.
(D), loading and unloading
1. Fork loaded items, should be adjusted according to the need to adjust the spacing between the two forks, so that the two forks load balanced, shall not be skewed, the side of the items should be close to the shelf, the weight of the fork should be in line with the center of the load curve signage.
2. The height of the load shall not block the line of sight of the driver.
3. During loading and unloading, the forklift must be braked.
4. When approaching or evacuating the goods, the speed of the fork should be slow and steady, and pay attention to the wheels not to crush the goods cushion wood, so as to avoid crushing the goods tensile up to hurt people.
5. When you use the fork to fork the goods, the fork should be as deep as possible to fork into the load below, but also pay attention to the fork tip can not touch other goods or objects. Minimum gantry tilt should be used to stabilize the load, so as not to slide backward after the load. When the load is lowered, the gantry can be tilted forward a little to facilitate the placement of the load and the extraction of the forks.
6. It is prohibited to pick up the load at high speed and collide with hard objects with the fork head.
7. Do not stand on the forklift during operation.
8. Do not stand around the forks when the forklift is in operation to prevent the load from collapsing.
9. Do not use the forks to lift personnel to work at high places to avoid falling from height.
10. It is not allowed to use the braking inertia to slip the goods.
11. Prohibit the use of a single fork operation.
12. Prohibit overloading.
Forklift safety regulations technology
1. Forklift loading objects, the weight of the loaded object should be within the allowable load range of the machine. When the weight of the object is unknown, the object should be forked up from the ground 100mm after checking the stability of the machine, to confirm that there is no overload phenomenon before delivery.
2. Fork loading, the object should be close to the landing gear, the center of gravity should be in the middle of the landing gear, to confirm that there is no error, before lifting.
3. After the object is lifted off the ground, the landing gear should be tilted back before traveling.
4. Start should be smooth, change the front and rear direction, should wait for the machine to stop before proceeding.
5. Forklift trucks should be slowed down when traveling in turning, backing up, narrow passages, uneven surfaces, etc., or at intersections and close to the goods. Except for emergencies, it is not advisable to use the emergency brake.
6. two forklifts at the same time loading and unloading a truck, there should be a person to direct the contact to ensure safe operation.
7. No single fork operation and the use of fork top or pull cargo.
8. Forklifts should be reinforced with safety ropes when taking fragile, valuable or unstable goods, and should be guided by a person when necessary before traveling.
9. internal combustion engine powered forklift, into the warehouse operation, there should be good ventilation. Strictly prohibited in flammable, explosive warehouse operations.
10. It is strictly prohibited to carry people on the forks. Cab in addition to the specified operator, it is strictly prohibited for anyone else to enter or ride outside.
11. After operation, the forklift should be parked in a flat, solid place, so that the forks fall to the ground and brake the wheels.
12. When carrying out maintenance and overhaul under the vehicle, the internal combustion engine should be turned off, the hand brake should be tightened, and the wheels should be securely fastened.
13. Vehicles need to be repaired after the test drive, should be driven by qualified personnel, the car shall not carry people, loads, when the need for a test drive on the road, should be hung on the test license plate issued by the traffic management department.
14. In the ramp parking, downhill parking should be put on the reverse gear, uphill parking on the first gear, and should use triangular wedges and other tires plug tight.
Forklift safety regulations
According to the "Chinese People's Republic of China *** and the State Safety Production Law", "special equipment quality supervision and safety monitoring regulations", "plant motor vehicle safety regulations", "special equipment registration and use of management rules", "motor vehicle driver within the enterprise" and combined with the actual development of the following operating procedures. Requirements for all employees to comply with relevant state laws and regulations, as well as a variety of facilities, equipment, the use of the scope and method of strict implementation.
In order to strengthen the safety of forklift operation, the development of this safety regulations.
1, personnel
1.1, driving a forklift must be professionally trained, through the safety production supervision department of the examination, to obtain a special operating license, and by the company agreed to drive, prohibited unlicensed operation.
1.2. Drinking and driving is strictly prohibited, and no eating, drinking, chatting, playing cell phones and talking on walkie-talkies are allowed while driving.
2, start
2.1, before the vehicle start, check the starting, audio signal, battery circuit, operation, braking performance, forks, tires, so that it is in good condition.
2.2. When there is a mechanical problem, you cannot repair it by yourself. Should turn off the forklift and inform the mechanical repair personnel.
2.3. When starting, check the surrounding area for people and obstacles, and then sound the horn to start.
2.4. When the forklift truck is loaded for starting, the driver should make sure that the load is smooth and reliable. When starting, the forklift should start slowly and smoothly.
3, driving
3.1, the forklift truck in operation, no one is allowed to get on and off the vehicle, the forks are strictly prohibited to stand on people. Indeed need forklift assistants work, should be equipped with a special basket for forklift, the fork should be forked into the basket below the special fixed slot.
3.1.1, working in the cage: the number of not more than 2 people, must wear a helmet, seat belt, all tools in the tool bag to avoid falling.
3.1.2, in the process of working at height in the cage, forklift drivers:
3.1.2.1, if the nature of the work at height is inventory, labeling and other basically non-hazardous work, forklift drivers do not leave the forklift, in order to provide assistance in a timely manner;
3.1.2.2, if it is the maintenance of lamps and lanterns, pipelines and other work that requires the use of metal tools. Forklift drivers can choose to wear a helmet, sitting in the cab to assist; can also choose to leave the forklift cab, wear a helmet within 8~10 meters around the forklift for safety monitoring, prompting pedestrians to go around and warning unrelated personnel shall not operate the forklift.
3.1.2.3 The forklift can only be moved after the safety frame is placed below 2 meters
3.2 Except for loading and unloading, the forklift must be driven on the right side of the road;
3.3 The forks of the forklift must be 50-150mm away from the ground when unloaded; the height of the goods away from the ground when loaded should not be more than 500mm, and the lifting gantry must be tilted back to the limit.
3.4, if there is someone in front of you, you should press the horn to prompt your route;
3.5, should be with other forklift trucks to maintain a safe distance of three forklift trucks of their own length, except for forklift trucks meeting;
3.6, in the intersection or narrow intersections, you should be careful to walk slowly and press the horn to stop at any time;
3.7, in and out of the work site or driving On the way, pay attention to any obstacles scraping overhead. Non-emergency, can not turn sharply and brake sharply;
3.8, when driving on the ramp,
3.8.1 Empty vehicle up and down the slope - if the empty vehicle on the slope exercise, need to reverse uphill, the forks forward to drive downhill. This way the center of gravity will fall on the front wheels.
3.8.2 Up and Down Ramps with a Load - If you are traveling up a ramp with a load, you need to drive the forks forward up the ramp and backward down the ramp. In this way, the center of gravity will also fall on the front wheels, under no circumstances are not allowed to turn around on the slope;
3.9, forklift trucks are not allowed to overtake in principle, but to overtake the parked vehicle, should slow down to sound the horn, pay attention to the observation, to prevent the vehicle from sudden start or someone jumped off the vehicle.
4, operation
4.1, overloading is strictly prohibited, partial load driving.
4.2, when loading and unloading goods, that is, during the period from the beginning of the fork load bearing to the smooth load bearing and vice versa, the brake must be activated.
4.3, the operating speed should be slow, and impact loading of goods is strictly prohibited.
4.4, to comply with the "seven no"
4.4.1 not allowed to raise the goods to do long-distance driving (height greater than 500 mm).
4.4.2 Do not allow the use of forks to pick over the pallet and the use of braking inertia to slip the method of unloading.
4.4.3 Do not allow direct shoveling of dangerous goods.
4.4.4 Do not allow the use of a single fork.
4.4.5 It is not permitted to use inertia to load or unload goods.
4.4.6 Do not allow the use of forks to take people to work, the forks are lifted up under the forks are strictly prohibited to stand people and maintenance work.
4.4.7 It is not allowed to use forklift to tow other cars, if you really need to forklift towing, then need to be agreed by the director of the administrative group.
4.5, after stopping, it is prohibited to hang the goods in the air, after unloading the goods should be lowered first fork to the normal driving position before driving.
4.6. When the goods are loaded on the forks, the weight of the goods should be shared equally on both forks, the goods should not be skewed, and one side of the goods should be close to the shelf. Small goods should be put into the collection box (board) to prevent falling. Forklift loaded items shall not block the driver's line of sight, such as the emergence of blocking the driver's line of sight should be reversed slowly, such as encountered a slope should not be traveling in reverse, there should be a person on the side of the command forks toward the upward advance.
4.7, the fork in the approach or evacuation of the goods, the vehicle speed should be slow and smooth, pay attention to the wheels do not run over the goods, cushion wood (pallet) and fork head, do not scrape the goods to support personnel.
4.8, forklift lifting or traveling, prohibit any person to stand on the fork to hold the object or play a balancing role. Forklift fork lift, fork range within a radius of 1 meter is prohibited.
4.9, handling goods affecting the line of sight or slippery goods, should be reversed at low speed.
4.10, before transporting goods on the container truck, you should first observe whether the container truck and the shipping platform is tight, whether the truck wheels are in accordance with the provisions of the triangular wood pads, whether there are people in the carriage, estimate the load-bearing capacity of the truck and the truck and the pedal tilt, to confirm the safety of loading and unloading again.
4.11, found or damaged goods, facilities should be reported truthfully.
4.12, in order to protect the driver, forklift trucks are equipped with overhead protection. Driver's body, including hands and feet should be within the scope of protection
5, parking
5.1, try to avoid stopping on the slope, if unavoidable, should take other reliable objects to plug the wheels to tighten the handbrake and turn off the engine. When parked, the fork should be lowered to the lowest position, tighten the rear brake, cut off the circuit, and can not be parked in the longitudinal slope of more than 5% of the road
5.2, can not be parked in the emergency access, entrances and exits, next to the fire facilities.
5.3, the forklift should be turned off when it is not in use temporarily, pull the brake.
6, charging
6.1, the use of chargers, should be selected and forklift matching charger, to be gently held and put.
6.2 After charging, turn off the power first, then pull out the charger plug, and hang the charger, and forbid to put it on the ground.
7, maintenance
7.1, found that the forklift has abnormal phenomenon, should immediately stop and check.
7.2, is strictly prohibited in the case of forklift start maintenance, installation and disassembly of parts. Can not repair the forklift and mounting and dismounting parts
7.3, in strict accordance with the company's forklift maintenance, repair procedures for maintenance.
8, accidents
If you encounter an accident, you should do:
8.1, tightly crouch to the steering wheel or operating handle, and grasp the steering wheel or operating handle.
8.2, lean your body against the opposite side of the forklift tipping direction.
8.3. Take care to prevent injury to the head or chest, and never jump off a forklift when it is tipped over.
Production planning and implementation of the supervisory process
Process Responsibilities Job requirements Related documents
/Records
( Planner,
Materials controller
(Materials controller
(Planner
(Planner
(Planner
(Planner
(Planner
(Orders issued and Order Forecast
1.1 All internal and external sales orders can only be sent to the Planning Department after passing the contract review, otherwise the Planning Department will not be executed, and the same applies to the change of orders.
1.2 On the 20th of each month, the business department sends the formal demand for the next month to the planning department to prepare the production plan for the next month, and the second month's market demand for the planning department to prepare the materials, and the third month's market demand forecast in order to arrange for the pre-ordering of foreign materials.
1.3 Foreign orders are issued by ITC on a rolling basis, and the cycle of orders issued should have a 60-day cycle in principle.
1.4 When there are changes in market demand, orders should be revised in a timely manner in order to adjust the material program to avoid material backlog.
1.5 The Planning Department receives the evaluation of the order through the capacity budget.
1.6 According to the order delivery date and factory production capacity to set the material delivery date.
1.7 According to the material delivery date, the material controller will input the content of the order into the master plan of the "MRP system".
1.8 When the following situations occur, the planner should modify the "master plan list" and the material controller to modify the master production plan, the relevant items of the order have been modified (including models, color, order number, quantity, etc.);
Materials can not be delivered according to the original delivery date.
Designs could not be completed on time resulting in delays in the production schedule
Insufficient material procurement lead time.
(Preparation of monthly production plan
2.1 The planning department prepares the monthly production plan according to the order situation and the main production plan, and will notify you if there are additional orders.
2.2 Weekly production planning should be verified to plan the corresponding model "master plan list (MRP
automatically generated)" of the arrival of materials.
2.3 When the monthly production plan is affected by other factors (such as lack of materials, technical problems, incomplete information, market demand adjustments, etc.), the need to adjust the monthly plan
Finished product storage, delivery process
1. Purpose of the finished product storage effective management to ensure that the finished product in the effective storage period of intact quality. 2. 2. Scope of application applies to the company's finished product storage management. 3. 3. finished goods storage, delivery process responsibilities and work requirements process responsibilities work requirements related documents records overdue not overdue production department team leader team leader, warehouseman team leader and foreman supervisor and team leader supervisor production line to open the finished goods into the warehouse of the warehouseman, according to the batch number, model number, quantity, color into the warehouse; finished product stacking requirements: - according to product color, batch number, model divided into areas. Color, lot number, model division of the region, respectively, neatly stacked, not allowed to side, upside down; - stacked layers can not exceed the number of layers specified on the wrapping paper, and according to the requirements of the respective obvious mark. Storage conditions: - Finished products should be stored in a non-acidic, non-alkaline, non-corrosive environment; - The warehouse should be kept neat, clean, dry and ventilated environment; - Do a good job of fire prevention, anti-theft and other measures to ensure product safety. If the stock of products is found to be stored beyond the expiration date, fill in the "overdue stock report form of finished products" every month, report it to the supervisor, and notify the relevant departments after marking the overdue stock. After the business department receives the report of overdue stock, it will arrange the quality control to inspect the overdue stock before shipment. Qualified, normal shipment. Failed, reported to the department head, the planning department to arrange rework. Payment order finished goods inventory report finished goods overdue inventory report flow process duties job requirements related documents records business sector staff staff staff staff business sector issued by the approved (for example: sales accounting department) finished goods "transfer order" into the warehouse received by the market, ITC or OEM issued "transfer order", according to the single "transfer order". "After receiving the "transfer order" issued by the marketing department, the warehouse will prepare the goods according to the requirements of the single; if there is a change in the date of shipment of the export machine, the relevant departments should be notified into the warehouse; into the warehouse in accordance with the principle of first-in, first-out, register the batch number, model, where to send the actual date of shipment to arrange for verification of the shipment of the model, color, quantity and accuracy of the shipment, loading and shipment; the warehouse should be used as a basis for the "transfer order" every month. The warehouse should use the "transfer order" as the basis for statistics on the shipment summary of various models, in order to check with the Marketing Department, Financial Services Department, International Trade Department and OEM. Transfer order Preparation: Audit: Approval:
Non-conforming products handling process
1. Purpose Purpose
In order to ensure that the defective materials to be timely and reasonable treatment, to reduce unnecessary waste, cost savings, the development of this procedure.
This procedure for ensure nonconformity material handling well, reduce unnecessary waste, economize cost.
2. scope scope
Where the company due to quality problems and need to deal with defective materials.
All our company need to handle nonconformity material of quality problem
3. definitiondefinition
SORT-------- picking/processing:
SCRAP---. ---- scrap
RTV--------- return to supplier
REWORK------ rework
4. Responsibilityresponsibility
Quality------- is responsible for checking and confirming the material.
Quality department ------ responsibility for material inspection, approve.
Stock department ------- responsibility for material receiving and keeping, issue.
Stock department ------- responsibility for material take over and saved , put out.
Production department ------- responsibility for material picking, processing.
Produce department ------- responsibility for material sort , machining.
PMC ---------- responsibility for material planning and control.
PMC department -----responsibility for material plan & control
Purchasing department -------responsibility for material purchasing and supplier returns.
PD department-------responsibility for material buying & return to vendor
5. reference documentrefer document
N/A
6. procedure procedure
6.1 Return to vendor procedure
6.1.1 IQC will inspect the incoming materials delivered by the supplier according to the different material numbers in batches, and if any quality problem is found, it will be written in the <<IQC Packaging Material Inspection Report>> and handed over to MRB for processing. The IQC will be able to handle this.
IQC inspection materials for vendor according material part number , if look for have quality problem , in < < IQC packing material inspection report > > mention expressly, deliver to MRB handling.
6.1.2 MRB decided to return to the supplier, by IQC in the ID LABEL label "RTV", the defective material material will be returned to the cargo hold. The defective material will be returned to the cargo hold, stored in the cargo hold in the pending area or return area, by the PMC issued << return orders >> to the cargo hold.
After MRB decision return to vendor, IQC put " RTV " label by ID LABEL, and return the material to stock, stock saved the material on the "stay by handling zone" or "returning material zone", send< < return material sheet > &> to stock by PMC. gt; to stock by PMC.
6.1.3 Purchasing department contact the vendor time for take back material, (or can be contacted directly by the quality department, but to inform the purchasing department and PMC), will be the exact time to verbally notify the cargo hold to be ready for the return of the goods, (if necessary, using written notice)
PR department contact vendor time for take back material,( quality department can direct contact, but need inform PR department with PMC), tell time oral notice to stock prepare to return material, (necessary use written notice)
6.1.4 Supplier according to the specified time to the factory to take back material, the cargo hold according to the <<Return Form>>, will be returned to the material again after counting the supplier's representative, and will be the supplier's representative signed acceptance of the
Vendor come to take by nonconformity material, stock according < < return material record > >, check material again and take it to vendor. check material again and take it to vendor, then send < < return material record > > of vendor signed to PR department & PMC.
6.1.5 Before MRB decide to return material, will make following consideration:
Before MRB decide to return material, will make following consideration:
6.1.5.1 Whether the incoming material can be accepted in any other way, e.g., picking, rework.
Incoming materials whether it is can according other wise have been accepted e.g. sort repair.
6.1.5.2 Whether the returned material is an important part of the product, and if used, whether it has serious impact on the final quality of the product. If it is used, does it have a significant impact on the final quality of the product.
Nonconformity material whether it is to form product of important place, if has been used, whether makes serious influence for last quality of production.
6.1.5.3 Whether it will cause production line downtime or shipment delay if it is returned.
If being going to return material, whether making production line stop work or missing shipping date.
6.2 Selection/processing procedure sort/machining procedure
6.2.1 IQC inspection of incoming materials, according to AQL standards to determine the whole batch of unqualified, handed over to the MRB for processing, when the MRB final determination of the material results for the selection of the material, the IQC fill out the < < IQC selection instructions > >, distributed in the selection department, and the incoming material will be posted on the selection sticker to be handed over to the cargo hold.
When IQC inspection incoming materials, inspector according AQL determinant material is nonconformity, send to MRB handle, when the MRB decision sort this material, IQC record the < < IQC sort from > >, distribute to sort department ,and put "sol" label in materials, send to store. label in materials, send to store.
6.2.2 Goods cabin received to choose the incoming material, the material will be placed in the "to be dealt with" temporarily or directly to the material to the selection department.
After store receive need sort materials, and take it put in " stay handle place" or send to sort department.
6.2.3 Selection, IQC to select personnel to provide quality standard and related Note, if necessary, can send personnel to the scene to guide, at any time responsible for the selection of personnel to consult and query the selection of the effect.
When sorting, IQC offer quality standard to sort person and related notice item , necessary can send inspector going scene , Responsibility with sot person consult inquire and inquiry sort effect .
6.2.4 After sorting, the person in charge of selection statistics of the batch of incoming materials sort man-hour, will be defective and good products with obvious signs of separation and isolation, and fill out the <<IQC selection instructions>> handed over to the IQC.
After sorting, the principal statistic incoming materials sort man-hour , take with nonconformity material & good material separate, and write < < IQC sort form > > to IQC.
6.2.5 IQC approve sort result, and check <<IQC sort instructions>> > to IQC.
IQC approved sort result, and check <<IQC sort form> > to IQC. sort form>>, send to related department, the good material can put in store or use in production. nonconformity put in "returning The good material can put in store or use in production. nonconformity put in "returning material zone".
6.2.6 Defective products will be handled according to the result of the decision after consultation with the related department.
The handle result according to decision, after nonconformity negotiate by related department.
6.3 Rework procedurework
6.3.1 When QA in the batch inspection process When QA in the batch inspection process found that the product does not meet the quality requirements, you need to timely notify the production department team leader, director, and issued rework orders, stamped "REJECT".
When QA find the material not reach quality requirement, need to inform production foreman director etc, and issue to rework record, put in " REJECT " seal.
6.3.2 Rework started by the production department team leader or assistant to personally teach employees to rework the details of the operation, and do the demonstration, the quality standards can consult the quality department.
Will do again , beginning by production department leader or foreman instruct worker operate details ,show demonstrate, quality standard can
6.3.3 Rework completed fill in the rework sheet, the reworked material to QA re-inspection, such as QA in the re-inspection process is still found in part of the product does not meet the quality requirements, still need to ask the production department to rework, until the rework OK.
6.3.4 Rework QA re-inspection OK, QA re-inspection of materials stamped "PASSED", and make a record.
Reworked defective materials by the production department for scrap or processing.
6.4 scrapping procedurescrap procedure
6.4.1 Due to engineering changes or process improvements, or ordering errors, purchasing errors, etc. need to scrap the material.
6.4.2 Distribute engineering change notification from PE department to the following departments for scrapping the materials: quality department, cargo hold, production department, purchasing department, PMC.
6.4.3 After the cargo hold gets the scrapping notification, place the materials in the scrapping area and count the number of the materials, and fill in the << scrapping request form>> and hand it over to the PMC.
6.4.4 PMC receive <<scrap application form>> > immediately after the notification of the quality department to the cargo hold to confirm the quality of the Department of Quality in accordance with the PE department issued by the change of tips to confirm the quality of the situation.
6.4.5 If the quality department to check the information and materials do not match, immediately notify the relevant departments to review, and then confirm after the review is clear.
6.4.6 The quality department confirms that the material can be scrapped, write a report to inform the PMC and the cargo hold.
6.4.7 PMC received the Ministry of Quality's confirmation of the inspection, fill out the virtual & lt; & lt; scrapping application form & gt; & gt; handed over to the cargo hold, and arrange for the scrapping of the material "implementation of the department" and "implementation of the time", cargo hold Receive <<scrapping application form >> immediately send the material to the scrapping "executive department".
6.4.8 After receiving the scrapped material, the executive department will check whether the material and information are consistent before scrapping.