Process Management Plan
ProcessMANManufacturing EquipmentMethods
Step No. Description Operator's skill certificate Machine/Device /Jig /Tools used in this process Process Critical Characteristics Product Critical Characteristics
1IQC: Cell, PCB, PCM, PTC, shell, insulation paperIQC inspector qualification Vernier caliper, projector, digital multimeter, secondary detection performance device Cell: PANASONIC CGA103450
Voltage: 3.75V≦V≦3.95V
Volume: Min≥1850mAh
Shell:
Face:
L length:213.88±0.1mm W width:92.36±0.1 mm
T thickness:12.1±0.1mm
Bottom:
L length:219.95±0.1mm W width:98.95±0.2mm
T thickness:5.8±0.1mm
PCB, PTC and insulation paper are inspected according to IQC standards.
2Welding current limiterSoldering qualification Lead-free constant-temperature soldering iron /
Socket welding jig
The operator should wear grounding bracelet in the left hand and anti-static gloves in both hands1. Never weld current limiter with other electronic parts and make the wrong welding for prevention of solder ball or dross in the protection board.
2. The temperature of soldering iron is 370 ± 10℃, the welding time of each solder joint is ≤3S, as well as the brightness and size of solder joint are uniform.
3Programming PCM testTest qualification

Test jig /
PC / Writer
The operator should wear grounding bracelet in the left hand and anti-static gloves in both hands1. The test steps should be in strict accordance with standard operating procedure (SOP) without error.
2. Handle PCM with care, keep records, and timely give feedback on the quality problem.
4PCM socket welding

Soldering accreditation

Lead-free constant-temperature soldering iron /
Socket welding jig
The operator should wear grounding bracelet in the left hand and anti-static gloves in both hands1. Avoid welding defects to the plug seat feet or welding the socket with other electronic parts to cause burn. The socket comes with no solder ball or dross.
2. The temperature of soldering iron is 370 ± 10℃, the welding time of each solder joint is ≤3S, as well as the brightness and size of solder joint are uniform.
5
Thermistor welding

Soldering accreditation

Lead-free constant-temperature soldering iron The operator should wear grounding bracelet, anti-static gloves and finger caps.1. Never weld thermistor with other other electronic parts or weld it wrongly to burn the protective film. The protection board should have no solder ball or dross.
2. The temperature of soldering iron is 370 ± 10℃, the welding time of each solder joint is ≤3S, as well as the brightness and size of solder joint are uniform.
6Wire bonding


Welding qualification

Lead-free constant-temperature soldering iron /
Socket welding jig(SSD-936)

The operator should wear grounding bracelet in the left hand as well as finger caps and anti-static gloves in both hands1. Never weld wire with other other electronic parts or weld it wrongly to burn the protective film. The protection board should have no solder ball or dross.
2. The temperature of soldering iron is 340℃--360℃, the welding time of each solder joint is ≤3S, as well as the brightness and size of solder joint are uniform.
7PCM visual inspection

Appearance inspection qualification

3-5 times magnifying glass
Anti-static brush
Tin plate jig
Toothpick
The operator should wear grounding bracelet in the left hand as well as finger caps and anti-static gloves in both hands1. Use a brush to clean the protective plate.
2. Check whether parts on the protection board have welding defects, polarity errors, missing problems, etc.
8PCM dispensing

Dispensing qualification

Syringe
Turnover disk
The operator should wear grounding bracelet in the left hand and finger caps in both hands1. Dispense an appropriate amount of curable adhesive on thermistor welding point, as well as B- and B+ solder point on the protective panel.
2. The adhesive should be accurately dispensed on the required point with no overflowing and missing.
9Automatic detection of cell

Cell detection qualification

Cell sorterN/A1. All the cells have to be totally and precisely tested. After test, they need to be placed in order.
2. Observe visually whether they have leakage, deformation, and other undesirable phenomena.
3. Defective products should be labeled.
4. Cells in the same group come with a differential pressure of <1mV, and an internal resistance of ≤ W3m.

10Spot welding of cell

Spot welding qualification

Cell spot welding jig
AVIO spot welder
The operator should wear safety goggles.1. Check the position of all cells and conductive films (polarity identification and insulation paste direction) to prevent short-circuit.
2. After spot welding, the conductive piece and monomer cell should be centered.
3. Spot welder Model: AVIO Channel: CH1/CH2, Power: 24-45w, Pressure:0-3Kg/N, Peak: M, Current: 1.65KA, Voltage: 3.55V
11DuPont and insulation adhesive sticking of cell

Appearance inspection qualification

Automatic cutting machine (SLD-1000)N/A1. Mount the cell into the spot welding jig and adjust its polarity.
2. Paste the second cell in the middle with 0.13mm * 25mm * 50mm DuPont single sided tape and1.6 * 4.1 * 45.5 single sided rubber pad.
3 batteries were attached on both sides of t0.1mm * 12mm * 50mm
4. Each adhesive tap should be pasted flat with no fold.
5. The tape should be pasted in the predetermined range.

12Solder joints check, cell shaping


Appearance inspection qualification


Cell shaping jig, automatic cutting machine
N/A
1. VM nickel strap is adjusted inward and the cell group is adjusted in the same plane. The nickel plate shall not be higher than the cell face, and.
2. PET2 glue shall be aligned and not stick nickel strap pads. The current limiter should be kept parallel with the cell without piercing its surface.
3. Check the spot welding position of each cell and conducting strip to prevent short circuit. After spot welding, the conductive piece and monomer cell should be centered.
4. The glue should be accurately pasted.
13PCM and CELL weldingAppearance inspection qualification

Lead-free constant-temperature electric soldering iron, lead-free solder tipThe operator should wear antistatic wrist strap and gloves as well as mask.1. Each solder joint should be smooth, bright and secure. Do not leave residue tin ball, dross inside the battery, or it may cause a short circuit.
2. The battery should be placed in order.
3. Soldering iron temperature: 340℃--360℃, welding time of each solder joint: ≤ 3S.
14CORP-PACK solder joints checkAppearance inspection qualificationDesktop magnifier, anti-static brush, toothpickThe operator should wear antistatic wrist strap and gloves.1. Solder ball and splash can not be left on the protective board.
2. Conducting strips should be flat and temperature-sensitive resistors should be fitted in place.
15Integrated detection of semi-finished goods Test qualificationNebula tester, PCThe operator should wear antistatic wrist strap and gloves.Open-circuit voltage: Approx 11.1V
FCC: 3500mAh - 3700mAh
Cycle count: 1 - 3
Discharge over-current: 6A-9A
Internal resistance: <170mΩ
Thermistor: 8K-12K
1. During operation, the cell should not be short-circuited and the pole piece should not be damaged by person.
2. Qualified and defective products should be segregated with each other.
3. If batteries fail in the test twice, they need to be isolated for confirmation and analysis.


16Learning test Test qualificationPC/Learning machineThe operator should wear antistatic gloves.1. Operate according to BAT-730 instructions.
2. Select 3S2P learning Program.
3. If the test result is "pass", the product is approved to be qualified. Other results all indicate defective products.
4. Tested defective products should be identified and timely sent for maintenance treatment.

17Adhesive dispensingAppearance inspection qualificationDispenserN/A1. The glue should be dispensed within a specified range.
2. Handle the shell with care in operation. Do not scratch the surface of the shell, and stack it at random.
18AssemblyAppearance inspection qualificationSyringe / CutterThe operator should wear grounding bracelet and antistatic gloves1. The assembling unit of battery should be centered into the bottom case, and a certain amount of thermally conductive glue should be dispensed on the thermistor.
2. Handle the shell with care in operation. Do not scratch the surface of the shell, and stack it at random.
19Automatic dispensing

Appearance inspection qualificationEFD dispenser
Dispensing jig
Syringe barrel / needle
N/A1. Handle with care when assembling the main parts. Do not scratch the face shell or randomly stack the battery.
2. After pressing the start button, the operator should not put the hand and head over into the dispenser.
3. Test procedures and program contents are not free to change and write.

Note: Glue pressure: 30 - 60PA, dispensing control speed: 60mms
20Shell laminatingAppearance inspection qualificationLaminating jigThe operator should wear antistatic gloves1. Apply adhesives to the corresponding position of the internal shell.
2. Quickly cover the face shell when the components are dispensed with CEMEDINE. Check whether the bottom shell and face shell are well matched and the peripheral gap is uniform.
3. Air pressure of laminating machine: 3-5Pa, time: 2 minutes

21Nameplate Affixing

Appearance inspection qualificationN/AN/A1. The nameplate should be pasted in the right location and direction. The surface of nameplate and barcode shall have no spots and breakage, as well as the writing should be clear and neat.
2. Prior to pasting, the appearance of nameplate should be ensured with no defects, and the surface of the battery should be kept clean.
3. Avoid scratch to the surface of the battery during operation. The nameplate should be flatly pasted in the appropriate place, without bubbles and crease.
22Product code pastingAppearance inspection qualificationNon-dust clothN/A1. Surface spots, damage, wrinkles and other undesirable phenomena should not be found on the product code. In addition, the writing should be clear and neat.
2. The product code should be flatly pasted in the appropriate place, without bubbles.
3. After pasting the commodity code, check the barcode. It should not be reversely pasted, wrinkled, damaged, polluted, or found air bubbles and other defects.

23Comprehensive testing of finished products

Test qualification620 tester/PC The operator should wear antistatic gloves in both hands. 1. The test program shall not be randomly selected and written. The battery can bit be stacked in disorder, which may cause missing and false test.
2. Accepted goods and rejects must be separated clearly. Defective products are definitely not allowed to inflow into the next process. Timely find rejects and send them for maintenance.
24Appearance inspection of finished products

Appearance inspection qualificationDesktop magnifying glass, knife, non-dust clothThe operator should wear antistatic gloves in both hands. 1. The output jack of battery shall not have scratches, skew, subsidence, and shall well match the shell.
2. Check whether the face shell and bottom shell are well coordinated, coming with no malposition, stress marks, scratches, paint stripping, deformation, uneven peripheral seam, etc.
3. The nameplate and barcode should both enjoy good appearance, avoiding folds, damage, pollution, bubbles, reverse and missing pasting, etc.
25Packing Appearance inspection qualificationBaler, electronic scale, automatic cutting machine (SLD-1000), PCThe operator should wear antistatic gloves in both hands.1. A bubble bag can only be put into a battery, and the carton can be fully filled with 20PCS. Packing in strict accordance with requirements.
2. All the batteries should be put into the bubble bag in the same direction. They should also be neatly placed in the carton, ensuring consistence in logo and battery direction.
3. Do not forget to offer inventory, inspection report and customs information, paste original packaging and PASS logo, as well as shipping mark.
26OQCOQC inspector qualification


Vernier caliper
Internal resistance tester
Digital Multimeter
The operator should wear antistatic gloves.1. Each groove of knife card is loaded with 1PC battery, and each layer is filled with a total of 10PCS batteries. Each box has 2 layers of knife cards which are separated with a gasket, as well as can be put into 20 batteries.
2. Batteries in the same box shall not have stickers indicating different date of delivery.
27
Shipment
OQC inspector qualification


Electronic scaleN/AEnsure the following information is correct: shipping quantity, shipping address, carton identification, product model, batch number, PASS and ROHS dedicated logo.
    Controls  
Measurement Methods SampleControl Methods SPC/Cpk Actions when 'Out-of-Control'
Size Frequency Resp.Conditions are Encountered
Digital multimeter
Secondary battery performance detection device
Sampling plan GB/T2828.1-2003
Sampling plan AQL:0.65
per lot N/AIQC/SQE
Isolate defective products, deal with it as per the WI of input unqualified products
Vernier caliper
Projector
AQL:0.65N/AIQC/SQE
Digital multimeter
Vernier caliper
PCBA AQL: performance:0.4
cosmetic:0.65
N/AIQC/SQE
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/ 2hrsIPQC

visual
100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/ 2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/ 2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/ 2hrsIPQC

visual
100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/ 2hrsN/AIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/ 2hrsN/AIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/ 2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
3pcsN/Afirst piece confirmation: cell, voltage, internal resistanceIPQC
5pcs1 time/ 2hrspatrol inspection
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcsN/APerform first piece confirmation if parameters are adjusted.IPQC
1PCS1 time/ 4hrsX-MR
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/2hrsIPQC

visual
100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/ 2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/ 2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/2hrsIPQC
comprehensive tester100%per lotP-ChartProduction
Isolate defective products, deal with it as per the WI of input unqualified products
3PCSN/Afirst piece confirmation: semi-product performanceIPQC
5pcs1 time/2hrs 
1104 tester100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/ 2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/2hrsIPQC

visual
100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/ 2hrsN/AIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/2hrsIPQC
comprehensive tester100%per lotP-ChartProduction
Isolate defective products, deal with it as per the WI of input unqualified products
3pcsN/A
first piece confirmation: semi-product performance
IPQC
5PCS1 time/2hrs
patrol inspection
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
5pcs1 time/2hrsIPQC
visual100%per lotN/AProduction
Isolate defective products, deal with it as per the WI of input unqualified products
N/A1 time/2hrsIPQC
visual-per lotN/AOQCN/A
visual-per lotN/AOQCN/A
Main Products