Molds & Tooling
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PPO Missing First Article Verification Causing Batch Scrap
Problem Phenomenon
[Problem Phenomenon] After changing PPO grades or molds, mass production started directly without first article verification, resulting in batch defect scrap
Cause Analysis
Process windows differ greatly between PPO grades; parameters noted in data sheets are only general guidelines, and special situations (low shot volume, large parts, thin walls, gas assist) may require adjustment; skipping first article verification amplifies risk
Solution
First article full-dimension and performance verification is mandatory when changing grades or molds; solidify parameters after special process debugging; archive first article records; after adjustment, take continuous samples to verify the effect, and resume mass production only after confirming stability
Key Takeaway
PPO parameters are a starting point, not an end point; first article verification is the gate of mass production; after confirming effectiveness, solidify the parameters and practices into the work instruction to prevent recurrence; include this case in the defect archive as a reference for troubleshooting similar problems in the future
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