Manufacturer Best Practices Discussion: Designing for ...mddb.apec.org/Documents/2010/SCSC/WKSP1/10_scsc... · – Mechanical Model Review • Analyze functional model that proves

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2010/SCSC/WKSP1/015

Manufacturer Best Practices Discussion: Designing for Safety, Reliability and Quality at Hasbro

Submitted by: Hasbro

APEC Toy Safety Initiative – Open Dialogue on Toy Safety for All Stakeholders

Hong Kong, China12 January 2010

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Critical Review of the Product at Various Design Stages

•  Concept Stage •  Product Definition Stage •  Detail Development Stage •  Pilot and Test Stage •  Production Stage

CONFIDENTIAL: Property of Hasbro Far East Limited

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•  What requirements apply –  What is the age grade

•  The Safety Age Grade for the product is assigned in the concept stage

–  How will the child use the toy •  Review product characteristics for targeted age of the user

against the physical and mental development capabilities of the user

–  What are the hazards associated with the product •  Initial Risk Assessment is performed at the concept stage •  Risk Assessment continues throughout development stages

–  What promotional claims will be made about the product


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•  Inputs to the design team as concept is refined •  Development of initial test plan •  Perform Design Failure Mode and Effects Analysis

(DFMEA) on critical products •  Review of competitive product in the market


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•  Test plan specifications finalized •  Revision of DFMEA as required •  Review of development models as applicable

–  Mechanical Model Review •  Analyze functional model that proves out the engineering design

–  Sculpting/Pattern/SLA Review •  A review of sculpted part waxes or hardcopies, tooling patterns or SLA

generated parts for safety concerns

–  Check Model Review •  Verify that the functioning model matches the intended design •  Verifies the test plan functional requirements can be achieved


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Pilot and Test Stage •  Vendor builds samples for testing •  QA Lab tests samples for compliance to test plan •  Revision of DFMEA as required (including any risk areas due to

manufacturing process) •  Children’s Field Testing occurs as necessary

–  Placement of product in consumer’s household to get an independent assessment of the product

•  When engineering pilot product is approved, the process moves on to production

–  Product meets all safety and reliability requirements –  Chemicals used in the manufacturing process are compliant to Hasbro

requirements


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Production Stage •  Vendor builds product under production conditions with

production workers •  Samples are tested either at an internal or 3rd party laboratory

for compliance to test plan •  When production pilot product is approved and has passed first

inspection, the product is released for shipment with Quality Notice –  Product meets all safety and reliability requirements –  Chemicals used in the manufacturing process are compliant to

Hasbro requirements verified at a 3rd party laboratory –  Product Technical File is compiled and posted on Hasbro Intranet


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Post Production Assessments

•  Incoming Inspection Results •  Consumer Affairs Weekly Complaint Summary •  Customer Evaluation Returns Analysis


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Program Highlights

•  Factory Coating Control Program •  Testing Program •  Vendor / Factory Audit Program


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Coating Control Program Requirements •  Purchase coatings from a Hasbro authorized source •  Control systems at factory to assure that all coatings and processing

agents are tested at incoming and labeled as compliant throughout the manufacturing process –  Applicable for all primary factories and subcontractors.

•  Testing of each batch of coating materials. –  Certifications from the manufacturing are not allowed to prove

compliance. •  Require documentation that only approved coatings are used in the

factory to manufacture product. •  All materials used by subcontractors must be supplied from the vendor

of record. •  Primary factories will be audited at a minimum of twice a year and

subcontractors at once a quarter.


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Factory Coating Controls •  Manufacturing Control

-  Audit of factory paint application processes at OEM factories and subcontractors to ensure use of proper materials, control processes and traceability systems

•  Testing at Various Stages -  Material Level -  Paint Level -  Product Level

•  New Products: at FEP and QN stages •  Existing Products: Regularly at yearly interval and unannounced product

audit at 1st party (Vendors), 2nd party (Hasbro) and 3rd party (Outside) Laboratories


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Factory Product Testing Program •  Testing at Internal Lab

–  Tested at FEP and QN Milestones •  Requires production materials at FEP

•  Vendor Testing –  Incoming lots by batch –  Finished goods at defined intervals

•  3rd Party Lab Testing –  Finished goods on all products once a year

•  Potentially more often based on retailer requirements

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Vendor / Factory Audit Program •  Audit All Vendors twice a year •  Audit All Subcontractors Per Schedule

–  Decoration Factories - 3 times a year –  Molding Factories - 2 times a year –  Sewing Factories - once a year

•  Audits will be both scheduled and unannounced audits

Page 15 January 12, 2010 CONFIDENTIAL: Property

of Hasbro Far Wast Limited

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