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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
Page 1 Page 1
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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
CONFIDENTIAL: Property of Hasbro Far East Limited
Page 4
• 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
CONFIDENTIAL: Property of Hasbro Far East Limited
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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
CONFIDENTIAL: Property of Hasbro Far East Limited
Page 6
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
CONFIDENTIAL: Property of Hasbro Far East Limited
Page 7
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
CONFIDENTIAL: Property of Hasbro Far East Limited
Page 8
Post Production Assessments
• Incoming Inspection Results • Consumer Affairs Weekly Complaint Summary • Customer Evaluation Returns Analysis
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Page 10
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.
CONFIDENTIAL: Property of Hasbro Far East Limited
Page 12
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
CONFIDENTIAL: Property of Hasbro Far East Limited
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CONFIDENTIAL: Property of Hasbro Far East Limited
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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CONFIDENTIAL: Property of Hasbro Far East Limited
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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