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PPI is an ISO 9001-2008 and Underwriters Laboratories certified facility. Quality is fully integrated throughout our entire organization, from top management driven to total involvement by all production employees. All quality processes are documented in our Total Quality System Manual. PPI has been selected by numerous customers as a preferred dock-to-stock supplier.
Mold Qualification Process The Preproduction Plastics mold qualification process consists of four steps. These steps are called Test-1 (T-1 for short), T-2, T-3 and Critical Dimension Inspection. They all have different purposes, with the final goal being to achieve a highly consistent and repeatable production part. Each phase of testing requires participation from our customer, where there may be a need for specifying such things as critical dimensions, creating tolerances that are repeatable, reviewing paint and secondary operations, verifying process control, and setting priorities. |
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A short description of each test
is as follows: T-1: This is
the initial test of a newly built or reworked tool. The purpose is to test
the mechanical components of the mold to ensure that it will function
properly. The parts run during this test are to be reviewed in the raw state;
no de-gating or de-flashing is done. That way, everyone can see exactly what the
mold produces. Data is gathered at this time to begin building a process plan
for future mold use. T-2: After
obtaining customer feedback and approval of the T-1 test, the tool undergoes
a T-2 test. This is where the molding process is centered and repeatable
results are obtained. To obtain process control, PPI uses a combination of
melt temperature, shot speed, and mold temperature. PPI’s molding technicians
continue to establish the molding process plan. Coordinated with this tooling
run is the completion of all fixtures and development of any secondary
operation and/or finishing process plans. The molded parts are then inserted,
painted, finished and packaged. Parts supplied at a T-2 test are to be
reviewed for form, fit, function, and all cosmetic and secondary
requirements. All data is recorded for use at the next step. T-3
– Beta Production Run: After
T-2 approval by the customer, the tool is put back in the molding machine for
the final qualification step, the T-3. At this point, the quantity run is normally
the first production release of the first production order. The molding
process is optimized to produce the best, most consistent results possible.
T-3 parts are representative of what the customer can expect in subsequent
production runs. All data recorded during the T-tests is used to build the
final Part Process Plan, which is used in all future productions. Critical
Dimension Inspection: When
required, the inspection of critical dimensions is begun after completion and
acceptance of PPI’s Cp/CpK study. This study
demonstrates that our molding process is in control and our parts are
consistent. The critical dimension inspection of the part is completed on all
dimensions mutually agreed by the customer and PPI. All this
attention to the mold and molding process is crucial to the quality of the
parts produced. With customer involvement throughout the process, the result
is a win-win for everyone, and a high probability of future successful
production runs. Quality Assurance ISO 9001-2008 Certified by Perry Johnson
Registrars |
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