6.3 -DETAILS OF COMPONENT INSPECTION

COMPONENTS

Part inspected for recording purposes are taken a minimum of twice a day, once after production begins in the morning and once after lunch. The size of each sample lot will always be 5 parts, taken consecutively as they exit the press. These lots are put into labeled envelopes and taken to a well lighted inspection area to be measured, visually inspected, and recorded by the QA Manager or someone trained and authorized to do so.

Recorded dimensions will be the length , width , height. Diameter and Height will be recorded for round pans. We refer to the length as being the pans largest dimension wit the width being the next largest dimension. Recorded data is in inches unless otherwise requested.

Parts are measured with a digital vernier caliper clamped down long the part edges for lengths and widths and at corners for heights. In every case the parts measured along all physical points within the dimension. The maximum value obtained for each dimension is recorded.

Special case:

Square - In order to maintain consistency and be certain both sides are Being measured in a corresponding fashion, the length of the Square is considered to be the dimension measured when the “grain” of the metal of the part flows with the grain of the calipers clamp. Thus, the width will be the side measured when the flow of the part metal is perpendicular to the flow of the caliper metal.

ROUNDS- To insure the entire circumference of a round is within Tolerance limits and there are no bulges or deformations, all Round pans will be slowly rotated within the calipers clamp So that each point along its edge is measured. Again , the Largest measured diameter for each pan is measured.

The height of a round pan will be measured by placing a 0.1 inch machined metal plate across its open top end and then clamping down across the plate and pan together to compensate for the lack of a corner. The recorded dimension is the maximum height of each pan measured, minus the plate thickness.

NON-RECORDED INSPECTIONS:

All of the previously mentioned tests are continuously conducted throughout the duration of a run by our various staff, as was mentioned In section 2.2 . These tests are conducted at the presses while running . Every member of our staff is aware that they must be vigilant in the inspection of all parts and will stop production and alert a manager if any nonconformities are discovered,

It is actually this non-recorded inspection which most directly prevents the production of any flawed components and also guards against a situation where the official recording of the sample measurements may be delayed for some reason.

DIES

Dies are critically inspected by the tooling foreman before being used in production. They are also inspected by setup personnel before being locked into a press.

If work is done on a die for any reason, it is inspected and approved by the tooling foreman before it is allowed to be returned to production.

Please refer to section 8 for new tooling information.

PRESSES

Presses are monitored by their operators and the setup personnel. Any change in performance or noticeable problems are reported to the plant foreman.

All repair work is done by our maintenance personnel under the direction of the plant foreman.

We will generally have two presses shut down at any given time for preventative maintenance work in order to avoid any sudden problems.

As a precaution, every press is equipped with a ‘safety field’ triggered when contact is made with any part of the metal surfaces surrounding the press or breaking the magnetic field. This will instantly shut down the press before contact with moving parts can be made.