The Q.A./Q.C Procedure is implemented to maintain quality production of Alubond U.S.A. Aluminum Composite Panel. The three phases are Pre-production Inspection, Production Proper and After Production Inspection.
A. Pre-production Inspection
The following raw materials are being subjected to series of test and getting approval before it is brought to the next phase.
- Aluminum Coil
- Plastic Granules
- Adhesive Film
- Protective Film
Aluminium
| Test | Physical Properties |
| Tools | Visual, Micrometer- with O.05mm Tolerance accepted International , Meter Tape, weighing scale, new Coil & color coil guide (200x 200mm) |
| Procedure |
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| Test | Dry Adhesive Test |
| Tools | 50 mm width Scotch Tape, Sharp pointed metal, New coil Sample |
| Procedure |
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| Passing Result | No cracks visible on the surface of the sample, no coating Peel-off should be seen on the tape |
| Test | Pencil Hardness Test |
| Tools | 2H Pencil- Flat lead, New coil sample( 200x200mm) |
| Procedure | Make 6mm line on the surface of the sample coil using the Pencil on 45 degrees angle with putting download pressure |
| Passing Result | No coating cracks and coating peel off visible on the surface of the sample |
| Test | Impact Test |
| Tools | Impact tester, New coil sample( 200x200mm) |
| Procedure | Drop the lkg weight from 500mm height directly to the coil sample |
| Passing Result | No coating cracks and coating peel off visible on the surface of the sample |
| Test | T-Bend Test |
| Tools | New coil sample( 200x200mm) |
| Procedure | Partially cut lOmm strip from the edge of the sample. o Fold lOmm strip 3 times to zero degree |
| Passing Result | No coating cracks and coating peel off visible on the surface of the sample |
| Test | MEKTest |
| Tools | MEK, Cotton cloth, New coil sample( 200x200mm) |
| Procedure | Pour ample amount of the MEK on the cotton cloth. Wipe the cotton cloth with MEK directly to the sample surface 50 times backward & 50 |
| Passing Result | No color fading off visible on the surface of the sample |
General Notes: All specimen samples are labeled at the back with testing date, kind of test performed & results obtained.
Plastic Granules
| Test | Physical Properties |
| Tools | Visual, sense of touch, LDPE sample |
| Passing Result | Visually inspect that granule are smooth and soft when touched, shining under light, needle hole in the middle are not present |
| Test | Float Test |
| Tools | Tub with water, LDPE sample |
| Procedure | Put ample amount of granule sample on the tub with water. Greater quantity floats on the water surface |
| Passing Result | Greater quantity floats on the water surfaceGreater quantity floats on the water surface |
Adhesive Film
| Test | Physical Properties |
| Tools | Visual, Meter Tape, weighing scale |
| Procedure | Visually inspect the adhesive film from damages arise from unloading and specification width and weight as per shipping documents |
| Passing Result | Moisture not present in any areal part of adhesive. No cloudy marks on the surface of the adhesive |
| Test | Boil Test |
| Tools | Specimen sample, Iron box |
| Procedure | Prepare the sample by heating the adhesive over the panel using Iron Boil the sample with adhesive continuously for 2 hours |
| Passing Result | Delaminating should not be observed |
Protective Film
| Test | Physical Properties |
| Tools | Visual, Meter Tape, weighing scale |
| Procedure | Visually inspect the adhesive film from damages arise from unloading and specification width and weight as per shipping documents. Wipe cotton clothe with thinner on the print design of the sticker |
| Passing Result | Moisture not present in any areal part of protective film. Printed design should retain after wiping with thinner |
| Test | Oven Test |
| Tools | Specimen samples, Oven |
| Procedure | Prepare the sample by stick the protective film. Put in oven for 2 hours at 80 degrees Celsius. Take out from the oven & let it naturally cool completely Peel off the film. |
| Passing Result | The film should not leave any gum or adhesive on the panel surface |
Production Proper
The production line is in three 8-hour shift with Q.A./Q.C. present on each shift.
- Boiling water test is performed on each coil change
- Defective part of sandwiched panel coming from the production line are cut off immediately and recorded
- Sandwich panel should meet the characteristics as listed prior to application of Protective Film
Testing items: Standard index
Vestige: Indistinct
Ripples, edge wave: Indistinct
Bubble (<10mm): < / m2
Flaw (<3mm): < pieces/m2
Scratch: Total length <100mm/m
Abrasion: Total area < 300mm/m
Color difference: Indistinct by eyes; De< 2 by color matching machine
Boiling water resistance: No change within two hours
Coating omit: Not allowed
The Finished product should meet the physical characteristics with in the tolerance allowed.
Length: ±3mm
Width: ±2mm
Thickness: ±0.2mm
Squareness: <5mm
Warpage: < 5mm 1m
1800 peeling force: 4mm panel: 0.5aluminum 2:7N/mm, 3mm panel: O.3aluminum 2:5N/mm
- Pulling strength of panel are checked every 30 minutes interval.
- Each panel are marked with sequence no., color code, panel specification, production date, time, shift no .. The same are recorded in sheet report including the quantity produced per batch of production.
- One sample of 200 x 1250mm is kept per batch of production with marking at the back side of panel such as Production date, color, coil no, batch no & customer’s name.
After Production Inspection
Final Quality check is done after the sandwich panel comes out from the production line.
- Dimensions are checked as per production chart order.
- Bubble, ripple, edge wave, abrasion are checked.
- Accomplish Final Inspection Report.
- Q.C. Passed stickers are fixed at the back of each sheet.