PVC FABRICATION QUALITY CONTROL MANUAL

Transcription

1 PVC FABRICATION QUALITY CONTROL MANUAL REV COVERING THE WORLD PROTECTING THE EARTH

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3 TABLE OF CONTENTS TABLE OF CONTENTS [17] 1. INTRODUCTION PROGRAM SCOPE RESPONSIBILITY AND ORGANIZATION QUALITY POLICY ENVIRONMENTAL POLICY HEALTH AND SAFETY POLICY RESPONSIBILITIES OF THE PARTICIPANTS PROJECT REALIZATION QUALITY CONTROL MATERIAL PRODUCTION MEETING RELATIVE AND MINIMAL REQUIREMENTS REPORT PRODUCTS RECEPTION DOCUMENTATION VISUAL INSPECTION QUALITY CONTROL RESOURCES MANAGEMENT, ASSEMBLY OF GEOMEMBRANES PVC MACHINE CALIBRATION WELDS DESTRUCTIVE TESTS REPAIRS (BY INSERT) FOLDED LINERS FOR HORTICULTURE ROLLED LINERS FOR HORTICULTURE PRODUCTS INSPECTION INSPECTION OF THE FINISHED PRODUCTS NONCONFORMITY IDENTIFICATION PACKAGING AND SHIPPING OF THE PRODUCTS PARTICULAR PRECAUTIONS DOCUMENTATION IDENTIFICATION 32 PROPERTY DECLARATION THIS MANUAL IS CONFORMING TO THE ISO 9001 STANDARD. THIS MANUAL IS CONFIDEN- TIAL AND IS ASSIGNED TO THE ABOVE MENTIONNED PERSON. IT MUST NOT BE COPIED, NOR LENDED WITHOUT AUTHORIZATION FROM SOLMAX INTERNATIONAL INC S PRESIDENT. REV.07.12

4 INTRODUCTION [18] INTRODUCTION Solmax International inc. has applied, since its opening, a quality control program acknowledged by the industry. However, with the growth of the company and the current competition in the environmental market, we must be at all times able to retrace the realization history and ensure a superior quality level for all the projects we ve undertaken It is in this context that the present quality control manual has been designed, It is mainly intended for use by the assembly operators and the PVC Manager. 2. PROGRAM SCOPE This document covers all the inspection procedures. These procedures allow Solmax International Inc. to ensure a high and constant quality level in its prefabrication work in the plant. These procedures describe all the steps of a project in general. 3. RESPONSIBILITY AND ORGANIZATION Solmax International takes firm commitments regarding the quality of the products and services offered to its customers, the respect of the environment, and the health and safety of its employees. These commitments result in rigorously respected working procedures, measurable concrete objectives, and by the following policies : 3.1. QUALITY POLICY Solmax International Inc. has an objective to offer its customers information, technical assistance and in-plant custommade prefabrication services in the areas related to the geosynthetics use. To do so, the objectives of the company regarding quality must be implemented through its quality program. The realization of the objectives lie with all the employees as well as the management personnel of the company. Furthermore, all the employees must receive the directives and the training necessary to the implementation of the company s objectives regarding quality. Solmax International Inc. quality policy, as well as the general objectives, are described in the quality manual ENVIRONMENTAL POLICY Solmax conducts its business in a manner that protects the environment. We strive for continual improvement of our environmental performance through the implementation, monitoring and updating of our environmental objectives Solmax commits to: Manage its facilities in a manner to be in conformity with the laws and regulations, while focusing on pollution prevention and reduction of adverse environmental effects;

5 [19] Identify, assess and limit the potential risks with respect to the environment and implement appropriate corrective measures, Promote and raise awareness, commitment and accountability of managers and employees with respect to environmental protection; Carry out verifications to confirm that its management practices comply with the objectives of the policies, laws and regulations and the principles of sound environmental management, and to inform the Board of Directors, at determined intervals of time, of the environmental situation of its operations. 3.3 HEALTH AND SAFETY POLICY It is in Solmax International Inc. s policy to operate in a safe and responsible manner in the respect to the health and safety of our employees, our customers, our trading partners and the community in which we work internationally. We do not compromise our commitment in health of safety for profit or production. The organization is responsible to conform to the health and safety policy. Furthermore, every employee, including the subcontractors and contractors, are responsible to work with respect, healthiness and safety in the work environment. This is an employment condition. We must work safely to prevent and eliminate accidents. The health and safety are integrated in all company levels. We conform to all laws and regulations in effect. Solmax International supports the activities of R&D that allows us to predict, measure and reduce the impact of our activities on health and safety. Solmax International will communicate rapidly and openly the status of the results in health and safety to the communities and individuals that request it. Solmax International integrate the aspects and impacts on health and safety in every financial decision the company makes. All the products and services we offer to our customers are aligned with the health and safety policy of Solmax International Inc.

6 [20] 3.4. RESPONSIBILITIES OF THE PARTICIPANTS VICE PRESIDENT OPERATIONS, QUALITY AND TECHNICAL SERVICES The V.P. Operation, Quality and Technical Services is mandated to support, supervise and advise all the participants regarding quality, production and health and safety in their function QUALITY SYSTEM COORDINATOR The principal functions of the coordinator consist in the management of the quality system as well as the technical support related to the implementation of the quality, environment and health and safety for all the personnel management system TECHNICAL SERVICES COORDINATOR The Technical Services Coordinator must also gather information from the PVC department in order to keep up to date the test data base and allow the issue of the quality reports to the customers asking for them PVC MANAGER The PVC Manager is authorized to implement the quality control program and to ensure that his requirements concerning quality are not dependent on any damaging interest. Thus, he must ensure to maintain at all times these requirements. Mainly, his role is to inform the PVC production department on the particularities of a project, to make a random verification of the daily controls or tests as well as to ensure the approval of the finished product. Finally, he must be convoked or informed of any irregularities in the implemented control process. He must then warn the PVC production department in order for the latter to bring the required corrections. He must also ensure, with the help of the other participants, that the nonconformities are identified and noted, make their follow-up and ensure the conformity of the corrective measures taken PVC PRODUCTION PERSONNEL The PVC production personnel, under the supervision of the team leader, has the formal responsibility to ensure that all the works realized in the plant respect the internal quality requirements of this document as well as the ones required by the customer. The directives coming from any other person in charge must be referred to the PVC Manager for approval.

7 [21] The authorized PVC production personnel must supervise all the controls and trials required by this document. He must, using the provided documentation, allow to retrace the follow-up of each realization. He must not go forth in what exceeds his abilities or experience and if he is not certain of the implications of a particular subject, he must take note of the questions without answering them immediately and refer to his immediate superior as soon as possible. 4. PROJECTS REALIZATION 4.1. QUALITY CONTROL MATERIAL The team leader is responsible for the quality material that he was given (tensiometer, sampler, measuring tape, etc.). If an equipment breakage happens, the team leader must take the necessary arrangements in order to remedy the situation. During the assembly of the geomembranes, if the tensiometer is not available to execute the quality control tests, he must immediately inform his immediate superior in order to remedy the situation. No geomembrane assembly must be permitted without the authorization of his superior and of the V.P. Operations, when the tensiometer does not function properly PRODUCTION MEETING In case of a particularity of a plant assembly project or for any modifications to the minimal requirements of this manual, an information meeting must be held by the PVC Manager in the presence of the principal participants of the project. This meeting should allow the establishment of the production mandate. Notably are discussed all the particular procedures concerning the quality control during reception, preassembly, packaging and shipping of the products RELATIVE AND MINIMAL REQUIREMENTS During each project preparation, the Technical Services or the PVC Manager must prepare a summary of the customer s requirements. This form is made from the plans and production work order and must include all the relevant information in order for the PVC personnel to respect the requirements. If the customer s requirements are less strict than Solmax International Inc. s, the latter then prevails REPORT All the follow-up forms (used during the PVC panels production) must allow the history of the preassembly of the materials used to be retraced. They must be clear and precise.

8 [22] 5. PRODUCTS RECEPTION 5.1. DOCUMENTATION At the products delivery, the unloading officer must note on the bill of lading the following elements: - The reception date ; - The number of pallet shipped ; - The number of rolls shipped - The officer s signature. He must also give a sample of the raw material batches to the team leader for laboratory tests ends. During the raw material delivery, the PVC Manager ensure the conformity of the material by getting done, by an authorized person, tensile, thickness and puncturing tests on the sample taken on one of the shipment rolls. The results of these tests are transmitted to Technical Services. The Logistics Manager must ensure that all the information written on the reception slip are conforming to the expedition list of the supplier or the purchase order. Following this reception, Technical Services makes the information entry using the detailed expedition list in the quality database. During the reception of the supplier s quality control reports, Technical Services must verify them. This verification consists of comparing the given results to those required by Solmax International Inc. as well as to ensure that these reports correspond to the received products. These reports must be clearly identified and conserved during the period of the warrantee or in the archives for a period of ten years for the materials that are not covered by a warrantee specific to a project VISUAL INSPECTION A visual inspection of the state of the products must be done by the fork lift driver. This procedure includes a verification of the labelling and the packaging. Any anomaly must be noted on the bill of lading. The non labelled rolls will be set aside and identified as nonconforming until their identification QUALITY CONTROL The welding foreman verifies the material used during the production. The latter must ensure its general visual aspect as well as the roll length. Any detected anomaly must be reported as defined by the nonconformity procedure.

9 [23] 6. RESOURCES MANAGEMENT, ASSEMBLY OF THE GEOMEMBRANES 6.1. PVC MACHINE CALIBRATION PROCEDURES AND METHODS A calibration of the PVC machines is done : After a break of 30 minutes or more After a maximum of around four (4) hours of production. And/or when there is a change of material type. This last condition is defined as being any variation of the membrane type (reinforced or non reinforced) and of the thickness. This welding test is done by the authorized person, with a sample coming from the roll s/he will assemble (or another roll having the same type of material). Before executing this welding test, the welder must adjust his machine and heat up the heating element (the die). Before starting production, the welder must wait for the trained and authorized technician to have obtained satisfying results on the samples taken. The performance of this sample during the test is analyzed and the maximal forces, as well as the obtained rupture types (see rupture type US-EPA) are recorded in the database PEELING TEST A peeling test consist in submitting a weld sample to a tensile strain on a tensiometer, trying to peel, i.e. to open up the weld (see Figure 1). The rupture type and the maximal force are noted. This test gives an indication on the quality of the weld. For each material corresponds a normalized test procedure, as indicated by Table 1 - Annex. Figure 1 - Peeling Test

10 [24] SHEARING TEST The shearing test resembles the peeling test, but instead of trying to peel the weld, it is submitted to a traction strain in the plane of the weld, that leads to the shearing of the weld strictly speaking (see Figure 2 ). The type of rupture and the maximal force are noted down. This test gives an indication on the real performance of the weld in use. For each material corresponds the normalized test procedure, as indicated in Figure 1. Figure 2 - Shearing Test MINIMAL REQUIREMENTS SAMPLES The samples are taken at regular intervals on the length of the weld sample. The weld must be placed at the center of each sample. For the non reinforced geomembranes, five (5) samples must be taken for the shearing and five (5) more for the peeling, as demonstrated by the following figure (Figure 3). Figure 3 - Sampling

11 [25] MINIMAL FORCE The minimal force recorded during the calibration test must be equal or greater to the force required by the customer or as indicated at the minimal specifications of the production work order TYPE OF SHEARING RUPTURE The observed rupture type must be indicated using the American Environmental Protection Agency classification (US- EPA). For the non reinforced geomembranes, the accepted ruptures are those specified by the US-EPA, as stated by the technical data sheet MFT-LAB-31 (see in annex). For the reinforced geomembranes, only the DEL type rupture (delamination in the reinforcement plane) or BRK (breakage in the sheet outside the welding zone) are accepted TYPE OF PEELING RUPTURE The observed type of rupture must be indicated using the American Environmental Protection Agency classification (US-EPA). For the non reinforced geomembranes, all the rupture types are accepted if they meet the minimal requirements. For the reinforced geomembrane, only the DEL type rupture (delamination in the reinforcement plane) or BRK (breakage in the sheet outside the welding zone) are accepted NONCONFORMITY If one of the obtained results (rupture type or resistance) is not conforming to the permitted requirements, the trained and authorized technician must take a new weld sample after having modified the PVC machine parameters. It should be tested the same way as the previous one. No production can start without obtaining conforming results DOCUMENTATION REPORT The calibration report is written directly in the PVC database. It indicates : - The test number; - The product type; - The date and time; - The power and sealing time; - The name of the welder; - The maximal forces obtained (peeling/shearing); - The obtained rupture type (peeling/shearing); - The initials of the trained and authorized technician; - The welding machine number; - The tensiometer number.

12 [26] The results of this report must be kept for a period of ten (10) years or according to the maturity of the warrantee of the contract WELDS PROCEDURES AND METHODS The high frequency or heating wedge fusion methods are used for the welds (longitudinal and transverse welds) between the width of the geomembranes. The equipment used is fixed and the geomembrane sheets are moved on a conveyer. The production is done continuously, in an automated way. In order to ensure the best possible adherence of the weld, the welder must verify the cleanliness of the edges of the widths and must clean them if necessary HIGH FREQUENCY FUSION During the welding process, the polarized molecules are agitated by an electric field. By inversing its polarity several million times per second, the field leads to a rapid modification of the orientation of the molecules. This agitation between the molecules manifests itself by an increase in the material temperature. When, under a certain pressure, this temperature exceeds the fusion point of the geomembrane, a fusion of the two surfaces in contact occurs producing a permanent joint FUSION BY HEATING WEDGE During the realization of a weld by heating wedge, a certain pressure and temperature, greater than the geomembrane fusion point, are applied to allow the fusion of the two surfaces in contact and thus produce a permanent joint AIR FUSION During the realization of a repair on a PVC panel, a hot air welding torch is used for the welding (Figure 4). Figure 4 - Hot Air Fusion

13 [27] WELDS INSPECTION VISUAL INSPECTION A visual inspection is done continuously on the welds by the assistant welder (right after the die). This inspection is done on 100% of the weld s length. Any imperfect adhesion, perforation, tear or other defect that could be detected will be repaired (see section 6.4) AIR LANCE INSPECTION If required by a customer, an air lance inspection can be executed by an integrated system. This inspection is done on 100% of the length of the welds. Any imperfect adhesion, perforation, tear or other defect that could be detected will be repaired (see section 6.4) IDENTIFICATION ROLL For each project, all the available information on the rolls used must be noted down by the welder and conserved in the file (see PVC data base). This information must at least include : - Type of material ; - Project name ; - The panel number ; - The batch identification number ; - The roll number ; - The length used ; - The preassembly date. The rolls already started but not finished are identified with their original identification numbers (Batch No. and Roll No.), the length used and the material type. At the end of each project, the list of the rolls used must be drawn up and included in the project file ASSEMBLY PLAN For each project, the welder must note an assembly plan for each panel, identifying it by the roll number The assembly plan is verified by the team leader, then validated and computerized by technical services. It is conserved in the project file, in electronic format.

14 [28] 6.3. DESTRUCTIVE TESTS PROCEDURES AND METHODS The destructive tests are peeling and shearing tests executed on samples prepared during the production to verify the resistance of the welds in place, and ensure they still meet the customer s or Solmax International Inc. s specifications. The requirements concerning the type of ruptures and the force obtained are the same as for the calibration, except if stated otherwise. The procedures used are also the same as those described to test the samples during the calibration of the welding device. If more than one (1) sample on five (5) does not pass the test, the test will be considered nonconforming NONCONFORMITIES If a nonconformity case occurs, the panel will be identified as nonconforming and the PVC Manager will be informed. The nonconformity will be treated as defined by the nonconforming products control procedure MINIMAL REQUIREMENTS FREQUENCY A sample prepared with the same type of material as the one produced must be destructively tested at the maximal frequency of one (1) per panel or one (1) per 915 linear meters of welding DOCUMENTATION REPORT The results of the destructive tests are directly written in the PVC DB. They include : - The test number; - The panel number; - The number of the welded widths; - The date and time; - Parameters of the weld; - Name of the welder; - The maximal forces obtained in peeling and shearing; - The rupture type (peeling/shearing); - The initials of the technician ; - The welding device number; - The tensiometer number.

15 [29] This report is kept during a minimal period of ten (10) years or according to the maturity of the warrantee of the contract REPAIRS PROCEDURES AND METHODS The nonconformities picked up by one of the steps of the quality control program are repaired and verified according to the procedure, except for the nonconforming welds (for nonconforming welds, see ) INSERTS Any imperfect adhesions, perforations, tears and other defects must be repaired by fusing an insert using a hot air jet. This insert must exceed the defective zone by a minimum of 2-3 all around the defect. All the repairs must be visually inspected by a trained and authorized technician other than the one who executed the repairs, in order to assess the quality of the work DOCUMENTATION REPORT The repairs report should indicate: - The repair number; - The location of the repair; - The date of the repair; - The reason of the repair ; - The technician s initials ; - The QC technician s initials. (See PVC Data base) This report is kept in the file during a minimal period of ten (10) years or according to the maturity of the warrantee of the contract IDENTIFICATION Each repair by insert must be clearly indicated in the assembly plan by the welder and the technician must fill in the repairs report sheet.

16 [30] 6.5. FOLDED LINERS FOR HORTICULTURE PROCESSES AND METHODS When required by the customer, the liners of different size are folded. The liners are folded by a team on a table installed for this end. This table allows by a colour system to rapidly visualize the liners dimensions as well as the final dimension required by the customer. Then, the liners are tied with straps or sealed in a bag according to the customer s request DIMENSIONAL INSPECTION All the folded liners are dimensionally verified by a production employee in a guide designed to this end in order to verify if the product respects the customer s specifications PACKAGING AND IDENTIFICATION The folded liners are packaged in boxes by a production employee. Each box is identified using an identification sheet describing its content and is affixed on the front side of the box. Another method can also be pre-approved by the quality department WORKING INSTRUCTION Each product type must be the subject of a working instruction in order to properly define the customer s acceptance parameters DOCUMENTATION Each folded and packaged liner is identified on the horticulture PVC production report VISUAL AND DIMENSIONAL INSPECTION The team leader verifies the content of each box before their closure. This inspection includes a verification of the content vs. the identification sheet, a liner count as well as a sampling of some liners for visual verification ROLLED LINERS FOR HORTICULTURE WORKING INSTRUCTION Each product type must be the subject of a working instruction in order to properly define the customer s acceptance parameters PROCEDURES AND METHODS When required by the customer, the liners of different sizes are rolled. The liners are rolled by a production employee on the Hortimax. Each rolled liner is individually positioned on a cardboard tube, protected by packaging and visibly identified.

17 [31] DIMENSIONAL INSPECTION When required by the customer, the rolled liners are dimensionally verified by the production employee in a guide designed to this end in order to verify if the product respects the customer s specifications PACKAGING AND IDENTIFICATION All the rolled liners are stacked on a pallet by a production employee. Each pallet is identified on its front side with an identification sheet describing the content of the pallet. Another method can be pre-approved by the quality department DOCUMENTATION Each rolled liner is identified on the horticulture production report VISUAL AND DIMENSIONAL INSPECTION The team leader verifies the content of each pallet before its release. This inspection includes a verification of the content vs. the identification sheet, a count of the rolls as well as a dimensional verification. 7. PRODUCTS INSPECTION 7.1. INSPECTION OF THE FINISHED PRODUCTS Each finished product is controlled by the team leader in order to verify if all the customer s and Solmax International Inc. s specifications were met NONCONFORMITY Any nonconforming product is treated, identified, analyzed, rectified and documented in accordance with the nonconforming products control procedure NONCONFORMITY REPORT When a nonconformity report is necessary, it must indicate all the relevant details to the analysis and resolution of the nonconformity, such as: - The inspected product ; - Produced and inspected quantity ; - Inspection date ; - Name of the technician of the PVC Manager ; - Detected Nonconformity ; - Inspection details. This report is archived during a minimal period of ten (10) years.

18 [32] 7.3. IDENTIFICATION All the inspected products are clearly identified using a conformity label. 8. PACKAGING AND SHIPPING OF THE PRODUCTS 8.1. PARTICULAR PRECAUTIONS The finish and solidity of the loading pallet must be verified attentively before loading the geomembrane panels on them. Before sending the preassembled panels, the team leader must verify the identification of the content of the pallet vs. the information on the documents and the solidity of the packaging DOCUMENTATION The conformity certificates including the in plant quality control results are transmitted to the customer in a final report. An electronic copy is conserved by the quality department for a duration of at least ten (10) years. For the horticulture products, the certificates are transmitted to the customer only if required IDENTIFICATION All the panels manufactured must be clearly identified and must include the following information: - Name of the project ; - Material type ; - Panel dimension ; - Panel number ; - Weight.

19 ANNEX COVERING THE WORLD PROTECTING THE EARTH

20 [34] Table 1: Normalized tests, peeling and Shearing MATERIALS TEST STANDARD Non reinforced Membranes Reinforced Membranes Peeling & Shearing Peeling & Shearing (Grab) SPEEDS (mm/min) (in/min) ASTM D (2 ) 500 (20 ) ASTM D (12 ) 300 (12 ) SAMPLE (mm) (po) 25 x 150 (1 x 6 ) 25 x 150 (1 x 6 ) 50 x 150 (2 x6 ) 100 x 150 (4 x6 ) DIMENSION DISTANCE BETWEEN JAWS (mm) (po) 25 (1 ) 25 (1 + welding) 25 (1 ) 50 (2 + welding) For all the executed tests (calibration or destructive), a sample of 10 X 6 is conserved by the quality department, until the maturity of the warrantee of the contract, or for ten (10) years, according to the longest conservation time of the two.