Inspection Standards at Putnam Plastics
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Questions and Answers

According to the provided information, what is the maximum allowable size for an included object, such as a gel or contamination, in terms of area per foot?

  • 0.10 mm
  • 0.10 mm2 (correct)
  • >0.10 mm
  • >0.10 mm2

    • What is the primary purpose of the QIP (Quality Improvement Plan) mentioned in the text?

  • To establish visual inspection criteria based on the specific part being inspected. (correct)
  • To provide guidance on how to prevent the occurrence of gels and flow lines.
  • To determine the type of contamination that can be tolerated in the product.
  • To define the acceptable size of gels and contaminants in the final product.

    • Which of the following visual characteristics is NOT specifically mentioned in the text as a potential defect?

  • Chatter marks
  • Cracks (correct)
  • Die lines
  • Scratches

    • What is the most likely cause of chatter marks as described in the text?

    <p>Excessive pressure applied during the manufacturing process.</p> Signup and view all the answers

    What is the primary purpose of the photos provided in the text?

    <p>To provide examples of how visual defects may appear in the finished product.</p> Signup and view all the answers

    What is the inspection frequency for the 'Delamination' test?

    <p>One test at the beginning of every spool.</p> Signup and view all the answers

    Which document details the use of M3 Metrology Software on Starrett Scopes?

    <p>DMS#015802</p> Signup and view all the answers

    Which of these quality control tests is performed on every single piece of product?

    <p>Visual/surface</p> Signup and view all the answers

    What is the document number for the procedure on tensile/elongation?

    <p>DMS#1155</p> Signup and view all the answers

    What does 'ID' stand for in the context of this document?

    <p>Inside Diameter</p> Signup and view all the answers

    Which attribute is subject to on-line, laser monitoring?

    <p>Wall Thickness</p> Signup and view all the answers

    If a drawing specifies a roundness of $\text{0.25}$, what would be the corresponding ovality measurement used at PPC?

    <p>0.50</p> Signup and view all the answers

    For 'Wall Concentricity', where are the dimensions recorded?

    <p>One piece each at the beginning and end of every spool</p> Signup and view all the answers

    Which of the following is the correct formula to calculate ovality?

    <p>[ODmax - ODmin = Ovality]</p> Signup and view all the answers

    What is the sample size for the 'Wall Ratio' inspection?

    <p>1 pc at the beginning and 1 pc at the end of each spool</p> Signup and view all the answers

    What is the purpose of document DMS#1141?

    <p>Verifying Requirements Prior to shipping</p> Signup and view all the answers

    What is the production identifier for the product being described?

    <p>2531</p> Signup and view all the answers

    What does the symbol 'O' represent on drawings, according to this document?

    <p>Circularity</p> Signup and view all the answers

    How many pieces are checked for 'Wall Thickness' at the beginning of each spool?

    <p>One piece</p> Signup and view all the answers

    What is the stated frequency of visual surface testing?

    <p>100% of each piece</p> Signup and view all the answers

    Which document outlines the process for 'In Process and Shipping Audit'?

    <p>DMS#1242</p> Signup and view all the answers

    According to the document, what is the primary purpose of document #1151?

    <p>To define the standards for workmanship and inspection methodology of products at Putnam Plastics.</p> Signup and view all the answers

    Which department is specifically excluded from the general application of this document?

    <p>Filmcast Department</p> Signup and view all the answers

    What documentation will primarily dictate the inspection and testing needs for production items?

    <p>Customer Specifications, the Quality Inspection Plan (QIP), and Device Assembly Work Instructions.</p> Signup and view all the answers

    According to the document, what is the maximum allowable curvature for parts 6 inches or less in length?

    <p>1/4 inch</p> Signup and view all the answers

    Who has the responsibility to revise document #1151 as needed?

    <p>The Director of Quality and Regulatory Affairs or their designee.</p> Signup and view all the answers

    When inspecting end cuts, which of the following is an acceptable condition?

    <p>Ends that are square</p> Signup and view all the answers

    What responsibility is assigned to employees conducting tests or inspections?

    <p>To ensure compliance with the work instruction for the product being manufactured.</p> Signup and view all the answers

    If a Quality Inspection Plan (QIP) does NOT specify end cut requirements, which standard should be used?

    <p>Use Table 1 in the document</p> Signup and view all the answers

    If inspection criteria differ between this document and a document in the Reference Documents list, which takes precedence?

    <p>The reference document listed takes precedence.</p> Signup and view all the answers

    Which of the following is a reason for end cuts to be considered nonconforming?

    <p>End cuts with some minor strings</p> Signup and view all the answers

    Under what conditions should end cuts be inspected, unless noted otherwise in the QIP or specification?

    <p>With the unaided eye at 12-18 inches under normal lighting</p> Signup and view all the answers

    What documentation is used to record the inspection and test requirements for development items?

    <p>The Quality Inspection History Form.</p> Signup and view all the answers

    According to the document, how long should a part be inspected?

    <p>A maximum of 10 seconds per part</p> Signup and view all the answers

    Which document provides guidance on the control of non-conforming product?

    <p>Control of Non-Conforming Product (DMS#1018).</p> Signup and view all the answers

    What is the latest revision date referenced in this document?

    <p>4/7/2021</p> Signup and view all the answers

    Based on the document, which parts are exempt from the maximum curvature requirement?

    <p>Parts cut from spools</p> Signup and view all the answers

    What is the minimum number of readings required to determine if growth or shrinkage has stabilized?

    <p>3 readings</p> Signup and view all the answers

    What will happen if the dimensions of the tubing shift outside specified tolerances?

    <p>Appropriate changes must be made and the collected product discarded.</p> Signup and view all the answers

    What should be done if the specified tubing has different geometries on either end?

    <p>Inspect additional samples as needed.</p> Signup and view all the answers

    What is the Acceptable Quality Level used for inspections in this procedure?

    <p>2.5</p> Signup and view all the answers

    What does C=0 in a sampling plan signify?

    <p>No defects allowed in the sample.</p> Signup and view all the answers

    How often can the process of verifying the hot piece restart after making adjustments?

    <p>It can restart multiple times as needed.</p> Signup and view all the answers

    What is required for a different sampling plan if the customer or QIP requests it?

    <p>The change must be approved by the quality team.</p> Signup and view all the answers

    What should be done if growth or shrinkage does not stabilize in three readings?

    <p>Review the methodology used in the measurements.</p> Signup and view all the answers

    Study Notes

    In-Process and Final Inspection

    • This document defines standards and methods for inspecting products made at Putnam Plastics
    • It applies to production and development parts, excluding the Filmcast Department. Specific requirements in other documents supersede this document's general requirements.
    • All personnel involved in inspection and testing are covered
    • Responsibilities for revisions belong to the Director of Quality and Regulatory Affairs, or designee
    • Employees performing inspections/tests must comply with the document
    • References are various forms and documents with specific designations (e.g., DMS#1252 for Product Scope Reading Form 3)

    Definitions

    • IPA: Isopropyl Alcohol
    • OD: Outside diameter
    • ID: Inside diameter
    • Roundness/Circularity: Specified form of a diameter (OD or ID)
    • Ovality: Difference in maximum and minimum diameters (ODmax - ODmin)
    • Concentricity: A measurement of wall thickness variation around a circumference, expressed as a percentage
    • Curvature: Deviation from a 180-degree straight line; "bow"
    • Cut Perpendicularity: The measurement of how perpendicular a cut plane is to its longitudinal axis, measured in degrees

    Inspection Procedures

    • Quality inspectors must inspect products against customer specifications or quality inspection plan (QIP) and record results
    • For products that require dimensional changes after the extrusion process, it's acceptable to collect samples with an offset dimension if tracked properly
    • Products being made must be inspected regularly for compliance with specifications
    • Inspection data that doesn't meet specifications should be marked. Non-conformances are documented for production items that don't meet quality standards

    Inspection of Spooled Product

    • Calculate the number of samples needed based on AQL (Acceptable Quality Level)
    • Samples must be identifiable by bag number, layer number, or spool number for record-keeping
    • Take a minimum of two pieces from each lot's end, and record measurements
    • Inspectors should ensure uniform product winding.
    • The spooled product samples should be inspected every 30 minutes of collection.

    In-Process Inspection

    • Quality inspectors and operators must inspect products based on customer specifications and quality inspection plans
    • All products must comply with specifications using appropriate instruments and gauges
    • Inspection data is recorded on appropriate forms
    • If a product's nature prevents regular checks, notify the supervisor/designated person.

    Product Disposition

    • Products and work orders that pass inspections are moved to Post QC.
    • Samples are identified by sample numbers matching inspection records
    • Wall thickness is the average of at least 4 readings taken around the circumference of the part, unless specified in the QIP
    • Concentricity requirements are based on nominal wall thickness
    • OD specifications are averages unless stated otherwise in the QIP

    In-process and Final Inspection

    • Products for the customer are inspected using C=0 Sampling Plan (Acceptable Quality Level 2.5) unless otherwise specified.
    • Compliance with ANSI/ASQ Z1.4-2003, MIL-STD-105E, or ISO 2859-1 standards for sampling is required.
    • Samples must be collected randomly and throughout the lot.
    • If the AQL is met in the in-process inspection, additional inspections are not required. If dimensions change due to shrinkage, a full re-inspection may be necessary.
    • In-process inspection samples can be used for final AQL needs if necessary.

    Cut Quality

    • End cuts must be square, without fraying, deformities, or splits.
    • Visual inspection, using either unaided eyes or instruments, is used to assess end cuts for non-conformities, following criteria in Table 1.
    • Examples of non-conforming cuts (end cuts that cause deformation or roughness are provided).

    Inspection of Tri-Layer Product

    • Delamination test is performed by cutting tubing at a 45-degree angle. Inspect the cut section for complete separation. Products should not readily separate.

    Non-Conforming Products

    • Nonconforming products are identified and reported following established procedures for non-conforming product handling.

    Quality Inspection History Form (DMS#2531)

    • A form used to record quality inspection history (e.g., recording the required inspection checks)

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    In-process and Final Inspection PDF

    Description

    This quiz covers the inspection standards and methods defined for products manufactured at Putnam Plastics. It includes specific terminology used in the inspection process as well as personnel responsibilities. Familiarity with the requirements detailed in this document is essential for all involved in inspection and testing.

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