Podcast
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?
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?
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?
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?
What is the most likely cause of chatter marks as described in the text?
What is the primary purpose of the photos provided in the text?
What is the primary purpose of the photos provided in the text?
What is the inspection frequency for the 'Delamination' test?
What is the inspection frequency for the 'Delamination' test?
Which document details the use of M3 Metrology Software on Starrett Scopes?
Which document details the use of M3 Metrology Software on Starrett Scopes?
Which of these quality control tests is performed on every single piece of product?
Which of these quality control tests is performed on every single piece of product?
What is the document number for the procedure on tensile/elongation?
What is the document number for the procedure on tensile/elongation?
What does 'ID' stand for in the context of this document?
What does 'ID' stand for in the context of this document?
Which attribute is subject to on-line, laser monitoring?
Which attribute is subject to on-line, laser monitoring?
If a drawing specifies a roundness of $\text{0.25}$, what would be the corresponding ovality measurement used at PPC?
If a drawing specifies a roundness of $\text{0.25}$, what would be the corresponding ovality measurement used at PPC?
For 'Wall Concentricity', where are the dimensions recorded?
For 'Wall Concentricity', where are the dimensions recorded?
Which of the following is the correct formula to calculate ovality?
Which of the following is the correct formula to calculate ovality?
What is the sample size for the 'Wall Ratio' inspection?
What is the sample size for the 'Wall Ratio' inspection?
What is the purpose of document DMS#1141?
What is the purpose of document DMS#1141?
What is the production identifier for the product being described?
What is the production identifier for the product being described?
What does the symbol 'O' represent on drawings, according to this document?
What does the symbol 'O' represent on drawings, according to this document?
How many pieces are checked for 'Wall Thickness' at the beginning of each spool?
How many pieces are checked for 'Wall Thickness' at the beginning of each spool?
What is the stated frequency of visual surface testing?
What is the stated frequency of visual surface testing?
Which document outlines the process for 'In Process and Shipping Audit'?
Which document outlines the process for 'In Process and Shipping Audit'?
According to the document, what is the primary purpose of document #1151?
According to the document, what is the primary purpose of document #1151?
Which department is specifically excluded from the general application of this document?
Which department is specifically excluded from the general application of this document?
What documentation will primarily dictate the inspection and testing needs for production items?
What documentation will primarily dictate the inspection and testing needs for production items?
According to the document, what is the maximum allowable curvature for parts 6 inches or less in length?
According to the document, what is the maximum allowable curvature for parts 6 inches or less in length?
Who has the responsibility to revise document #1151 as needed?
Who has the responsibility to revise document #1151 as needed?
When inspecting end cuts, which of the following is an acceptable condition?
When inspecting end cuts, which of the following is an acceptable condition?
What responsibility is assigned to employees conducting tests or inspections?
What responsibility is assigned to employees conducting tests or inspections?
If a Quality Inspection Plan (QIP) does NOT specify end cut requirements, which standard should be used?
If a Quality Inspection Plan (QIP) does NOT specify end cut requirements, which standard should be used?
If inspection criteria differ between this document and a document in the Reference Documents list, which takes precedence?
If inspection criteria differ between this document and a document in the Reference Documents list, which takes precedence?
Which of the following is a reason for end cuts to be considered nonconforming?
Which of the following is a reason for end cuts to be considered nonconforming?
Under what conditions should end cuts be inspected, unless noted otherwise in the QIP or specification?
Under what conditions should end cuts be inspected, unless noted otherwise in the QIP or specification?
What documentation is used to record the inspection and test requirements for development items?
What documentation is used to record the inspection and test requirements for development items?
According to the document, how long should a part be inspected?
According to the document, how long should a part be inspected?
Which document provides guidance on the control of non-conforming product?
Which document provides guidance on the control of non-conforming product?
What is the latest revision date referenced in this document?
What is the latest revision date referenced in this document?
Based on the document, which parts are exempt from the maximum curvature requirement?
Based on the document, which parts are exempt from the maximum curvature requirement?
What is the minimum number of readings required to determine if growth or shrinkage has stabilized?
What is the minimum number of readings required to determine if growth or shrinkage has stabilized?
What will happen if the dimensions of the tubing shift outside specified tolerances?
What will happen if the dimensions of the tubing shift outside specified tolerances?
What should be done if the specified tubing has different geometries on either end?
What should be done if the specified tubing has different geometries on either end?
What is the Acceptable Quality Level used for inspections in this procedure?
What is the Acceptable Quality Level used for inspections in this procedure?
What does C=0 in a sampling plan signify?
What does C=0 in a sampling plan signify?
How often can the process of verifying the hot piece restart after making adjustments?
How often can the process of verifying the hot piece restart after making adjustments?
What is required for a different sampling plan if the customer or QIP requests it?
What is required for a different sampling plan if the customer or QIP requests it?
What should be done if growth or shrinkage does not stabilize in three readings?
What should be done if growth or shrinkage does not stabilize in three readings?
Flashcards
What is the purpose of this document?
What is the purpose of this document?
This document defines the standards and procedures for inspecting manufactured products at Putnam Plastics.
What does this document apply to?
What does this document apply to?
This document applies to all production and development parts, except those handled by the Filmcast Department, which uses a separate document DMS #6126.
Who is this document applicable to?
Who is this document applicable to?
This document applies to all personnel involved in the inspection and/or testing of manufactured products.
Who is responsible for maintaining this document?
Who is responsible for maintaining this document?
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What are the responsibilities of employees performing testing or inspection?
What are the responsibilities of employees performing testing or inspection?
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What are "Reference Documents and Forms"?
What are "Reference Documents and Forms"?
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What is a Quality Inspection Plan (QIP)?
What is a Quality Inspection Plan (QIP)?
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How and when are Quality Inspection Plans (QIPs) created?
How and when are Quality Inspection Plans (QIPs) created?
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In-process and Final Inspection
In-process and Final Inspection
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Ovality
Ovality
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Wall Thickness
Wall Thickness
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Roundness/Circularity
Roundness/Circularity
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Concentricity
Concentricity
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Verifying Braided and Coiled Patterns
Verifying Braided and Coiled Patterns
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Operation of the Vision System
Operation of the Vision System
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Metrology
Metrology
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Pcs per Spool
Pcs per Spool
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Length
Length
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Visual Surface Inspection
Visual Surface Inspection
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Wall Concentricity
Wall Concentricity
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Wall Ratio
Wall Ratio
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Delamination
Delamination
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Laser Inspection
Laser Inspection
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Maximum Curvature for Parts (≤ 6 inches)
Maximum Curvature for Parts (≤ 6 inches)
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End Cut Inspection Method
End Cut Inspection Method
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End Cut Acceptance Criteria
End Cut Acceptance Criteria
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Non-Conforming End Cuts
Non-Conforming End Cuts
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End Cut Quality Requirements
End Cut Quality Requirements
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In-Process and Final Inspection Document
In-Process and Final Inspection Document
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End Cut Inspection Process
End Cut Inspection Process
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End Cut Inspection Table (Table 1)
End Cut Inspection Table (Table 1)
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What is a gel (or fisheye)?
What is a gel (or fisheye)?
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What are die lines or flow lines?
What are die lines or flow lines?
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What are scratches?
What are scratches?
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What are chatter marks?
What are chatter marks?
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What is the TAPPI standard (T-564)?
What is the TAPPI standard (T-564)?
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Hot Piece Study
Hot Piece Study
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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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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.
