The role of quality at Metsec is split into two key functions:
- Quality Assurance
- Inspection and Test
Quality Assurance from a product point of view begins as soon as an enquiry is received; the Quality engineers in conjunction with the Technical Centre review the product specification taking account of items such as: dimensions, tolerances, material specifications, structural properties, application and more. The output of this review results in a technical pack being created which details all the elements required to ensure product conforms to the customer specification and includes:
- Customer Specifications
- Product Drawings
- Tooling Design
- Machine Setting Instructions
- Process Plans
- Control Plans
- Packing Specifications and Labelling Instructions
- Delivery Requirements
Inspection and Test: When the try-out of new tooling has been completed and production samples are available, the samples are measured against the customer requirements detailed in the products technical pack, and the resultant inspection report along with other supporting documentation form part of the part submission warrant (PSW) issued to the customer for approval.
When product approval is received from the customer, the approval is incorporated into the technical documentation and issued for production release. Production approval is then issued to the production department and product is then inspected on future production batches in accordance with the requirements specified in the relevant technical pack.
Inspection procedures and testing equipment at Metsec is varied and is borne out of the requirements determined during the enquiry process.
Inspection of product can be carried out at the machine or in Metsec’s inspection room. Inspection equipment includes:
- CMM equipment whereby product up to 3.0 metres in diameter can be measured.
- Profile laser scanning equipment which is utilised on the cold roll forming lines to ensure profiles produced conform to specification; this is done by scanning the profile and comparing to CAD data.
- State of the art Eddy current testing equipment which checks the integrity of the weld on all welded profiles (100% weld inspection).
Inspection can be further supplemented with the use of dedicated checking fixtures, to check form, length and piercing detail, this is often utilised for the manipulated and fabricated products whereby conventional methods of inspection could be too costly or too time consuming.
Destruction tests of welded profile is carried out in conjunction with in line Eddy current testing whereby a sample from each parent coil of material is tested to destruction ensuring that the weld is as strong as the parent material; all test samples are kept for a minimum of one year with photographic evidence kept for the lifetime of the product.
Welded and fabricated products are manufactured to strict manufacturing parameters and welders are assessed to the latest standards BS EN 15614 and BS EN287. All welded product is 100% visually inspected by PCN qualified weld inspectors prior to being released for despatch with additional samples being taken at random for independent testing at UKAS accredited laboratories. Detailed weld inspection records are kept for each batch of product.