1. Types of Inspection for Processes, Finished Products, and WIP Products:
Dimensional Quality Control:
- FAI – First Article Inspection – inspecting all the dimensions: Conforms – approval to continue production; Deviates – transfer to the planning department.
- Repeated Product – etching the first sheet, inspecting all the dimensions, receiving approval and continuing production.
- Routine Production – sample inspection as per customer requirements or statistical control based on Desired Level of Quality charts or monitoring in accordance with the “Suron Standard”* (usually more stringent than the standard level).
*Suron Standard – The parts in each of the four corners and the middle of every sheet are inspected.
Visual Quality Control:
• Visual inspection under a magnifying glass or a digital microscope. This inspection detects visual defects such as scratches, stains, wrinkling, and drying stains.
• A certificate of compliance (COC) is issued, and best-fit for customer requirements is ensured. Customer specifications are compared with the finished part. A Dimensional Inspection Report, Plating Reports, and so on are generated.
Dimensional measurement instruments
A 16H Horizontal Beam Optical Comparator
Quality Control of Stencils for the SMT Market:
• Hands-free quality control using a computerized system that scans the finished stencil and compares the manufactured stencil to the cutting file.
• Advanced control ensures first-rate inspection of all the pad measurements in the stencil, their full opening, and other irregularities, if there are any.
Quality Control Via Computer Scanner – Vision Machine:
Dimensional and Visual quality control using a one-of-its-kind, automated, innovative optical system.
• The system compares the measurements defined in the client specifications and the measurements of each finished product.
• The machine operator types the data in, and the system performs optical measurements for 100% of the dimensions and for 100% of the parts.
• When the inspection is finished the system generates the results as a detailed Excel file of all the parts that were produced.
• Parts that deviate from the customer’s specifications are detached from the sheet, and the production process is revised as necessary.
2. Material Review Board (MRB) Process for Handling Customer Complaints and Internal Irregularities:
• Discrepant products are isolated in a “Confined Area” and discussed regularly by an MRB team that consists of managerial representatives from the following departments: planning, QA, PP&C, and customer service.
• The team examines all customer complaints and internal irregularities in depth.
• The information system automatically generates the MRB reports, including all the disposition details.
• As per the Lean Management method, guidelines are provided, as needed, to improve manufacturing processes and ensure optimal utilization of technologies and materials.
• The meeting summary is forwarded to the relevant personnel so work practices can be improved, and to prevent similar irregularities in the future.
3. 5S Policy for Continuous Improvement of Work Stations:
The 5S Policy is an integral part of the Lean Management methodology adopted by Suron. This policy ensures optimum production, quality, and compliance with the high standards of manufacturing complex metal parts.
SORT – Improve sorting habits; arrange and store computer files, documents, work stations, and tools.
SET in ORDER – Organize tools, equipment and materials systematically and efficiently. Comfortable work surfaces and work tables, improved passageways and means of access.
SHINE – Maintain daily cleaning of all work areas, including cleaning tools, returning tools to their place, cleaning tables and work surfaces.
STANDARDIZE – Meticulously follow the work plan, work regulations, safety practices, quality specifications, and quality measures for every technology.
SUSTAIN – Maintain the standards, while performing routine, periodic inspections and distributing inspection results to all levels of management and factory workers.