Established guidelines on quality control inspection of extruded aluminium profiles and flat stock, pre-worked panels and sheet materials.

EXTRUDED ALUMINIUM PROFILES: (Goods / Materials Received):

QC Inspection procedures are applied to all extruded aluminium profiles, upon notice from Planning Department of the receipt of unloaded profiles.

Q. C. PROCEDURES:

Quality Check:

Ensures all delivered materials are as per purchased orders (furnished to QC by Sales upon ordering of materials), an actual physical count is conducted. Profile configurations are also checked against approved die drawings. General material descriptions are noted in this stage. Suppliers are advised of any shortfalls.

Visual Check (Quality):

This ensures acceptable limits of good surface finish. The following are checked in each and every profile bar:

1. Scratches: scratches are not acceptable on all visible surfaces and are subject to rejection if noted.

2. Marks & Die Lines: permanent marks caused by ropes, tapes, water stains are not acceptable. Jigs marks are acceptable only when confined within the 50 mm waste cut at each end of the profile; bar.

3. Mechanical Damage: dents and other deformities caused during handling, transport, etc. are not acceptable and are subject to rejection.

Any defects noted by Quality Inspectors are clearly marked on subject profiles. Instrument Check: Precision instruments are used to measure and / or check quality and specifications such as anodic coating thickness and colour range limits.

CONTRACTS, APPROACH AND EXECUTION

Al Taiseer Aluminium Factory, in keeping with its traditions of excellence in the development and execution of its projects, recognizes and exercises overall project planning and control over several key areas of activities as pre-requisites in ensuring cost effective and top quality products in the performance of its contractual obligations. In close coordination with the client or client’s consultant, materials procurement, design engineering, manufacturing, quality assurance, packing and delivery of products are all carried out in the most efficient manner.

OVERALL PROJECT PLANNING AND CONTROL: KEY AREAS
Procurement:

The timely requisition and delivery (i.e. with sufficient lead time) of materials for fabrication particular to a contract is of primary concern in prompt and on-schedule deliveries of manufactured products. These include aluminium extrusions, weatherstripping gaskets, sealants, glass, hardwares and accessories. Materials for Al Taiseer’s standard S-2000 door and window systems are held in- stock in sufficient quantities enabling construction mock-up samples for client’s approval on testing and even early deliveries for small to medium-sized contracts.

Design and Engineering:

In most cases, Al Taiseer’s highly qualified design staff is involved from project inception, development and execution. At each phase of a project, our design engineers play key roles in project scheduling, preparation of detailed shop and fabrication drawings as well as structural calculations and installation procedures whenever called for. Contract requirements for approvals of both designs and materials samples in conjunction with clients; consulting engineers are carefully monitored and controlled to meet exacting standards.

Production:

It ensures that quality standards are consistently met and maintained. Al Taiseer Aluminium Factory gives utmost importance and commitment to the following:

1. Prior to commencement and during production of a certain project, inspections are made by Supervisors for compliance to material specifications.
2. Ensure accuracy and precision of machinery and equipment.
3. Whenever required, we construct mock-up samples for the client’s approval for compliance with specification requirements and/or testing for the             determination of performance characteristics.

Quality Assurance / Control:

Products and services are regularly inspected and reviewed for built-in quality. Management of product quality involves every phase of project implementation; from procurement, design, production, and quality inspections up to delivery.

QUALITY ASSURANCE/CONTROL PROCEDURES DEMANDED ARE STRICTLY FOLLOWED BY AL TAISEER’S QUALITY INSPECTORS.

1. Preliminary Inspection:

Quality inspectors are fully knowledgeable with the established standards, inspection procedures and instruments conduct thorough checks of materials received with respect to their visual, surface, physical and dimensional tolerances. A reference QC Manual for Preliminary Inspection of Goods Received specifically covers aluminium extrusions, flat, stock sheets and panels. Once all checks on materials nave been made and cleaned for usage, all significant surfaces of profiles are then protected with low tac tapes.

Another important component of AL Taiseer’s quality assurance efforts is the regular inspection of equipment for accuracy and precision. These are all properly recorded and signed by Supervisors in section logbooks.

2. In-Process Inspection:

Each team is led by highly experienced chargehand(s). The various work stations are rigorously inspected for on-going quality. During normal production runs, these work stations carry the following responsibilities:

A.) Cutting / Machining Section – on completion of cutting and machining operations, materials are derigged of any swarf, burrs or sharp edges. Machines, jigs and fixtures are checked at no less than weekly intervals during use. Cut bars are checked for accuracy of dimensions and meters.
All inspections are recorded in section logs and signed by the supervisor(s).

B.) Sub-assembly Section – proper set-up of hardware and accessories are ensured. Proper operations of same are checked.

C.) Glazing Section – glasses to be used are checked for dimensional deviations, wave defects, scratches, trapped dirt inside leaves of insulating glass units, etc. before glazing. Proper glazing practices are observed to comply with the required glazing standards and code of practice.

D.) Final Assembly Section – ensures that individual components of a unit have been assembled
correctly.

3. In-House Window/Door Testing:

An additional control in quality assurance, Al Taiseer has acquired a fully computerized test bench capable of testing doors and windows for performance to exacting British, European (DIN) and American Standards. On a periodic or random basis, windows or doors can be selected from the production line and their exact performance tested and verified. Potential problems are identified and resolved early in the manufacturing process.

4. Final Product Inspection:

Inspectors are all familiar with the standards laid down by Al Taiseer with reference to the British Standards method of compliance and sound trade practices. All integrate and fully cooperate with management to ensure that no product leaves the works fall below the criteria dictated by the required standards. (Reference – Quality Inspection Check List). With regards to the acceptance of a unit, a QC label of acceptance is attached and documented as required.

5. Delivery and Protection:

Aluminium window and door frames, components, loose glass and accessories are protected with low- tac tape or other suitable packing materials from the time or leaving the factory premises up to being installed in the building. Suitable storage areas/conditions are usually provided by the client to safeguard all units/materials prior to installation. Our in-house containers are specifically modified to suit particular contract unit requirements for individual unit protection during delivery.

All units, assemblies or elements are prepared and packaged for transport to site. All corners, edges and finished surfaces are adequately protected to avoid damages in during handling and transit.

6. Anodic Coating Thickness (micron test):

Random inspection usually limited to 5% of the number of bars in a bundle is made for compliance
with the specified minimum coating thickness.

Instrument: Permascope E110 – 5 readings at regular intervals along the profile height.

7. Colour Range:

5%* of number of bars/bundle minimum checked as specimen.
Control Limits: +/- 8% when calibrated against maximum/minimum colour range limits, usually 5
readings at regular intervals along profile length.

Instrument: Dr. Lange universal measure unit 4, with digits read out.

8. Dimensional Checks:

Extruded profiles are checked according to special agreed tolerances stated on the approved die
drawings in order to:

This enable assembly of various combinations of frames, mullions, shutters, etc. to fit together exactly
within specifications during manufacture.
This enables hardware and accessories easily fit into the profiles.

The following checkpoints and applicable standards are:
A.) Tolerance in length – Table 7, BSI 1474:1972.
B.) Tolerances on thickness of bars and regular sections – Table 9, BSI 1474:1972.
C.) Tolerances on thickness of hollow sections – Table 16, BSI 1474:1972.
D.) Angular tolerances for extruded sections – Table 11, BSI 1474:1972.
E.) Tolerances on straightness for extruded bar, regular sections and extruded round tube – Table 17,
BSI 1474:1972.
F.) Tolerances on twist for extruded solid and hollow sections – Table 18, BSI 1474:1972.
G.) Tolerances on concavity and convexity for extruded sections – Table 18, BSI 1474:1972.
Instruments – venire caliper, (100m – dia type) combination square, protractor and tape.

*Note: Random inspection of 5% of the number of bars in a bundle is Al Taiseer Aluminium Factory
standard for checking goods/materials received based on sound practice and previous
experience for dimensional tolerances, colour range and anodic coatings.

Indication tests for other type of damages, mechanical damage, dents etc. are a visual
inspection only of 5% of bundle bars selected.

Individual inspection of profiles bars is carried when any rejection occurs within a certain
bundle.

FLATS STOCK, PRE-WORKED PANELS AND SHEET MATERIALS:

Similar QC inspection procedures are initiated on all incoming flat stock, pre-worked panels and sheet materials to ensure goods received adhere to specifications, correct sizes, and tolerances.

Visual Checks: Acceptable limits of good surface finish for profiles/extruded sections pertaining to scratches, marks, mechanical damage and anodic coating of thickness and colour range wherever applicable, shall also apply to flat stock, sheet material and pre-worked panels. In addition, pre-worked panels must meet requirements regarding basic surface finish standards and
dimensional tolerances as follows:

1. Flatness – panels shall be flat, surface duration should not exceed 1/3000 of length at any location.
Alternative methods of measuring flatness:
A.) Lay panel on a flat surface.
B.) Place a 6 inch rule on top of the facing.
C.) Measure clearance between the rule and panel facing, clearance must not exceed 0.375 mm.
– Panels exhibiting rippling, oil canning or waving in excess of the above are not acceptable and are subject to rejection.
– Specific units being of borderline acceptability are not acceptable if above defects are noticeable at a distance of 3 meters under normal light conditions.

2. Thickness – +/- 3% of the specified thickness.

3. Length and Width – +/- 3mm of the specified length and width.

4. Squareness – angular deviation from the designed angle of a corner shall not exceed 0.002 inch per inch (or 1.97 mm per meter).

5. Reinforcement and Stiffeners – Stiffeners or reinforcement members embedded within the panel core shall be checked for correct location under the following guidelines.
A.) Location of specified center line of reference edge shall be within 3mm from the actual center line or reform edge.
B.) Alignment of insert within the core shall be within +/- 3mm.

5. Reinforcement and Stiffeners – Stiffeners or reinforcement members embedded within the panel core shall be checked for correct location under the following guidelines.
A.) Location of specified center line of reference edge shall be within 3mm from the actual center line or reform edge.
B.) Alignment of insert within the core shall be within +/- 3mm.

6. Panel Skin Core Adhesion – panels manufactured using contact adhesives shall be checked for uniform of panels’ skin to core along the panel perimeter. Panels shall be broken open and sampled/ tested for adhesion during the manufacturing process.

WORKSHOP INSPECTION

A. Before commencing any new job, Supervisors will check with Drawing Office that materials to be used are specified.
B. On completion of machining operations, materials will be deragged of any swarf, burrs or sharp edges.
C. All cutting machines shall be checked weekly for accuracy and operation. All jigs and fixtures will be checked for accuracy alignment before a production run and inspection to be recorded in the relevant section logs and signed by the Supervisor.
D. Random checks should be carried out by Operator, Supervisor and Quality Control Inspector on accuracy of meters and other cuts.
E. On final assembly of all parts, a complete inspection by Q.C. Department to be carried out on
acceptance by Q. C. The Q. C. label approval must be attached and documented as required.
F. Q. C. Inspector shall fill in attached report sheet daily and send copy to Production, Sales, and master copy to G. M. for their own use and file.