Comprehensive across production systems assessment of the ...
Assessment of Production
Transcript of Assessment of Production
APPROVAL INSPECTION TESTING
TECHNICAL APPROVALS FOIq CONSTRUCTION UK Member of EOTA (European Organisation for Technical Approvals)
UK Member of the UEAtc (European Union of Agr~ment)
Assessment of Production Agreed Quality Plan
for
Promat TL board
Agr~ment Certificate 09/4646
Note to the inspector: all documents referenced in this qp are without any dates. Hence it is imperative please that BBA inspector to report nature of all changes
made in these reports at the next visit. If this proves to be unworkable then we will need the actual dates of these documents in eth quality plan, please.
Document reference Promat AQPKingspan LocationSeptember2017
Date of issue September 2017
BBA Section responsible Construction Products
BBA Project Manager Gayetree Ramkorun
Other products covered by All insulations certificates for Kingspan
BBA Certificates manufactured on this site:
Qualit~ Plan (18-06-42) Iss8 Page 1 of 8 Job number: Product:
BBA00011241 0001 BBA00011241/1
Product name: Promat TL board which is a calcium silicate board (Promatect HD) bonded to the foil faced Phenolic insulation (Kingspan Kooltherm K10) board which is glass tissue faced on the other side.
Product range:
Bonding Line
Name Application Components Length Width Thickness (mm) (mm) (mm)
Promat TL board An insulated Calcium silicate soffit board
Kooltherm K10 phenolic (foil faced on one side and the other glass tissue)
Calcium silicate board (Promatect H D)
24OO 1200 20-120mm
6mm
Phenolic Line
Medium to high density phenolic foam core faced with tissue or foam
Kooltherm K10 Tissue / foil faced soffit insulation
Kooltherm K10 phenolic (foil faced on one side and the other glass tissue).
24OO 1200 20-120mm
Production location:
Produced by: Kingspan Insulation Limited
Address: Pembridge
Leominster
Herefordshire
Postcode: HR6 9LA
Telephone:
Fax:
Contact:
Title:
E-mail:
Steve Mesham
Management Representative
Is the above production site covered by /SO 9001 Registration?
If YES, Registration No: 388 issue 4
Assessed by (organisation): LPCB
Yes
Qualit~ Plan (18-06-42) Iss8 Page 2 of 8 Product:
Job number:
BBA00011241 0002 BBA00011241/2
Scope of assessment: Design and Manufacture of insulation and composite insulation materials for the construction industry.
Purchasing data & receiving inspection and testing: All materials are purchased to agreed specifications as laid down in our ISO9001 Quality System. Bonding Line materials are visually checked and processed in accordance with Works Procedure No 4 latest version. If a delivery of any material does not appear to meet the specification set out in the Raw Material Database, then a concession is raised and authorised by the Technical Processing Manager.
Incoming product, raw Original supplier Acceptance limits materials and Components
Apollo Chemicals- spec no. C of A 474
Bonding Line Adhesives (SIKA UK) spec no. 578 C of A
Phenolic Insulation Kingspan Insulation Ltd Internal Specification
Promat Conditionally accepted against
substrate delivery notes and
customer free issues
Identification (type, class, grade, specification, etc)
A9368 GREEN
(Sikamelt-9677)
K10
Promatect HD TP C4E
The raw materials are checked before offloading as per Works Procedure 3 and 4 latest issues. Any raw materials that are outside of specification are dealt with as per Works Procedure 24 latest issue.
The following table is an example of the style, format and content that is required. However it can be modified for proportions, orientation (portrait or landscape*) or converted to other non table formats. * Please note that landscape orientation can be irritating to the reader (client) and therefore should be used with caution.
Product identification and traceability:
Every order that is placed is given an Order Number. The Production Programmes (QSP8b for Bonding Line Line) are then formulated to incorporate all the necessary orders, quoting the respective Order Numbers.
Line 1 - Pembridge
Board Production: Before use, phenolic resin is taken from the bulk tank and pumped into the resin day tank. The acid, blowing agent and resin are pumped at a pre-set rate to the mixing head. When a stable flow is achieved the machine goes from recirculation to dispense and foam exits the dispense nozzles onto the base substrate. The top layer of substrate is also supplied from a roller at the rear of the lay down. This layer is applied to form the top of the substrate. The whole of the ’wet end’ is controlled by a fully automated system
The board then passes into a fixed gap conveyor contained within an oven between 50 and 75 °C (depending on thickness). The partially cured board then passes through a second oven to complete curing.
After packing/wrapping, the stacked boards are placed in temperature controlled curing chambers and left to condition for a minimum period of 48 hours a representative sample is placed with each produced product.
Product identification and traceability: Bonding Line
All blank boards that are made in house are inkjet printed on the edge with product type, date and time of manufacture. This allows traceability to the production records for that board
Bonding line: line 3 Pembridge
Quali~ Plan (18-06-42) Iss8 Page 3 of 8 Job number: Product:
BBA00011241 0003 BBA00011241/3
The process is fully described in the IMS Pb/Sb/Bs IMP 250 Latest Issue.pem 12.05.2014.Basildon-08.07.2015
Line 1
Board Cutting: The boards are cut to the required dimensions by a two-stage operation:
and selby-
(1) Side trimming: by use of a hogging cutter in conjunction with a scoring blade. The unit is adjusted manually to achieve the correct width.
(2) Cut to length: by use of a traversing across cut saw which moves in relation to the board. Control of the unit is via an encoder which the operator sets to the required length.
Method of production and process control:
Bonding Line: line 3 - Pembridge
Calcium Silicate board is lifted with suction pads and placed onto the horizontal conveyor. From the loading station, the board is conveyed into the laydown area were a prescribed amount of hot melt adhesive and one part moisture curing adhesive applied in beads. Insulation panels (K10) are manually placed onto the adhesive coated Calcium Silicate board. These composite boards then travel through a press. These then enter the lifting area where using suction pads the composite is placed onto a pallet, labelled, wrapped and banded.
Process Control:
Bonding Line
Alignment is by the operative’s fingertips. The laminate then passes between a set of compressive rollers (compresses the foam by approx 3mm) before moving on to an automatic stacking unit.
As per IMS PEMBRIDGE/SELBY/BASILDON IMP 250 Latest Issue-pembridge and selby- 12.05.2014.Basildon-08.07.2015
Phenolic Line
Works procedure No. 33
In-process inspection and testing:
As per IMS Pb/Sb/Bs IMP 250 Latest Issue.pem and selby-12.05.2014.Basildon-08.07.2015.
Results are recorded on form - SAP based PI Sheet viewed through SAP QA33 format.
Bonding Line
Property measured Action on rejection
Adhesive coating Weight
Width (Insulation) Length (Insulation)
Method used
Line side weigh scale
Steel tape
Acceptance limits
60-80 gsm (As SOP)
1195mm (+ 0,-2)
2397mm (+ 0,-2)
Frequency
At start up and hourly
Every 30 minutes
Every 30 mins Squareness Steel tape <0.3% of Length
Inform Team Leader
Qualit~ Plan (18-06-42) Iss8 Page 4 of 8 Product:
Job number:
BBA00011241 0004 BBA00011241/4
t Alignment Visual inspection } Continuous Inter laminar Strength On Line Continuous
Visual
Visual (At lifting station)
Final inspection and testing:
Phenofic Line
Property measured Works Frequency Acceptance limits Action upon procedure (minimum) rejection
Thermal Conductivity (@ 10 Deg C mean)
Compressive strength
Density
QC11p
One per production run
One per production run
Every 30mins
Max 0.0210 Wm-IK-1
K10 _>100 kPa
None (result recorded)
Board Rejected
Board downgraded
Bonding Line
As detailed in the in-process inspection and testing section. No further testing occurs
Calibration:
Calibration procedures are described in Pb IMP 206 - Calibration latest issue.
t Equipment Identification Calibration date / Due date Bonding Line Adhesive Scales Serial No. SCA-08 - Ext. Cert. 7010 Last 13/05/15 Next due 05/16 - 12 MThs
Packaging:
Boards are automatically stacked and polyethylene shrink-wrapped. Each pack bears a label showing relevant information regarding product description and traceability; including works order number, and bearing the appropriate BBA identification mark (where applicable). Phenolic boards packed with corner protectors.
Bonding Line
Number of laminates per stack is in accordance with Works Procedure No 9 Latest Issue. Each palletised stack employs cardboard corner protectors, polythene shrink wrapping, 3 plastic bands across the width, and a piece of plywood on top, a label which bears Promat HD, dimensions and date of manufacture.
Labelling: Packs are labelled with a product identification label showing the following information:
¯ Thickness of product No of boards per pack
Qualit~ Plan (18-06-42) Iss8 Page 5 of 8 Job number: Product:
BBA00011241 0005 BBA00011241/5
¯ Product name ¯ Board dimensions ¯ Blank Label used ¯ No BBA logo displayed on label on packs
wrapped at Pembridge ¯ Promat to add to product label/re label upon
delivery (1) Lamination date where applicable
Batch No ProduclJon date (1)
Use of the BBA symbol:
BBA logo is not currently in use for the labelling.
Training:
Training procedures are described in QM 6 Resource Management and IHSEPM Latest issues.
Complaints: Complaints procedures are described in WP20 Customer Complaints Procedure latest issue.
Qualit~ Plan (18-06-42) Iss8 Page 6 of 8 Product:
Job number:
BBA00011241 0006 BBA00011241/6
Quality policy: We undertake to have the product produced and placed on the market as described above. We will advise the BBA of any changes and receive agreement from the BBA before the changes are implemented.
Signed ............................................... QC Manager UK & Ireland
Title ................................................
05.09.2017 Dated ..............................................
End of Quality Plan
For BBA internal use only
BBA Cert(s): 09/4646 Approved by: Date:
Qualit~ Plan (18-06-42) Iss8 Product:
Page 7 of 8 Job number:
BBA00011241 0007 BBA00011241/7
Appendix - Document Revisions
Revision No Reason for re-issue Date
Qualit~ Plan (18-06-42) Iss8 Page 8 of 8 Job number: Product:
BBA00011241 0008 BBA00011241/8