Our quality control processes evolve around the 5 QCPs (Quality Control Perspectives): Regulatory, Durability, Safety, Functionality and Cosmetics. Each project will have its own set of Quality Specification produced with specific QCPs and the customer’s requirement in mind. The Quality Specification may be approved by the client before a QC plan can be devised. Projects may have varying sampling size and quality standard, depending on the criteria of a project (such as production volume, value and complexity of the product).
The properties of a metal piece are largely determined by its material composition and microstructures, but it can be very difficult to identify problems in these aspects. Our QC team utilizes a range of specialized analyses to resolve manufacturing issues related to metallurgy.
Spectrometer are used to provide precise analysis of common metals. We employ advanced digital CCD Spectrometer to monitor metal composition and ensure material quality throughout our production processes.
We also test our product samples with a range of chemical tests. This method is a reliable way to verify material composition and identify impurities or contaminants.
Metallugrical Microscopes are used in combination with advanced image analysis system to study and document microstructures on metal substrates. Our system can easily identify metallurgical issues on any product.
When subjected to a tensile load, a part will increase in length but decrease in cross-sectional area, weakening it to a point where it will eventually break. Elongation is a measure on how much a part can stretch before breaking. We use a range of Extensometers and Computerized Tensile Testing Machines to measure the elongation of a material.
UTS is the maximum tension stress (measured in MPa) a material can withstand under a tensile load before breaking. Universal Tensile Strength Testing Machines are used in this type of test.
Yield strength measures the stress a material can withstand without permanent deformation. Universal Tensile Strength Testing Machines and specialized Yield Strength Testing Machines are used in yield strength tests.
Hardness refers to a material’s ability to resist mechanical indentation, scratching, abrasion, cutting, penetration and other deformation. Material hardness is critical in engineering design, as it determines the functionality and durability of a product. We use a range of Rockwell Hardness Testers and portable Hardness Probe Testers in our harness tests.
Our QC inspection also involves extensive use of specialized equipment to monitor the dimensions and profile of our products. In the hands of our QC specialists, these tools can produce high precision measurement, which is crucial in our effort to ensure product quality.
Coordinate Measuring Machine (CMM) is used to measure the geometry of any physical object. CMM can incorporate different types of probes including mechanical probes and non-contact probes (optical, laser and white light).
The most common type of CMM is the 3D “bridge” CMM. These machines often have a computer-controlled probe that moves along three axes (X, Y and Z). The machine can record the position of sensor points to produce a 3D image, which describes the surface areas of the scanned part. These images can be used in a digital environment for further analysis.
FaroArm is a portable CMM machine that is manually controlled and allows unrestricted multi-axis movement. These machines can be deployed in a wide range of work environments and perform tasks beyond the limitations of a typical CMM.
Also called Optical Comparator or Profile Projector, this device draws on the principles of optics for dimensional inspection. The magnified silhouette of a part is projected on a screen and measured against the prescribed limits. It is a cost-effective non-contact measurement solution with high precision. We use a range of High Precision Optical Measuring Profile Projector and Automatic Video Measuring Machines to measure the dimensions and geometry of our products.
A height gauge is used to accurately measure the height of parts. We use a combination of manual and digital Height Gauge for height Measurement.
All surfaces have tiny irregularities on them, which are often very small and hard to detect. With the use of specialized Surface Roughness Testers, we can measure the roughness of any surface and provide quantitative data for our QC analysis.
Every component has its own importance in a design, and we should never overlook a humble screw or nut. We use a series of Go/no go Thread Pitch Gauges, Plug Gauges and Ring Gauges to ensure every thread profile is up to spec.
Pin Gauges and Plug gauges are tools used for measuring the diameter of a hole. They can also be used as reference tools for geometric deviations measurements.
A Feeler Gauge is a measuring tool composed of a set of folding metal strips with varying thickness. They are used to measure gap widths and ensure clearance between parts.
We utilize a range of digital Thickness Gauge to measure the thickness of sheet material. We also have specialized coating Thickness Gauges that allow non-destructive coating thickness measurement of non-magnetic coatings.
Conventional “tip and anvil” style Thickness Gauges can only measure smaller parts. When it comes to measurement on larger substrates such as pressure vessels, tanks or industrial machines, we often use the more versatile Ultrasonic Thickness Testers.
Some products may require special testing methods, with no proprietary QC equipment available on the market. In these cases, our engineering team will create our own solution for the project.
Mainly used to ensure housing part structures are in the right po
sitions according to the requirements.
Mainly used to validate the surface on a housing part is perpendicular to the referencing axis as stated in the requirements.
These gauges are used to ensure gear profile are up to specification.
Surface finishing and treatment is another important aspect in quality control. Our QC team is proficient in a range of specialized testing methods in this category.
The Salt Spray Test is a corrosion test used to check corrosion resistance of materials and surface coatings. It has gained a lot of popularity in the manufacturing industry due to repeatability, low cost and quick results. It should be noted that Salt Spray Test results generally do not correlate with the real-world performance of a product. It is instead used as a method to detect problems in coating pre-treatment or paint quality.
Adhesion testing is used to determine if the coating can properly adhere to the substrate. This category includes several test methods, including cross-cut test, scrape adhesion test, pull-off test, and others.
UV Weathering Test Machines can simulate the effect of sunlight and weather on products. This method allows us to effectively assess the weather resistance of products and the lifespan of colour coatings.
For products with stringent color requirements, we may offer a Color Comparison Test that follows the Pantone color matching system. We make use of professional color check light boxes and Pantone color books to ensure the color on your product matches exactly with your requirement.
Certain chemicals may cause discoloration, change of texture, swelling, blistering or flaking of coatings. Chemical Resistance Tests can help us identify coating problems and make the necessary changes on our finishing processes. A common example in this category is Alcohol Rubber abrasion Tester.
We also utilize a range of specialized Coating Thickness Gauge to measure the thickness of anodizing, electroplating, spray paint and powder coatings. These dual-purpose Thickness Gauges can be used on ferrous and non-ferrous metal substrates.
Ultrasonic testing is a widely adopted by the metallurgy industry to detect Hidden defects in a product. Our QC specialists are familiar with the use of digital Ultrasonic Flaw Detector to identify casting porosity or other quality issues in all kinds of substrates.
Our effort to consolidate customer satisfaction persists beyond the factory floor. We see packaging as an integral part of the product itself, and we couldn’t emphasize enough on the importance of proper packaging.
From our experience, we know just how tough the delivery ride can be. In our Packaging Tests, a range of specialized equipment is used to simulate the vibration and impact during delivery. The test results and the load on the bottom carton are all taken into account in the design of the packaging to ensure the package can withstand the delivery journey.
Quality assurance requires that your processes, products, technology, equipment, systems, etc., meet a variety of statutory and contractual quality requirements. We perform comprehensive quality control processes and certifications to ensure high standards are met.
With our high-level qualifications and resources, we are a highly trusted third-party able to perform quality control. Get in touch with us today to learn more about our quality control services.
Contact our Customer Service and let us know how we can help to catapult your next project to success.
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