Quality Control Processes and Tools

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).

Omnidex Quality Control Processes & Tools

Metallurgical Analysis

1. Mechanical Properties Tests

– We use scientific analysis to identify issues in our products

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.

2. Composition Analysis

- Spectrograph

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.

- Chemical Composition Test

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.

Metallographic Analysis

1. Metallugrical Microscope

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.

Mechanical Properties Tests

– Every mechanical property is just as important

We use several test methods to observe the behavior of a material when an external force is applied. These test results can help our engineering team to select the appropriate materials for different applications.

1. Elongation Test

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.

2. Ultimate Tensile Strength Test

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.

3. Yield Strength 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.

4. Hardness Test

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.

Dimensional Measurement

– Every dimension is crucial to the functionality of a product

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.

1. CMM

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.

2. FARO 3D Measuring Arm

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.

3. Optical Measurement Projector

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.

4. Height Gauge

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.

5. Roughness Tester

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.

6. Thread Gauge

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.

7. Pin Gauge/ Plug Gauge

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.

8. Feeler Gauge

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.

9. Thickness Measurement

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.

10. Ultrasonic Thickness Test

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.

11. Custom made Checking Gauge

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.

Housing Checking Gauge 1

Mainly used to ensure housing part structures are in the right po

Housing Products Checking Gauge_Omnidex — Housing Products Checking Gauge

Housing Products Checking Gauge_Omnidex — Housing Products Checking Gauge

Housing Products Checking Gauge_Omnidex — Housing Products Checking Gauge

sitions according to the requirements.

Housing Checking Gauge 2

Mainly used to validate the surface on a housing part is perpendicular to the referencing axis as stated in the requirements.

Housing Products Checking Gauge_Omnidex — Housing Products Checking Gauge

Housing Products Checking Gauge_Omnidex — Housing Products Checking Gauge

Housing Products Checking Gauge_Omnidex — Housing Products Checking Gauge

Idle gear and pinion gear checking gauge

These gauges are used to ensure gear profile are up to specification.

Idle gear and pinion gear checking gauge_Omnidex — Idle gear and pinion gear checking gauge

Idle gear and pinion gear checking gauge_Omnidex — Idle gear and pinion gear checking gauge

Idle gear and pinion gear checking gauge_Omnidex — Idle gear and pinion gear checking gauge

Surface Treatment Tests

– Our testing methods are much more than scratching the surface of a product

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.

1. Salt Spray Test

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.

2. Adhesion Test

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.

3. UV Test

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.

4. Color Comparison Test (light box & Panton color book)

5. Chemical Resistance Test

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.

6. Coating thickness Test

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.

7. Ultrasonic Detector

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.

Packaging Tests

– We are responsible from the start to finish

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.

Are You Ready To Start?

Recent Blog Posts

A Brief Overview of Metals Physical Properties

A Brief Overview of Metals Physical Properties

omnidexcn 6 October 2022

There are many ways to distinguish materials based on their physical properties. Metallurgy studies often look at physical properties as a broader category than mechanical properties. However, not all properties overlap. Using testing methods, physical properties can be distinguished from mechanical properties. In contrast to measuring mechanical properties, measuring physical properties does not require applying force to the material.

Steel is comparatively inexpensive compared to many other metals, which makes it an ideal metal for many projects. Cookware and cutlery, surgical instruments, industrial equipment, and outdoor site furnishings are often made from stainless steel, which has a bright finish and is non-reactive.

The properties and advantages of stainless steel and steel are different, and it is important to understand the differences in aesthetics, properties, and costs before choosing one alloy over the other.

Compare Corrosion Resistance and Cost of Steel and Stainless Steel

Compare Corrosion Resistance and Cost of Steel and Stainless Steel

omnidexcn 3 October 2022

Stainless steel and steel are both reliable metals, used in a wide range of applications, from large to tiny components. Which is the better option? Basically, it all depends !

Steel is comparatively inexpensive compared to many other metals, which makes it an ideal metal for many projects. Cookware and cutlery, surgical instruments, industrial equipment, and outdoor site furnishings are often made from stainless steel, which has a bright finish and is non-reactive.

The properties and advantages of stainless steel and steel are different, and it is important to understand the differences in aesthetics, properties, and costs before choosing one alloy over the other.

Valve manufacturing service China_An overview of industrial valve types and applications_metal casting service China_industrial manufacturing engineering service_offshore subcontract_OmnidexCN

An Overview of Industrial Valve Types and Applications

omnidexcn 23 September 2022

A valve is used in almost every situation that involves the flow of liquid or gas. You control the flow of water through your kitchen sink with a valve. A gas stove brings propane gas into its burners through a different valve. Outside the home, industrial valves are designed to withstand high pressures, either from fluids or gases, and to last for years in harsh conditions. Almost every utility, whether water, oil or gas, could not operate without heavy-duty, industrial-strength valves.

10 Myths to avoid in Electronic Contract Manufacturing_electrical and electronics manufacturing services_industrial manufacturing services_Omnidex

10 Myths to avoid in Electronic Contract Manufacturing

omnidexcn 10 August 2022

Making the right choice when selecting an electronic contract manufacturing company is essential for your product’s success. However, several common mistakes are commonly made when selecting the manufacturing partner. Many OEMs neglect other aspects while overemphasizing one (typically cost), in doing they have an unhappy experience with their final selected supplier.

6 Most Common PCB Quality Assurance Test_ICT Test _In Circuit Testing A Reliable Method to Identify Manufacturing Faults_electronics manufacturing_industrial offshore manufacturing services_Omnidex

The 6 Most Common PCB Quality Assurance Tests

omnidexcn 29 June 2022

Printed circuit boards (PCBs) are used in nearly every electronic product manufactured today. In order to fit integrated circuits and other critical connections with smaller dimensions, designers continue to push the limits of PCBs. In this article, we discuss various quality control testing methods used during the electronics manufacturing process.

We are always ready to help with your latest project.

Contact our Customer Service and let us know how we can help to catapult your next project to success.

+

Years In Business

+

Years of ISO 9001 Certification

+

Manufacturing Processes

+

Combined Years of Expertise

Follow Us:

Omnidex Group

Navigation

Our Services

The Omnidex Group Brochure

Copyright © 2024 Omnidex. All rights reserved.