Quality

PPI is an ISO 9001:2008 and Underwriters Laboratories certified facility. Our number one priority is Total Quality, by achieving consistent part quality and customer satisfaction we are a preferred dock-to-stock supplier.

Our dedication to quality enables us to operate efficiently and accurately, and in compliance with the ISO 9001:2008 standard. Our Quality Department coupled with our state-of-the-art equipment is staffed with qualified inspectors with decades of experience.

OUR QUALITY SERVICES INCLUDE:
  • Quality Assurance is ISO 9001-2008 Certified by Perry Johnson Registrar
  • Accuracy and repeatability in dimensional measurement and geometric characteristics
  • Statistical data analysis and decision making
  • Color accuracy and repeatability capability through the use of spectrophotometer readings
  • Moisture analysis of hygroscopic materials
  • Underwriter Laboratories recognized molder and applicator
  • IQMS/ ERP / Plant Management Software System
  • Pentium IV computers with SQC statistical process control software
  • Hansford Coordinate Measuring Machine
  • Standridge 36x72 surface plate, 2 36x48 surface plates
  • Minolta CR 300 Chronometer
  • BK Gardner Gloss Meter
  • IMS Dew-Temp Dryer Monitor
  • Ishida Weigh Scales
  • Jones and Lampson Optical Comparator and Measuring Machine
  • Various measuring instruments and tools including 24" and 40" digital calipers
  • Multiple Digital Cameras
Mold Qualification Process The Preproduction Plastics mold qualification process consists of four steps. These steps are called Test-1 (T-1 for short), T-2, T-3 and Critical Dimension Inspection. They all have different purposes, with the final goal being to achieve a highly consistent and repeatable production part. Each phase of testing requires participation from our customer, where there may be a need for specifying such things as critical dimensions, creating tolerances that are repeatable, reviewing paint and secondary operations, verifying process control, and setting priorities.

T-1: This is the initial test of a newly built or reworked tool. The purpose is to test the mechanical components of the mold to ensure that it will function properly. The parts run during this test are to be reviewed in the raw state; no de-gating or de-flashing is done. That way, everyone can see exactly what the mold produces.

Data is gathered at this time to begin building a process plan for future mold use. Please review the sample for any missing or incorrect features, however the part will not be considered dimensionally stable at this point of qualification. Acceptance of this step will initiate a T-2 test, which is a dimensionally stable, and a cosmetically finished part.

If this is a rework of an existing tool, this test is for approval of the reworked features only. If the revision does not entail any changes to part finishing requirements, then the next step may be full production, if indicated below.

T-2: After obtaining customer feedback and approval of the T-1 test, the tool undergoes a T-2 test. This is where the molding process is centered and repeatable results are obtained. To obtain process control, PPI uses a combination of melt temperature, shot speed, and mold temperature. PPI’s molding technicians continue to establish the molding process plan. Coordinated with this tooling run is the completion of all fixtures and development of any secondary operation and/or finishing process plans. The molded parts are then inserted, painted, finished and packaged. Parts supplied at a T-2 test are to be reviewed for form, fit, function, including all cosmetic and secondary requirements.

T-3 – Beta Production Run: After T-2 approval by the customer, the tool is put back in the molding machine for the final qualification step, the T-3. At this point, the quantity run is normally the first production release of the first production order. The molding process is optimized to produce the best, most consistent results possible. T-3 parts are representative of what the customer can expect in subsequent production runs. All data recorded during the T-tests is used to build the final Part Process Plan, which is used for all future productions.

Critical Dimension Inspection: When required, the inspection of critical dimensions is begun after completion and acceptance of PPI’s Cp/CpK study. This study demonstrates that our molding process is in control and our parts are consistent. The critical dimension inspection of the part is completed on all dimensions mutually agreed by the customer and PPI.

All this attention to the mold and molding process is crucial to the quality of the parts produced. With customer involvement throughout the process, the result is a win-win for everyone, and a high probability of future successful production runs.