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How do we assure high quality?

20 October 2021

Quality in the plastic manufacturing industry means that we use several quality control strategies to guarantee the highest level of customer satisfaction. By doing so, we also benefit by eliminating costs for making mistakes. Offering quality already starts with the design and material used for the product. It continues throughout the manufacturing process with the right setup in the machinery and eventually also the final tests on the product to continuously enhance the quality of the finished product. There are many considerations to take into account such as texture, size, injection time and cooling time. All need to be optimized for the best result. This all without losing time as per the production schedules, hence the importance for the right planning, always taking quality control into account. 

Defects

What could be a possible defect? We always try to minimize the amount of defects as much as possible, still sometimes we discover defects in our production process. Of course this is very unfortunate, but we make sure we learn from these lessons. At Rompa Group we assure that these faults are minimized. Especially during the initial production run we keep a close eye and monitor whether a defect is shown, which is  not often the case. Some of these defects could be:

  • Sink marks could appear if the outer wall of a certain part solidifies rather rapidly while the inside is still hot and fluid. 
  • Gas marks can appear due to inappropriate ventilation. All injection molds have air vents and should be located at the correct depth. We will see gas marks when the plastic is shot into the cavity and gas cannot exit properly, giving a burned mark.
  • We will see flashes when a mold does not completely seal correctly, meaning that the two sides do not come together tightly enough.
  • The defect called short shorts means that the injection mold did not fill properly and too little polymer was injected into the mold.
  • When plastics flow around a certain hole in a part it might create a weak spot, these weak spots are called weld lines.
  • Sometimes we see splays, these are surface blemishes which resulted from bubbles that trap air inside the plastic component.

Quality Control

After every production run a quality check is inevitable and essential. A quality check gives us a clear picture of the final product and we can determine if improvements can be made. Rompa Group applies several quality control methodologies. Below is an explanation of these processes.

  • Advanced Product Quality Planning & Control Plan (APQP). This process is to assure quality through strict planning. It focuses on determining if customers are satisfied by evaluating output and supporting continual improvement.
  • Production Part Approval Process (PPAP) promotes a clearer understanding of the requirements of manufacturers and suppliers. This helps ensure that the processes used can consistently reproduce the parts.
  • Statistical Process Control (SPC) employs statistical methods to monitor and control a process, so that it operates efficiently and produces more products conforming to specification with less waste.
  • Acceptable Quality Limit (AQL) is the worst tolerable process average that is still considered an acceptable quality level.
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Other processes we follow to guarantee quality

Recycle, reuse, repair and remanufacture

As an experienced manufacturer in this industry we work hard to reduce our waste. When we talk about the quality of the product we also take sustainability into account. Ensuring quality of the finished goods already starts with the design. For example, we are specialists in design for disassembly, this means that with this type of design process we already take the end-of-life of the product in consideration. With a smart design we continue to seek the highest quality of materials that are non-toxic, recyclable and making the product easy to repair.

 

The newest machinery

The right machinery for our production processes gives us the newest technologies to deliver the best quality. But also think about the right machine maintenance so we can minimize the downtime and maximize efficiency.

ISO certifications

ISO stands for International Organization for Standardization, it is a third party that checks our company runs and certifies us when restrictions and expectations are met. It's an independent, non-governmental organization with a big team of experts to ensure quality, safety and environmental protection. Rompa Group is a proud ISO certified plastics manufacturer. All our manufacturing sites around the world are ISO certified. Below we list these certifications:
 

All Rompa production sites are ISO certified in line with the following standards:

● ISO 9001 (quality)

● ISO 14001 (environment)

Quality certificates Rompa NL:


Quality certificates Rompa CN:

 

Quality certificates Rompa CZ:

 

Quality certificates Rompa MX:


Quality certificates Rompa DE:

Quality in manufacturing, but also many other services

While Rompa Group is a certified quality manufacturing company, we also have other services where we aim for the highest quality. This enables us to provide a complete package, from A to Z. By controlling the full run we can make sure that quality control already starts at the beginning, during the design and material choice process, but also until the very last where the finished goods are being delivered. Having full control makes communication easier, quicker and more efficient. This means that you can expect quality from A to Z, from design to delivery.

Interested in learning more about our assurance of quality? Make sure you contact us and we are happy to tell you all about it!