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Quality Assurance

Quality Assurance

At Perfection Spring & Stamping Corp, our goal has always been to supply not only the finest in engineering, but also the highest in quality. If "Engineering" is the gas in our engine, then "Quality" is our oil. We validate our systems with an independent auditor to obtain and meet the requirements of PDF ISO/TS 16949:2009 and are compliant to FDA-QSR. 

We are committed to the care of the environment and as such have implemented an PDF Environmental Policy  with annual program goals and monitoring to reduce, reuse and recycle an wastes in our value stream.  To insure compliance we have had our environmental management system certified by an independant auditor to meet   PDF  ISO 14001:2004 standards. 

We adhere to a zero defect goal to meet the specific quality standards set by our customers.  High quality begins with process control and monitoring. We combine real-time PDF SPC (PDF - 28KB) with comprehensive statistical analysis for every part we produce. This process includes pre-planning evaluation, in-line process control and off-line technical support. Our quality methodology adheres to PDF "Advanced Product Quality Planning" (APQP) (PDF - 34KB) practices. Each part we manufacture follows a standard quality approval process to establish confidence in the production plan, process, and method, not only us but of our customer. This system works to insure engineering design records are maintained, specification requirements are properly adhered to, and that the manufacturing process is repeatable while consistently meeting all print requirements. We share the data and results with every part we manufacture as part of our part submission to our customers.

Our standard production part approval process consists of 18 elements, modified based upon customer specific requirements, or product specification.

  1. Design Records
  2. Authorized Engineering Change Documents
  3. Engineering Approval Change Process
  4. DFMEA (Design Failure Mode and Effect Analysis)
  5. Process Flow Diagrams
  6. PFMEA (Process Failure Mode and Effect Analysis)
  7. Production Control Plans & Bill of Materials
  8. Measurement System Analysis Studies
  9. Dimensional Results
  1. Records of Material / Performance Tests
  2. Initial Process Studies
  3. Qualified Laboratory Documentation
  4. Appearance Approval Reports
  5. Sample Production Parts
  6. Master Sample Retention
  7. Checking Aids/Gages/Fixtures
  8. Adherence to Customer Specific Requirements
  9. Part Submission Warrant to the Customer (PSW)

We also employ a range of quality assurance and manufacturing methods which include:

PDFSPC (Statistical Process Control):(PDF - 29KB) This is an effective method of monitoring a process through the use of control charts. Control charts enable the use of objective criteria for distinguishing background variation from events of significance based on statistical techniques. Much of its power lies in the ability to monitor both process center and its variation about that center. By collecting data from samples at various points within the process, variations in the process that may affect the quality of the end product or service can be detected and corrected, thus reducing waste as well as the likelihood that problems will be passed on to the customer. With its emphasis on early detection and prevention of problems, SPC has a distinct advantage over quality methods, such as inspection, that apply resources to detecting and correcting problems in the end product or service.

PDF"5S" Methodology: (PDF - 88KB) 5S is a philosophy and a way of organizing and managing the workspace and work flow with the intent to improve efficiency by eliminating waste, improving flow and reducing process unevenness. This is accomplished through Sorting, Straighten, Shining, Standardizing, Sustaining and Safety.

PDFPoka-yoke: (PDF - 58KB) "Fail-Safing", "Foolproofing", or "Mistake-proofing", a method of preventing errors by putting limits on how an operation can be performed in order to force the correct completion of the operation.

PDFIMDS: (PDF - 33KB) Registration on the "International Material Data System". This system registers declarable substances within the product specifications that may be a concern to human health, environmental safety and recycling.

PDFRoHS Compliant: (PDF - 20MB) Known as the "lead-free directive, while a European Union directive, we review product specifications against following six substances: Lead, Mercury, Cadmium, Hexavalent chromium (Cr6+), Polybrominated biphenyls (PBB), and Polybrominated diphenyl ether (PBDE).

Controlling the Process:

Our philosophy is to "Plan and Control the Manufacturing Process." We do this with a detailed and proven pre-planning process, feasibility review, APQP tools, control plans, and detailed setup sheets. Once production begins, we rely on technology to ensure conformance to your specifications with the use of load monitors, electronics feed systems, and in-die sensors.


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Specifications

Quality Assurance Services
Audit plans
Control charts and plans
Failure Analysis Service
Full part layout
Gage R & R studies
ISR, FMEA, APQP, PPAP
Product Traceability & Lot Control
Material Certifications
Minimum Cpk
Packaging layout
Quality Manual
Statistical data
Statistical Process Control (SPC)
Recognitions & Awards
4 Time Chrysler Gold Pentastar Award
5 Time Phillips Consumer Electronics Award Winner
North American Lighting "Impact Cost Reduction" Award
Atwood Automotive "Outstanding Supplier Award"
Whirlpool "Recognition & Distinction Award"
Ohio Electric Motors Supplier Award
Eaton Zero PPM Quality Award
Fellowes '2009 Partner of the Year' Award
Standards & Compliances

ISO/TS 16949:2009            ISO 14001:2004

PDF Environmental Policy-Goals-Monitoring

ANSI-RAB           FDA-QSR Compliant
PDF ISO-TS 16949:2009
Quality audit performed by an independent third party Registrar, TUV Rheinland Germany, per ISO/TS 16949:2009, 3rd edition, 2009-06-15.
Logistics Services
JIT Delivery Tracking
Barcode Labeling for Lot Control
Advance Shipping Notice Capability (ASN)
EDI Scheduling
FIFO Inventory Rotation
Consignment Inventory
Equipment
Spring Testers
Measuring Projectors
Optical Comparators
Coordinate Measuring Machine (CMM)
MicroVu Programmable Video Measuring System
SPC Network Software
Tensile Strength Tester
Rockwell Tester
Humidity Control & Salt Spray Cabinet
Sediment Testing Equipment

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