1. No category

ARISTECH SURFACES
QUALITY MANUAL
BETH CALIFF [2/25/2014]
ARISTECH SUFRACES LLC 7350 EMPIRE DRIVE, FLORENCE KY 41042 USA
TABLE OF CONTENTS
1. Table of Contents
2. General Information
2.1 Aristech Quality Manual
2.2 Product Description
2.3 Manufacturer’s Information
3. Incoming Materials
4. Manufacturing Process
4.1 Production Flowchart
4.2 Formulation Specifications
4.3 Description of Production Methods and Controls
4.4 Quality Control During Manufacturing
5. Finished Products
5.1 Finished Products Specifications
5.2 Quality Control of Finished Products
5.3 Packaging and Storage of Finished Products
6. Disposition of Non-Conforming Materials
6.1 Policy and Procedure
6.2 Definition of Major and Minor Defects
6.3 Complaints Procedure
6.4 Non-Conformance Form and Example
7. Measuring and Test Equipment
7.1 Standardization of Quality Control Equipment
7.2 Equipment and Production Lines
8. Labeling, Traceability, and Records
8.1 Policy and Description of Traceable Label/Records
9. Policies and Instruction for Third-Party Inspections
9.1 Third-Party Testing & Authorized Listing Mark
9.2 Quality Control Manual Revisions & Inspections
9.3 Reviews and Updates
LAST PAGE
1
3
13
14
15
16
17
18
19
20
22
23
29
30
37
38
40
41
42
49
50
56
58
59
60
61
62
63
64
1|Page
2.0 General Information
2|Page
2.1 Quality Manual
3|Page
Purpose: The purpose of this Quality Manual is to introduce Aristech Surfaces LLC (ASLLC), its
organization and its quality management approach.
Scope: This manual applies to the Florence, KY ASLLC Operation:
•
Florence, Kentucky, which produces continuous cast acrylic sheets for the
o Bath Market
o Hot Tub Market
o Sign Market
o Custom Thermoforming Market
o Solid Surface Market
Lovelace Women’s Hospital
4|Page
Quality Policy: At ASLLC we collaborate with our customers on both product and process
improvements in both our own and our customers’ operations. These improvements include
cost reductions and new product developments that delight our customers and give them a
leading edge in the marketplace. This customer focus is integral to our quality culture.
Quality Objectives: It is the objective of ASLLC to continue to be the leader in our markets by
consistently providing products and services that meet or exceed the requirements and desires
of our customers and regulatory agencies. The effectiveness of our quality management
system is the responsibility of all ASLLC employees. It is not a static process; it is continuously
reviewed and improved with the goal of creating value for both the customer and ASLLC.
Quality System: At the base of our Quality System are the department-specific technical
procedures, which detail the steps necessary to create a high-quality, cost-effective product
within the framework of our operations. In addition to the procedures, batch data is logged
throughout the process, tests are conducted and recorded, and material is placed on hold for
additional testing or scrapped if it does not meet our rigorous specifications. These
responsibilities lie in the hands of our highly-trained Operations Team, who execute upon and
address any issues that may occur during the process.
QMS Processes: In addition to the responsibilities of the Operations Team, our QMS system
includes additional functional areas and compliance to many of the ISO 9001:2008(E) standards
such as the Purchasing Process, Control of Documents and Records, Product Realization,
Management Responsibilities, Control of Non-Conforming Product, Customer-related
Processes, Subcontractor Management, Analysis of Data and Improvement, Identification and
Traceability of Production Materials, Calibrations and Customer Satisfaction, to name a few.
Our Quality Manual defines the elements of our QMS processes.
Quality Measures: At the beginning of every fiscal year new objectives are deployed
throughout the organization. Progress on these objectives are reviewed throughout the year.
We measure our quality with customers on several different levels from customer scorecards to
customer sku-specific satisfaction levels. These interactions with our customers allow us to
more quickly respond to their needs. Our corrective and preventative practices result in
continuous improvement of our processes and products.
5|Page
Certifications:
Underwriters Laboratory (UL): Altair Plus®, Quarite Plus®, Quarite Select Plus®,
Quarite®,
Quarite Select®, Acrysteel®, General Purpose Acrylic, I300
National Science Foundation (NSF):
http://info.nsf.org/Certified/food/Listings.asp?TradeName=solid+surface&CompanyName=Aristech&St
andard=051&
Solid Surface for Food Zone (check for color specificity):
Acrylic Solid Surface MB, Acrylic Solid Surface MF, Acrystone MG
Acrystone MH, Acrystone MN, Acrystone NE, Acrystone NG
Acrystone NI, Acrystone TF, Acrystone TG, Avonite® Foundations™ FI-8699
Formstone F1
French VOC Regulations per ISO 16000 for Acrylic Solid Surface (Solids (MF), Minerals (MG),
and Pediments (MH))
NSF Product and Service Listings can be found for ASLLC at:
http://info.nsf.org/Certified/food/Listings.asp?Standard=051&Company=02930&
6|Page
7|Page
8|Page
9|Page
ISO:
ASLLC has chosen not to seek ISO certification. However, we are compliant with over
90% of the ISO 9001:2008(E) standards. From the executive team who develops,
communicates and measures the attainment of the annual corporate goals to the
most recently hired employee. Communication, data collection and training are the
key elements of our success. Below is a summary of how ASLLC addresses the ISO
standards and has done so for over a decade.
ISO 9001:2008(E) compliant to the following standards:
1.1 General – Demonstrating ASLLC’s ability to consistently provide product that meets customer and
applicable statutory and regulatory requirements and aims to enhance customer satisfaction
through the effective application of the system.
1.2 Application – no exclusions
2.0 Normative reference – ISO: 9001:2008(E)
3.0 Terms and Conditions – “Product” and “Service” are both applicable at ASLLC.
4.1 General Requirements – ASLLC determines the processes needed for the quality management
system and their applicability throughout the organization, the sequence and interaction of these
processes, the criteria and methods needed to ensure that both the operation and control of these
processes are effective, and ensures the availability of resources and information necessary to support
the operation and monitoring of these processes. ASLLC monitors, measures and analyzes these
processes and implements actions necessary to achieve planned results and continual improvement of
these processes.
4.2 Documentation Requirements
4.2.1 – Quality Policy and Quality Objectives - ASLLC practices Continuous Improvement activities both
internally in our facilities and externally with tolling partners and customers to provide customerfocused, cost-effective, timely and relevant solutions.
4.2.2 Quality Manual – A Quality Manual has been created.
4.2.3 Control of Documents – SJOPs (Safe Job Operating Procedures) are under a controlled and
managed process, with established review timetables, authorized reviewers and easy access.
4.2.4 Control of Records – We have controlled (physical) records pertinent to our products and
processes, which are kept for a period of 6 years (off-site) as well as electronic records in our
system. Additionally, we maintain a physical sample from every batch for a period of at least 8
months. Within the HR function, there is a record of education, training skills and experience for
employees as well as Functional Descriptions for each position within the Company. Purchasing records
(i.e., conformity to specification, results of testing, etc.) are maintained in hard copy format for an entire
calendar year. Each year the previous year’s copies are sent off-site for an additional 6 years of
storage. Order confirmations, packing lists and invoices are stored electronically.
5.1 Management Commitment – Top management provides evidence of its commitment to the
development and implementation of the quality management system by communicating to the
organization the importance of meeting customer expectations as well as statutory and regulatory
requirements, establishing the quality policy, establishing quality objectives and conducting
management review.
10 | P a g e
5.2 Customer Focus – ASLLC engages with regular communications and audits with customers to work
jointly on Continuous Improvement activities, customer complaint resolution, as well as new product
developments.
5.3 Quality Policy - Our customer focus at ASLLC is based on collaboration with our customers on
product/process improvements in both our and our customers’ operations, cost reductions, and new
product developments that delight our customers and provide them a leading edge in the marketplace.
This customer focus is integral to our quality culture.
5.4.1 Quality Objectives – Are an element of the overall Annual Goal Deployment throughout the
organization. Progress toward completion of the goals is reviewed at least twice per year with all
employees and their supervisor, and is communicated frequently by Upper Management.
5.4.2 Quality Management System Planning – The planning of our quality management system is
designed to meet the requirements in 4.1. When changes are made to the quality management system
they are planned and implemented.
5.5.1 Responsibility and Authority – Top management ensures that responsibilities and authorities are
defined and communicated within the organization.
5.5.2 Management – Top management appoints a member of the organization who has the
responsibility and authority to ensure reviewed processes are established, implemented, and
maintained. Reports are made to top management focusing on the performance of the quality
management system, needs for improvement and the promotion of awareness of customer
requirements throughout the organization.
5.5.3 Internal Communication – performance of the quality management system is reported monthly
within the top leadership review, and monthly to the manufacturing team and sales/marketing team.
5.6.1 Management Review – Top Management reviews the organization’s quality management system
at planned intervals to gauge its continuing suitability, adequacy and effectiveness.
5.6.2 Review Input –Input to management includes results of audits and customer scorecards, status of
current corrective and preventative actions, and new recommendations for improvement.
5.6.3 Review Output – Output includes a review of the quality management system processes, as well
as improvements related to customer requirements and any resource needs.
6.1 Provision of Resources – the organization has provided resources to implement maintain and
continually improve the quality management system’s effectiveness.
6.2.2 Competence, training and awareness – Production employees are trained for a new position by 1)
working with a qualified trainer on all tasks relevant to the job, 2) reviewing SJOPs (Safe Job Operating
Procedures), and 3) taking a qualification test. Once qualified, all Production Employees are required to
review a percentage of their department’s procedures monthly as well as taking a requalification test on
an annual basis. Corrections and additions to the SJOPs recommended by employees are made by the
Supervisor and changed in the system by a designated individual (currently, the executive assistant).
6.3 Infrastructure – compliant
6.4 Work Environment – compliant
7.1 Planning of product realization – we use the Stage Gate methodology for new product development
activities in addition to our Engineering documentation for process improvements.
7.2.1 Determination of requirements related to the product – This is managed through customer
specific contracts as well as technical specifications. All sales contract proposals begin with standard
terms and conditions, which have been approved by legal counsel. Customer-specific deviations to the
11 | P a g e
standard terms and clauses are generated and reviewed by the VP of Sales & Marketing with legal
counsel.
7.2.2 Review of requirements related to the product – A component of our contract negotiations with
customers.
7.2.3 Customer Communications - Communications with customers occur during regularly scheduled
conference calls, customer visits, negotiations, and customer requests, whether through customer
service or sales calls.
7.3 Design and Development – All elements of this part of the standard are handled completely in 4.2.3
and 5.2.
7.4.3 Verification of purchased product –Raw material qualification is conducted at incoming
inspection. Depending on the material, it may be placed on “hold” until it can be tested and released to
production.
7.5.1 Control of production and service provision – As referenced above in 6.2.2, employees are trained
and tested on procedural knowledge on an annual basis, and procedural documents are readily
available. Measurement equipment is calibrated on a scheduled basis. An effective sheet inspection
system is in operation. Product traceability is inherent in the process based on the time of
production. Lot traceability is assigned at the end of the line and integrity maintained until it reaches
the customer. This lot number provides the exact time the material was made, who made it at various
parts of the process, what raw materials were used, as well as which process conditions it underwent,
and what the quality characteristics of the finished product were as it came off of the line.
7.5.2 Validation of processes for production – see 4.2.3, 6.2.2, and 7.5.1
7.6 Control of monitoring and measuring equipment – An internal calibration program is managed
within the Maintenance Department by Maintenance Technicians. Instrumentation/gauges and
frequencies of inspections are defined.
8.2.1 Customer Satisfaction – An output of 5.2 is a series of “scorecards” developed by, for, and with
customers to identify areas of focus for CI and co-operative initiatives (Kaizen, trainings, etc.)
8.2.2 Internal Audits – Monthly review of Quality Return performance by markets are shared with
Manufacturing and Sales. Monthly review of quality performance by Market and Key Customers
(scorecard) using 6 month Moving Average (MA), 12 month MA and current month.
8.3 Control of Non-conforming product – Non-conforming sheet is either marked with a sticker via the
sheet inspection system or placed on Hold in the system due to non-conformance in one or more
qualitative/quantitative tests performed on the product as it is produced. The material that is placed
on Hold in production will either be tested more thoroughly in our analytical lab or scrapped. While
on Hold, the material cannot be shipped.
8.4 Analysis of data – inherent in 8.2.1 and 5.2.
8.5.2 Corrective Action - inherent in 8.2.1
8.5.3 Preventative Action – in addition to SJOPs, there are a group of documents titled “Critical Success
Factors” (CSF) that specifically address product/process specific issues identified through a Continuous
Improvement activity. During the production of these products, the CSF is reviewed by the supervisor
and the employee responsible for the production of the product. These CSF are audited for compliance.
12 | P a g e
2.2 Product Description, Florence, KY Site
ASLLC is located in Florence, Kentucky, and produces a number of different products for the
Bath, Hot Tub, Sign and Surfacing markets. ASLLC owns 4 of the current 11 continuous casting
machines in the world. These machines are approximately 350’ in length and can produce
sheet material in widths up to 110’’.
For the Bath and Hot Tub markets, ASLLC produces products with appealing surface
characteristics and excellent formability. The majority of our bath products are based on
standard bath colors (whites, biscuit, bone, etc.). Approximately 80% of bath and hot tub
products combined are made from acrylic (methyl-methacrylate). For the hot tub market, our
products focus on new looks and designs, which are much different than our bath market. We
use ground acrylic chips in our Quarite® series, which provides a textured surface when formed.
This feature is forgiving to both our and our customers’ production processes as it has the
ability to “hide” small flaws (mold marks, contamination, etc.). We also make products using
special pigment particulates that can impart a “pearlescent” look. We produce the monolithic
sheet here in Florence and have partnered with a lamination partner to produce a laminated
product, which is backed with extruded ABS.
For the Custom Thermoforming market we supply products, which are made into boat engine
covers and tractor fenders, to name a few applications. Like a portion of our hot tub sheet,
these products are also laminated with ABS. Because of the end use, these products are highly
valued for their surface appearance. In the sign market, we supply customers with material
that might go into a large billboard, channel letters or a backlit gas station sign.
Our surfacing products made in Florence are also acrylic, combined with ATH, a mineral filler.
We are the only manufacturer of solid surface products that is capable of making sheet as wide
as 60” and in lengths up to 204”. We are capable of making material at any thickness from .125
– .800”. In this offering, we currently make solids and 14 different pattern designs with a
number of different colors per pattern.
13 | P a g e
2.3 Manufacturer’s Information
Company Name:
Address:
Telephone:
Fax:
Email:
Contact Person:
Title:
Hrs of Operation:
Aristech Surfaces LLC
7350 Empire Drive, Florence, Kentucky 41042
1-800-354-9858 ext. 4867
1-800 -283-6497
[email protected]
Elizabeth Califf
Director of Corporate Quality
24/5
14 | P a g e
3.0 Incoming Materials
Supplier Address
JM Huber, 3100 Cumberland Blvd, Atlanta, GA 30339
BYK USA Inc., 524 South Cherry St., Wallingford, CT 06492
BYK USA Inc., 524 South Cherry St., Wallingford, CT 06492
Rohm& Haas, 100 Independence Mall West, Philadelphia, PA 19106
Arkema Inc., 9502B Bayport Blvd, Pasadena, Texas, 77507
Burje, 5 Lawrence Street, Bloomfield, New Jersey 07003
Schibley Chemical Co., Inc., 1570 Lowell St, Elyria, Ohio 44035
Schibley Chemical Co., Inc., 1570 Lowell St, Elyria, Ohio 44035
Schibley Chemical Co., Inc., 1570 Lowell St, Elyria, Ohio 44035
Schibley Chemical Co., Inc., 1570 Lowell St, Elyria, Ohio 44035
Schibley Chemical Co., Inc., 1570 Lowell St, Elyria, Ohio 44035
Schibley Chemical Co., Inc., 1570 Lowell St, Elyria, Ohio 44035
BYK USA Inc., 524 South Cherry St., Wallingford, CT 06492
BYK USA Inc., 524 South Cherry St., Wallingford, CT 06492
BYK USA Inc., 524 South Cherry St., Wallingford, CT 06492
Xpedex, 6287 Tri-Ridge Blvd, Loveland, OH 45140
Hi-Tech Extrusions12621 Chardon Windsor Rd., Chardon, Oh 44024
3.1/3.2 Approved Material Suppliers/QC for Incoming Materials
Material
ATH
ATU 100
ATU204
BA
BRC - 1
BRB-4 (t-butyl peroxypivalate)
BRB-5 (t-butyl peroxyneodecanoate)
BRB-6 (t-butyl peroxyneodecanoate)
BRB-7 (2-ethylhexanoyl peroxy)
BRB-8 (t-amyl peroxy-2-ethyl-hexanoate)
BRB-9
BYK 1142
BYK 7072
BYKP105
Foil Wrap
Gasket
Midwest Elastomers, 700 Industrial Dr., Wapokoneta, OH 45895
Ground Chips
JX-1 (n-dodecyl mercaptan)
Arkema Inc., 900 First Ave., King of Prussia, PA 19406
JX-2 (ethylene glycol dimethacrylate)
Evonik Cyro LLC, 299 Jefferson Rd, Parsippany, NJ 07054
JX-15 (HEMA 98 Stabilized w/200ppm MEHQ Evonik Cyro LLC, 299 Jefferson Rd, Parsippany, NJ 07054
JX-44 (triisoctyl phosphite)
Hacros Chemicals, Organics Division, 5200 Speaker Rd., Kansas City, KS 66106
JX-50 (Cyasorb or Eversob)
Everlight USA, Inc., 10507 Southern Loop Blvd, Pineville, NC 28134
Linseed Oil
American Chemical Services, PO Box 190, Griffith, IN 46319
Methymethylacrylate
Lucite Int'l, 7275 Goodlett Farms Pkwy, Cordova, TN 38016
Rohm and Haas Chemicals LLC, Louisville Plant, 4300 Campground Rd, Louisville, Ky 40216-000
Evonik Cyro LLC, 10800 River Rd, West Wego, LA 70094
Arkema/Altuglas Int'l, 100 PA Route 413, Bristol, PA 19007
Industrial Thermoplastica Pavese S.P.A. (ITP) Via Cavaliante, 13-27040 Bosnasco(PV-IT)
Hi-Tech Extrusions12621 Chardon Windsor Rd., Chardon, Oh 44024
Kronos, PO Box 673788, Detroit, MI 48267
Johnson Doppler Lumber, 3320 Llewellyn Ave, Cincinnati, Oh 45223
Chempoint, 411 108th Ave NE, Bellevue, WA 98004
Chempoint, 411 108th Ave NE, Bellevue, WA 98004
Modifier
Polyfilm
Polyhose
TIO2
Treated Pallets
Zelec NE
Zelec UN
Confidential
Color, Particle Size, Oil Absorption, C of A
Test particle size distribution on every 10th
bag for SS and every 20th bag for acrylic
chips
Obtain the C of A
Purity and Color
Obtain C of A
C of A & density by wht/gallon
Melting Point, C of A, solubility
Color, C of A, Acid Value
White bucket test on every shipment
White bucket test on every shipment
White bucket test on every shipment
C of A
C of A
%O2 and purity on each lot
%O2 and purity on each lot
%O2 and purity on each lot
%O2 and purity on each lot
%O2 and purity on each lot
Melting Point
Sp. Gr. Taken from Cof A
Refractive index & density by wgt/gal
Refractive Index and Infra Red
Spec and Grade
Testing Protocal
White ATH, 17 Micron Untreated Color, dirt count, CofA
Obtain the C of A
Obtain the C of A
White bucket test on every shipment
Butyl Acrylate 15 PPM MEHQ
Eugenol
foil/poly, woven 14# LDPE .000285
PVC
Epoxal 9.5
2.8 mil series F masking Film
LLDPE
2044
Heat Treated Wood
C of A
C of A
15 | P a g e
4.0 Manufacturing Process
16 | P a g e
4.1 Production Flowchart
Overview of Florence Plant
Process Flow
MMA Monomer
Bulk
Storage
Solid
Surface
Process
Additives
Reactor
Promoter
Pigments
Railcar
Ovens
Chips
Heating
Acrylic Sheets
Trim & Scrap
Solid
Surface
FG
Warehouse
Sander
Customer Shipment
17 | P a g e
4.2 Formulation and Assembly Specifications
This section of the Quality Manual would display the
“recipes” for making specific products. Included would
be chemicals used, batch sizes, pigment skus, product
types, sheet thickness, and machine used.
We are not able to include proprietary information
within this section.
18 | P a g e
4.3 Description of Production Methods and Controls
This section of the Quality Manual would display a
number of SJOPs which are relevant to specific
departments within the facility. Within these SJOPs, are
included the purpose, scope and limitations, chemical
references, definitions, responsibilities, chemical hazard
data warning, emergency response, safety equipment,
procedure and revision history.
We are not able to include proprietary information
within this section.
19 | P a g e
4.4 Quality Control During Manufacturing
Florence, Kentucky Site
Laboratory:
Quality control responsibilities are present throughout the entire operation. These
responsibilities are not relegated to Quality Inspectors, per se. There is one classification of QA
inspectors which have the sole function of inspecting and testing our products at the end of the
casting line. Within our other departments, there are QA responsibilities within each functional
area. When our main raw material, Methyl Methacrylate, arrives at our tank farm (railcar or
tanker), the tank farm operator checks each shipment for dirt. If dirt is present to a level that
will not be filtered out, the shipment will be denied. Our Analytical Lab checks new lots of raw
materials for specific gravity and by GC analysis. Our Pigment Lab inspects TiO2 and ATH for
consistency in color and particle size, in addition to developing new pigment formulations and
testing new pigments. Since we make our own pigment on-site, the Pigment techs measure,
correct and record color data by lot number in our system. For specific pigments which use
mica material, each batch is measured on a Hegman grind gage within 24 hours of use in
production.
Manufacturing:
Reactor Room – Viscosities of our base syrup, which we produce, are measured once a shift by
the Reactor Room (RR) leadman. The Reactor Room operation is controlled via a Delta V DCS
for the operation of all vessels, including the ATH (aluminum tri hydrate) dispersion operation.
Filtration is used as material is transferred and poured to the casting machines. It is the
responsibility of the 3rd floor operator to assure that the correct filtration is in place as this is
critical to quality in certain products. Pigment paste is dispersed in the Reactor Room on a
time-controlled sequence in a high shear mixer. Pigments and chips are lot controlled and this
information becomes part of the batch record when produced.
Casting Machine - Prior to a batch being poured to the casting machine, a sample is taken to
the casting machine operator who measures the viscosity. This is done for both chipped acrylic
products and Solid Surface products. If the viscosity is too high, it may be thinned down before
pouring. If it is too low, the machine may be slowed down to provide the batch in the Reactor
Room additional time to build viscosity. In addition to managing the feed to the casting
machine, these operators are responsible for setting the machine up for the desired caliper and
sheet size, using the correct filters and changing them when necessary. Most importantly,
these operators have responsibility for multi-million dollar casting machines. This part of the
operation uses a Man Machine Interface (MMI) to track what is happening internally in the
machine (temperature, speed, pressure, etc.). The batch is created in our system when the
casting machine operator enters the batch number and head in time into our system. This
20 | P a g e
begins the systematic tracking of material through our operation. A batch is not a batch until it
begins to pour to the casting machine.
QA – The QA operators are located at the back of our casting line where our material exits as a
“hard, flat and shiny” product. At this part of the operation, the QA operators are measuring
caliper variance across the sheet, color, formability, chemical stability, and examining the
sheets for defects. We have Cognex Vision Systems on 2 of our casting lines. This equipment
has 7 high power lamps and a camera that can check for defects such as bubbles,
contamination, gels, etc., and marks defects as they are detected. This information is stored in
a PC at the back of the line.
Sawline - The sawline operator’s main responsibility is to stack the material onto pallets as it
comes off of the line. They are also responsible for quality attributes such as saw cuts, polyfilm
application, and sheet size. Since every sheet passes through their hands, they have the
responsibility to inspect and report any defects they see.
Sander – The sanding operators are responsible for sanding solid surface material to
specification. Some of the most critical attributes during inspection of a SS sheet are caliper
control, chip distribution, chatter, contamination and rough sanding. If there is chatter or
rough sanding present, the sander is stopped and the sanding rolls are inspected. If there is
contamination, the sheet will be evaluated as to whether or not it can be reworked.
Packaging – Since this is the first view our customers see, it is important that we present a
quality product. Packages are labeled with our lot number, barcode, and product type;
wrapped or covered as appropriate, banded and shipped to either a warehouse or direct to the
customer.
21 | P a g e
5.0 Finished Products
22 | P a g e
5.1 Finished Products Specifications
TECHNICAL BULLETIN 200
Physical P r o p e r t i e s - Solid Surfacing S h e e t s
Aristech Surfaces LLC Foundations and Studio Solid Surfacing sheet products in attractive granite
colors provide exceptionally weatherable, strong, non-porous, scratch and stain resistant material for
architectural and utilitarian work surfaces.
PROPERTY
FOUNDATIONS
CLASS I
STUDIO
STUDIO
CLASS I
CLASS Ill
TEST METHOD
General:
Thickness Tested
Specific Gravity
Water Absorption (24 hrs.)
Mechanical:
Tensile Strength
Tensile Modulus
Tensile Elongation
Flexural Strength
Flexural Modulus
Barcol Hardness
Rockwell Hardness (M)
Un-notched Izod Impact
Notched Izod Impact
Ball Impact (1/2 lb. ball)
Thermal:
DTUL @ 264 psi
Coefficient of Thermal Expansion
Boiling Water Resistance
High Temperature Resistance
Flame Spread Index
Smoke Generation Index
Combustion Toxicity
Surface:
Consistency of Color (same sheet)
Light Resistance
Clean-ability/Stain Resistance
Stain Resistance
Fungi Resistance
Food Zone Use
0.500"
0.500"
1.6
1.6
0.04%
4,000 psi
1,100,000 psi
2.1%
8,000 psi
1,100, 000 psi
60
86
1.40 ft.lbs./ inch
0.14 ft.lbs./inch
> 150”
0.500"
1.3
0.03%
0.04%
3,700 psi
1,200,000 psi
0.38%
6,500 psi
1,200,000 psi
60
99
0.67 ft.lbs./inch
0.15 ft.lbs./inch
> 150”
2,300 psi
730,000 psi
0.34%
4,100 psi
720,000 psi
51
105
0.42 ft.lbs. /inch
0.15 ft.lbs./inch
>150”
200 F
2.3 X 10 -5 in./in./°F
No Effect
No Effect
<25
<25
Solid Colors – 98
Patterns – 67
180 F
2.1 X 10 -5 in./in./°F
No Effect
No Effect
<25
<25
Pattern – 62
Passes
No Effect
13/No Effect
Passes
No Growth
NSF 51 Approved
Passes
No Effect
5/No Effect
Passes
No Growth
NSF 50 Approved
ASTM D792
ASTM D570
ASTM D 638
ASTM D 638
ASTM D 638
ASTM D 790
ASTM D 790
ASTM D 2583
ASTM D 785
ASTM D 4812
ASTM D 256
NEMA LD3-3.8
175 F
ASTM D 648
2.9 X 10 -5 in./in./°F ASTM D 696
No Effect
ISSFA SST 8.1-00
No Effect
ISSFA SST 9.1-00
>75
ASTM E 84
>450
ASTM E 84
Pattern – 19
Pittsburgh Protocol
(LC50 Test)
Passes
ISSFA SST 2.1-00
No Effect
ISSFA SST 7.1-00
9/ No Effect
NEMA LD3-3.4
Passes
ANSI Z-124.3
No Growth
ASTM G 21
NSF 50 Approved
NSF
23 | P a g e
FGS – 0025
Issued:
Supersedes:
References:
3/10/2010
FGS – 0025 Revision Date 6-26-2013
FGS – 0021
Title: SOLID SURFACE SANDED SHEETS
Purpose: To provide specifications to be used for internal quality control of all sanded solid
surface products.
FACE FINISH
Sheets are to be finished such that the prime surface displays no visual chatter when viewed
under floor lights of 500 watts located next to Sander QA station (overhead lighting masks
chatter).
As a general rule, the following guideline applies:
Infeed Product Type
MBX/MFX/NDX
MGX/NGX
MHX/NRX
NEX/NIX
Minimum Prime Side Removal Amount
~.010”
~.015”
~.025”
~.035”
CHANGES: Revised surface defects description for clarity by removing specific product
reference.
Approver
Print Name:
Signature
and Date:
Title &
Dept:
Approver
Print Name:
Signature
and Date:
Title &
Dept:
This document and the information contained herein are the property of Aristech Surfaces LLC. Copies are
issued in strict confidence and shall not be reproduced, copied, or used as the basis for manufacturing or
sale of apparatus without consent
24 | P a g e
FGS – 0025
BACKSIDE ROUGH SANDING
When a product type is specified that calls for rough back sanding, the minimum amount of
material should be removed (50 grit finish) that provides removal of all gloss. No gloss spots are
acceptable as are no sander digs or divots; especially in 1/8” as this will show through to the
prime surface. It is recommended that the backside of 1/8” be periodically inspected throughout
a pallet to guarantee that no digs or divots are being left.
SURFACE QUALITY OF SANDED SHEETS
B grade sheets: Inventory levels have been identified for each color of ½” product which will
supply our B grade program. B grade is sorted on the sander. All material in excess of the B
grade levels identified will be scrapped off of the sanding line.
Surface Appearance: The surface appearance of the sanded sheet should be visually smooth
and distortion free when viewing reflected light off of the surface. This review needs to be done
using floor stand lighting with multiple 500 watt fixtures. Pay special attention to any surface
scratches which may not be visible if further away than 6"-12". It is necessary to run your hands
over the sheets to affirm a smooth surface in addition to viewing a smooth surface.
COLOR MATCH AND CHIP DISTRIBUTION
Sanded sheets are visually compared to stored sanded standards at the sanding line. If the visual
check does not correlate to the standard, place material on hold pending resolution between the
Sander Supervisor and the Color Lab. The stored color standards may be slightly darker than the
sanded sheet due to a higher level of fabrication.
SURFACE DEFECTS
Surface defects such as dirt, streaks, contamination, etc. can be observed either at the QA
inspection station or the inspection bridge. These defects are not acceptable. Any one of the
following defects, determined by the NEMA LD 3.11 procedure, will cause a sheet to be
classified as B grade:
• Streaks
• One 0.6 square mm or larger foreign particle*. (NEMA spec.)
• Any group of three or more foreign particles*, each having an area of 0.3 square mm or
larger and occurring within a 12 inch diameter circle on a sheet. (NEMA spec.)
• More than 10 foreign particles*, each having an area of .3 square mm or larger per sheet.
(Aristech spec.)
* Foreign particles may be drilled and filled.
This document and the information contained herein are the property of Aristech Surfaces LLC.
Copies are issued in strict confidence and shall not be reproduced, copied, or used as the basis for
manufacturing or sale of apparatus without consent
25 | P a g e
FGS – 0025
**** 9117 Kokura (white-on-white), 7810, and 7921: Due to the light tone-on-tone nature of
these sheets, this product color offering is prone to chip contamination from a number of sources.
At times, there may be as many as 5 particles as large as 5 to 6 square millimeters in size. This
level of contamination is acceptable as A grade material in these colors only. Contamination of a
frequency of more than 5 particles per sheet is to be documented as to the relative number and
placed on hold.
Contamination: Contamination defects will be routed to the Drill and Fill area for repair. All
product types and colors can be repaired when less than 15 contaminants are present
Bubbles: no bubbles or other type of sheet porosity are acceptable. These include pinhead,
hidden or surface bubbles.
Sander Induced Chatter: Visible chatter is not acceptable in the finished sheet.
Broken corners: Acceptable as long as length/width tolerances are maintained and break is 1/4"
or smaller.
CALIPER SPECIFICATIONS (UNSANDED INFEED FROM CASTER)
Caster
Nominal
Thickness
Low
High
0.125
0.133
0.236
0.255
0.260
0.315
0.330
0.375
0.472
0.490
0.500
0.510
0.760
0.110
0.125
0.225
0.240
0.245
0.295
0.315
0.360
0.455
0.475
0.480
0.490
0.745
0.140
0.141
0.270
0.270
0.275
0.325
0.345
0.390
0.491
0.505
0.525
0.535
0.775
0.250
0.225
0.275
Dupont
This document and the information contained herein are the property of Aristech Surfaces LLC.
Copies are issued in strict confidence and shall not be reproduced, copied, or used as the basis for
manufacturing or sale of apparatus without consent
26 | P a g e
FGS – 0025
CALIPER SPECIFICATIONS (SANDED OUTFEED FROM SANDER)
Finish Caliper
Caster
Nominal
Thickness
Sander
Nominal
Thickness
0.125
0.133
0.236
0.255
0.260
0.330
0.375
0.472
0.490
0.500
0.510
0.760
0.125
0.133
0.225
0.315
0.360
0.460
0.745
Low
0.095
0.110
N/A
0.217
0.217
0.295
0.340
0.453
0.453
0.453
0.453
0.725
High
0.125
0.126
N/A
0.255
0.255
0.325
0.370
0.491
0.491
0.491
0.491
0.755
Maximum Variance
Across Sheet
.010"
Maximum Cupping
.100"
Width
0" / + 1/4"
Length
0" / + 1/2"
This document and the information contained herein are the property of Aristech Surfaces LLC.
Copies are issued in strict confidence and shall not be reproduced, copied, or used as the basis for
manufacturing or sale of apparatus without consent
27 | P a g e
Grit Level Finish
Product
Type
MBD
MBQ
MFD
MFW
MFZ
MGD
MGW
MGZ
MHD
MHW
MHZ
NDW
NED
NEW
NGD
NGW
NGZ
NID
NIW
NRD
Face
Back
280
320
280
280
280
280
280
280
280
280
280
280
280
280
280
280
280
280
280
280
50
50
50
Glossy
280
50
Glossy
280
50
Glossy
280
Glossy
50
Glossy
50
Glossy
280
50
Glossy
50
Flip
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
Yes
Yes
Yes
No
No
No
Yes
Yes
No
L. Tungate
6-26-2013
This document and the information contained herein are the property of Aristech Surfaces LLC.
Copies are issued in strict confidence and shall not be reproduced, copied, or used as the basis for
manufacturing or sale of apparatus without consent
28 | P a g e
5.2 Quality Control of Finished Products at Florence, Kentucky
Site
Since the packaging is the first view our customers see, it is important that we present a quality
product. Packages are labeled with our lot number, barcode, and product type; wrapped or
covered as appropriate, banded and shipped to either a warehouse or direct to the customer.
With our lot number, we have a link to the batch that created that lot and the testing results
from that batch. This data is stored in our system and is accessible to a number of different
departments within our facility. Lot traceability enables us to understand everything about the
sheets we produced from raw materials consumed, defects scrapped on-line, end customer and
how the sheet performed in the customers’ shop. There is data entered into the system
throughout the process, including the status of a finished lot of material, whether it is on Hold
for additional testing, First Quality inventory or B-grade material. Within our warehouse, we
know the location and status of each lot of material.
29 | P a g e
5.3 Packaging and Storage of Finished Products
COMPANY CONFIDENTIAL
ARISTECH
ACRYLICS LLC
SJOP 92501
Date Revised : 05/ 06, 2014
S AFE
J ob
Date Reviewed: May 2014
O perating
P rocedure SUPERVISOR Sign-Off:
M Collins
Packaging Pallets
PURPOSE
The purpose of this document is to outline the proper procedure for Packaging Pallets at this
facility.
SCOPE AND LIMITATIONS
This procedure is applicable to Departments 81, 87, 92, 95 and 98 personnel responsible for
packaging pallets.
REFERENCES
REFERENCE NUMBER
SJOP 92110
SJOP 92103
SJOP 92105
SJOP 92102
REFERENCE TITLE
CARDBOARD CUTTING TABLE
NAIL GUNS AND STAPLERS
MATERIAL DOLLIES
DEFINITIONS
DEPTS
SJOP
T.S.
FANFOLD
AIR KNIFE
TAG STRIP
DEPARTMENTS
SAFE JOB OPERATING PROCEDURE
TEAM SUPERVISOR
CORRUGATED CARDBOARD USED TO MAKE BOXES
ATTACHED TO THE CARDBOARD CUTTING TABLE (SJOP92110)
LABEL WITH A SIX DIGIT NUMBER ASSIGNED BY
SEQUENTIAL NUMBER GENERATOR AND BARCODE
PRODUCT LABEL
DESCRIBING PRODUCT TYPE
30 | P a g e
DOCUMENTATION
Document Number
Document Title
FP-PKG-CHK-001
Weekly Inspection
SAFETY HAZARDS
Struck By, Caught Between, Slip, Trip, Strain
Pinch Point, Cut by, Saw Dust in Eyes, Puncture
Splinters
SAFETY EQUIPMENT
Safety Glasses with side shields, ear plugs, gloves
SPECIAL WARNING
When feeding banding from the banding cart to the package always keep (cut end) of banding within 1 inch of the
outside part of the pulling hand to reduce possible puncture or cut. HAZARDS Cut by, Puncture.
Leather gloves need to be replaced when they are no longer safe to use, torn, oily. As a guideline use the photos
below to determine if your gloves need to be replaced. As long as your gloves look like “New” or “slightly used”
there should be no problems. When they resemble the “used a lot” photo then replace them with new gloves.
Hazards Cut by, Puncture.
RESPONSIBILITIES AUTHORITIES
31 | P a g e
(A) Departments 84, 87, 92, 95, 98 All
(1) Responsible for following this procedure properly and safely.
(2) Responsible for checking equipment for obvious wear, loose or missing parts.
(3) Responsible for informing Team Supervisor of any condition of saw that might lead to
personal injury.
(B) Departments 87, 92, 98, 95, 84 Team Supervisor
(1) Responsible to follow up on all equipment to be repaired or replaced.
(2) Responsible for training of all department operators in this procedure.
Responsible for updating and revising this procedure.
OPERATING PROCEDURES
NOTE: Always be aware of your surroundings.
1. The first step is to locate the pallet(s) required and place the pallet in the packaging area.
(Pallets staged outside)
2. Cut fan fold to the exact size of the pallet. The fan fold is 70 inches wide. Larger pallets may
require two or more pieces of fan fold. Some pallets 70” and under do not require covering. To
cut the fan fold, follow these steps:
(SJOP 92110)
A. A bundle of fan fold will be at the packaging table. Take hold of the top layer of cardboard
and unfold it onto the table. (STRAIN, CUT BY)
B. Measure the length required. Use the air knife to cut desired length. (POSSIBLE CUT BY
AIR KNIFE.)
(SJOP 92110 )
3. Fasten the fan fold to the pallet using one inch staples. Staple each corner and any loose flaps.
A pallet which is prepared and ready for use is called a setup pallet. (PINCH POINT,
PUNCTURE.) (SJOP 92103) (AIR HOSES COULD BE TRIP HAZARDS) NOTE: MFB
and MBB only pallets will have chip board applied at the filpper and they are not to be stapled.
White poly film is applied to the empty pallet at the sawline by Sawline Operators.
4. Using a forklift, place the dolly at the sawline where it is to run.
5. Using a forklift pick up the setup pallet and place the pallet on the dolly. Insure that the pallet
is positioned securely on the dolly.
6. When removing a pallet from the line insure that the acrylic is stacked neatly and square on
the pallet. Packaging must remove 64x148 single batch pallets and must communicate with the
sawline lead man or operators. The saw line operators have difficulty moving the dollies with
32 | P a g e
5,000 pounds on them. To do this you must plan your work around being available to remove
these pallets, much the same as Reels and U-Pallets. ACRYLIC COULD SLIP FROM
PALLET AND CAUSE INJURY. Make sure the area is clear of Sawline Operators.
92501.2 Packaging a pallet.
.21 Measure the length, width and height of the material on the pallet.
.22 To determine the size cardboard needed, multiply the height by two, add the width. Finally
add one inch to this figure. This is the width of cardboard needed. To determine the length,
multiply the height by two and add the length, add one inch to this figure. .
EXAMPLE: The material is 36 inches by 60 inches. The material is stacked 8 inches high. To
determine the width: 8 inches high x two equals 16 plus 36 inches width = 52 inches plus one
extra inch equals 53 inches. To determine the length: 8 inches high x two equals 16 plus 60
inches length = 76 inches plus one extra inch equals 77 inches. The cardboard required to make
this box would be cut 53 inches by 77 inches. The width of the fan fold is 70 inches. Boxes
which are to be made larger than 70 inches require two or more pieces. Boxes this size should be
made using the measurements for the width. (SJOP 92110)
.23 Having determined the size fan fold needed complete the box as follows: Except Wilsonart
pallets.
A. Using a utility knife and tape measure, score each side of the fan fold the desired height of the
intended box. Crease and fold each side over. Cut each corner at one crease to make a flap.
(ALWAYS CUT AWAY FROM YOUR BODY, POSSIBLE CUT BY KNIFE) Staple each
flap with ½ inch staples, 2 to 4 per flap. (SJOP 92103) (AIR HOSES COULD BE TRIP
HAZARDS)
B. When making two or more piece boxes score only three sides and staple the width end of the
box. (SJOP 92103) (AIR HOSES COULD BE TRIP HAZARDS)
.24 Put corner protectors on each of the four corners of the acrylic. Place a desiccant packet on
top at two of the corners before wrapping. Fold the overlap white poly and tape together to
create a nice looking package. NOTE: UNDER NO CIRCUMSTANCES SHOULD TAPE
BE ATTACHED TO THE POLY FILM. IT TEARS THE POLY FILM WHEN
REMOVED. Place the cardboard box on the material.
.25 Banding materials on to the pallet can be done in three different positions and by one or two
operators. (SJOP 92102)
(1). Material can be elevated using the forklift. Elevate to a comfortable height. GLOVES, must
be worn, on both hands.
(2). Material can be banded while still on the dolly. In this position gloves must be worn.
33 | P a g e
(3). Material can be banded while resting on the floor. SAFETY EQUIPMENT IS WORN TO
PREVENT SPLINTERS FROM PUNCTURING HANDS WHEN PASSING THE BANDS
THROUGH THE CROSS RUNNERS. OR BEING CUT BY THE PLASTIC BANDING.
HAZARD: (DO NOT PLACE BODY IN CONTACT WITH THE PALLET OR
PACKAGE THAT IS BEING BANDED. POSSIBLE SPLINTERS, PUNCTURE)
.27 Use one band on each Length side of the pallet. This is for all size pallets. (SJOP 92102)
NOTE: Wilsonart and Avonite pallets do not get length bands.
.28 Place an edge protector on the top edge of the box where the band make contact.
The Width side of the pallet requires:
a. 2 bands for less than 51 inches and solid surface pallets with WIP tags.
b. 3 bands for 51 inches to 80 inches.
c. 4 bands for pallets 81 inches to 110 inches.
d. 5 bands for pallets over 110 inches, plus one additional band for every 25 inches.
92501.3 Placing tag and labels on pallets.
Listed below is the proper sequence for packaging and labeling pallets including Wilsonart. This
must be followed to allow the bar code system to work properly and to enhance the package
appearance. Note: Do not cover labels with banding!
ACRYLIC FAMILY GPA, IGP, GPM, I-3, IGM, S-3, IMA, I3M, CFA, DFA, GF
.31 Place a customer information tag label on the upper left hand corner of the front and rear of
the package. Place the label one tag width from the corner, and 1/2 inch from the top, just inside
the band. Press firmly around all edges of the label to insure proper adhesion.
Customer
Information
Label
Tag Strip
34 | P a g e
.32 Place a tag strip, 1/2 inch from the bottom and one tag width in from the corner of the
cardboard on the lower right of the package, front and rear (See Above). Press firmly around all
edges of the label to insure proper adhesion.
.33 Place a tag strip and a Customer Information Label, one tag width in, on the left side of the
both outside runners. Staple both labels on each end, using the Arrow T-50 stapler and 5/16"
staples. Be sure that staples are not placed into the Bar Code section of either label.
Tag Strip
Customer
Information
Label
.34 Place a product label to the left of the tag strip, 1/2 inch, on the front of the package and 1/2
inch from bottom of cardboard. Press firmly around all edges of the label to insure proper
adhesion.
.35 Place the HMIS label just to the left of the product label, 1/2 inch, on the front of the package
and 1/2 inch from bottom of cardboard. Press firmly around all edges of the label to insure
proper adhesion.
HMIS Label
Product
35 | P a g e
SOLID SURFACE FAMILY: MF, MB, MG, MH, TF
Use a one inch separation between tag strip and information label.
Part # label
Information Label
Information Label
Tag Strip
HMIS Label
NSF-51 Label
NOTE: ALL PERSONNEL ARE TO STAY / REMAIN OUT OF THE WAY OF
FORKLIFT AND CRANE OPERATORS IN MOVEMENT. ALL CRANE / FORKLIFT
OPERATORS ARE TO LOWER LOADS BEFORE PERMITTING ANYONE INTO
THEIR AREA. MATERIALS ARE NOT TO BE STACKED OVER 15 FEET HIGH.
HAZARDS: UNSTABLE LOADS AND STACKS COULD TOPPLE AND CAUSE
SERIOUS INJURY.
.036 Place the pallet in the staging area in E Bay. Packages are to be stacked neatly in this area.
REVISION HISTORY
Date
01/10
07/11
Rev.
1.0
2.0
05/14
3.0
Section
Purpose &
Operating
Procedure
Description of revision
Initial
Revision
Small change in wording.
36 | P a g e
6.0 Disposition of Non-Conforming Materials
37 | P a g e
6.1 Policy and Procedure
Aristech’s policy on Non-conforming sheet material is that it will be scrapped (both Acrylic and
Solid Surface) if defects are found or downgraded to “B Grade” in the case of Solid Surface
products. In addition to sheet products, all incoming raw materials, pigments, etc. will either be
re-worked, scrapped, or returned to the vendor depending on the issue and if it can be
corrected. Non-conforming material can be detected in several different ways as testing is
conducted throughout the process. The first step is to approve all incoming raw materials in
R&D. Prior to a batch pouring to the casting machine, there are several different qualities
which are tested such as viscosity and reactivity. Once the batch exits the back of the casting
machine, an inline camera system, illuminated by 7 high intensity lights, inspects and tags
several defects such as air, gels, contamination, etc. In addition to this in-line inspection, the
QA operators are obtaining batch samples throughout the batch. These samples are tested for
color, caliper, thermal stability, formability, and additional visual inspection. The process is
similar for Solid Surface on the Sanding line where every sheet is visually inspected and
compared to the standard.
38 | P a g e
39 | P a g e
6.2 Definition of Major and Minor Defects
40 | P a g e
6.3 Complaints Procedure
In 2013, our defect rate in the field was 0.20% for all Solid Surface and Polyester
Products.
Reason
1SD - Improperly Sanded
CNP - Poor Pattern
4BD - Bad Color
1MP - Mislabeled Package
CWP - Warpage
5CN - Contamination
Q9B - Cracking Sink
TOTAL
Total
34%
31%
14%
8%
7%
5%
1%
100%
The chart above shows the defect types experienced by customers in 2013, as classified by
ASLLC. The largest defect was the result of new sanding equipment that took time to dial in.
This defect was addressed, internally, by the sanding and engineering team. This defect was
34% of our total losses at the customer in 2013.
1. If a customer has a justified issue with our products or service, they would contact their
Customer Service or Field Sales rep to begin the credit process. If it is a product specific
issue, we request samples showing the defect. Once we have received all relevant
information, we issue a credit to the customer.
2. We have regularly scheduled conference calls with 3-4 acrylic bath and hot tub
customers every 3-4 weeks.
3. We have conducted Kaizen events for one of our customers in out facility, our
lamination partner’s facility, and at the customer’s facility. In this situation, we have an
ongoing action item list that includes all 3 parties.
4. We review recent performance and identify any new issue that the customer has
experienced with our product.
5. If relevant, we request samples for internal analysis.
6. Internally, we develop corrective action plans that are communicated to our customers
for their understanding either in writing or during our conference calls.
7. A detailed review of the credits is done on a monthly basis for all markets and major
customers. This information is shared with the manufacturing and sales teams.
8. Product quality credits in our acrylic products were reduced from 2.1% in 2011 to 1.5%
in 2012 to 1.2% in 2013. Solid Surface products had a decrease of 0.2% from 0.4% in
2012 to 0.2% in 2013.
41 | P a g e
6.4 Non-Conformance Form and Example
Non-Conformance Report
This is an internal document to be used in the event of non-conforming product
(produced or purchased) or services that we provide or that we purchase.
Goal: When an instance of non-conformance occurs, a root cause investigation
will be initiated. Based on the findings, corrective actions will be put in place,
either internally or with our suppliers/customers to prevent the re-occurrence of
the non-conformance.
Date Submitted:
Send to: [email protected]
CAPA# (to be filled in by ASLLC):
Customer/Vendor/Product: Lucite
Lot:
Quantity Delivered:
Quantity Defective:
Customer/Supplier contact person & email:
Detailed Description of Issue:
42 | P a g e
Corrective Action Request
(Initial response required within 24 hours)
Action Initiated by:
Request Sources:
Service Request
Process Monitoring
QA Inspection
Purchasing
CAPA #
Customer Complaint/Concern
Failure Mode Analysis
Risk Assessment
R&D
QA Inspection
Trending Data
Management Review
Problem Description:
Evidence Observed:
Preliminary Assessment of Potential Impact and/or Risk:
43 | P a g e
Corrective Action/Problem Analysis
Date:
CAPA#
List of Possible Causes and Supporting Data:
Analysis Results and Data:
Root Cause Determination:
Analysis Complete
Date:
By:
44 | P a g e
Non-Conformance Report (EXAMPLE)
This is an internal document to be used in the event of non-conforming product
(produced or purchased) or services that we provide and that we purchase.
Goal: When an instance of non-conformance occurs, a root cause investigation
will be initiated. Based on the findings, corrective actions will be put in place,
either internally or with our suppliers/customers to prevent the re-occurrence of
the non-conformance.
Date Submitted: 3/12/13
Send to: [email protected]
CAPA# (to be created by ASLLC; format: day of month/month/year/seq#):
03121301
Customer/Vendor/Product: Chemical Express
Lot: Wx2f-2081-678972
Qty Delivered:
Qty Defective:
40,000#
40,000#
Customer/Supplier contact person & email: [email protected]
Detailed Description of Issue: High level of contamination and GC not indicating
MMA
45 | P a g e
Corrective Action Request
(Initial response required within 24 hours)
Action Initiated by: Jim Cannoy
Request Sources:
Service Request
Process Monitoring
QA Inspection
Purchasing
CAPA # 03121301
Customer Complaint/Concern
Failure Mode Analysis
Risk Assessment
R&D
QA Inspection
Trending Data
Management Review
Problem Description:
A shipment off MMA was received in a tanker at 8am on
3/21/13. The white bucket test revealed a significant amount
of contamination which was black, rust and hard gels. The QC
indicated there was a chemical contaminant as well as the
particulate contamination.
Evidence Observed:
Black, rust and hard gels. GC indicated a chemical contaminant
as well. R&D is working to identify the chemical contaminant.
3/22: ASLLC R&D has determined the contaminant is methacrylic acid.
Preliminary Assessment of Potential Impact and/or Risk:
Use of this material in the process poses a high level of risk.
This material will NOT be used in production and has been
returned to Chemical Express.
46 | P a g e
Corrective Action Request
(Initial response required within 24 hours)
Action Initiated by: Jim Cannoy
Request Sources:
Service Request
Process Monitoring
QA Inspection
Purchasing
CAPA # 03121301
Customer Complaint/Concern
Failure Mode Analysis
Risk Assessment
R&D
QA Inspection
Trending Data
Management Review
Problem Description:
A shipment off MMA was received in a tanker at 8am on
3/21/13. The white bucket test revealed a significant amount
of contamination which was black, rust and hard gels. The QC
indicated there was a chemical contaminant as well as the
particulate contamination.
Evidence Observed:
Black, rust and hard gels. GC indicated a chemical contaminant
as well. R&D is working to identify the chemical contaminant.
3/22: ASLLC R&D has determined the contaminant is methacrylic acid.
Preliminary Assessment of Potential Impact and/or Risk:
Use of this material in the process poses a high level of risk.
This material will NOT be used in production and has been
returned to Chemical Express.
47 | P a g e
Corrective Action/Problem Analysis
Date: 03/23/13
CAPA# 03121301
List of Possible Causes and Supporting Data:
Chemical Express has conducted an initial investigation that has revealed
the following: the filter media used to transfer material into the
truck, had not been changed when scheduled. The filter, when
removed, had several small holes. Additionally, a new line had been
installed which included a 3-way valve. It has been discovered that the
valve was not seating correctly.
Analysis Results and Data:
Further investigation has determined that methacrylic acid contaminated
the shipment.
Root Cause Determination:
Chemical Express’s failure to change filter when scheduled. Chemical
Express’s
failure to thoroughly their operation through maintenance checks and
analytical analysis.
Chemical Express’s Corrective Action:
The mechanic responsible for changing the filter, failed to do so and has
been terminated based on this and several other errors. The 3-way valve
has been replaced and is on a daily operability checklist for the next 6
weeks. After that, the valve will be placed on a weekly operability checklist
for 3 months, and, finally, will be placed on a quarterly operability checklist.
This NCR will not be closed until the Actions are completed and functioning
properly. Estimated next review is July 30th, 2013
Analysis Complete
Date:
By:
48 | P a g e
7.0 Measuring and Test Equipment
49 | P a g e
7.1 Standardization of Quality Control Equipment
Aristech
Surfaces,
LLC
Instrument Calibration
Procedure
Date Revised:11/10/10
Authorized By:
Origination Date: 2/28/02
Page 1 of 18
PURPOSE
This procedure is written to define the requirements necessary for establishing and
implementing a n effective calibration control program. The aim of the calibration program
is to ensure that all process control instrumentation included in the program is calibrated
to within the manufacturer's accuracy specifications or the tolerances required by the
process for quality and safety purposes. Documented traceability to either the National
Institute of Standards and Technology (NIST) or other applicable agency must be
maintained.
Guidance is provided on the methods to be used for calibrating various instruments by
the Systems Engineer. This procedure is to be used with the work order, calibration
worksheet, instrument data sheet, database information, and the manufacturer's manual.
When the methods described herein are not practical, consult with the Systems Engineer
for a proper method.to document any deviations on the calibration worksheet prior to
turning-in the work order and attachments to the Systems Engineer after the job is
complete.
DISTRIBUTION LIST
Manager- Engineering and Maintenance (E&M Manager) (Controlled Copy)
Maintenance HPLT
Systems Engineer (Controlled Copy)
Instrument Technician
AMENDMENT
PROCEDURE
The Systems Engineer is responsible for insuring that the procedures accurately reflect
current practices within the area and procedural change requests are initiated as
needed. Changes are to be discussed between the Systems HPLT, the Instrument
Technician, and others as required. Revisions are to be initialed by the Systems
Engineer for implementation and copies re-distributed appropriately.
50 | P a g e
Aristech
Surfaces,
LLC
Instrument Calibration
Procedure
Date Revised:11/10/10
Authorized By:
Origination Date: 2/28/02
Page 2 of 18
SECTION 1.0 - TABLE OF CONTENTS
SECTION NO.
1.0
2.0
3.0
3.10
3.20
3.21
3.30
3.40
3.50
3.51
3.60
3.70
3.80
3.90
4.0
5.0
6.0
7.0
PROCEDURE TITLE
Table of Contents
Document Control
Calibration Procedure
Temperature Calibration
Level Calibration
Funnel Level Switch
Pressure Calibration
Speed Sensor Calibration
P-1 to 23 & R-1 to 12 Flow Switch
R-13/14 Water Flow Meters
Chemical Delivery Checks
Control Valve Checks
MMA Level Sensors
pH Analyzer Calibration Procedure
Records
Inspection, Measuring and Test Equipment
Calibration Worksheet
Master List
CURRENT DATE
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
11/10/10
51 | P a g e
Aristech
Surfaces,
LLC
Instrument Calibration
Procedure
Date Revised:11/10/10
Authorized By:
Origination Date: 2/28/02
Page 3 of 18
SECTION 2.0 - DOCUMENT CONTROL
Instrumentation Calibration Documents shall be maintained by the Systems Engineer
and include the following:
Document
Calibration Procedure
·---
·-·-·-
Calibration Worksheet
Master list of Instruments
Copies
-
2
·-
2
1
These will be controlled copies.
Uncontrolled copies will be distributed to plant personnel as needed beyond the
numbers shown above.
Completed Calibration Worksheets are to be filed for reference per Section 4.0.
The Systems Engineer shall initial or sign each page of the Calibration Procedure including
the cover of the Master List of instruments. The bottom of each Instrument Calibration
Worksheet shall contain the initials of the person authorized to approve completion of work
as follows: the Systems Engineer, or the salaried designee as specified in writing by way of
an interoffice correspondence per the Systems Engineer or the E&M Manager. The E&M
Manager may initial and/or a p p r o ve items in the absence of the Systems Engineer.
The Master List of Instruments and Data Sheets can be controlled via an electronic
database or file as well as in a hard copy format. Electronically controlled copies will be
inaccessible except by the Systems Engineer, the Systems Engineer designee, or the E&M
Manager through computer security access control.
52 | P a g e
Aristech
Surfaces,
LLC
Instrument Calibration
Procedure
Date Revised:11/10/10
Authorized By:
Origination Date: 2/28/02
Page 4 of 18
SECTION 3.0 -VERIFICATION AND CALIBRATION PROCEDURE
The calibration of instruments follows good manufacturing practices and is implemented
through the education and experience of the engineers on the engineering staff and
instrument technicians or approved contractor. The Systems Engineer shall issue work
instructions in the form of a maintenance work order for the instruments to be calibrated or
interlocks to be checked, and the work order shall have attached a Calibration
Worksheet. Manufacturer’s manuals are c o n s u l t e d on an as needed basis f o r
performing calibrations.
Once issued, the instrument technician performs the calibration. Any problems
encountered are documented on the worksheet. If repairs are required prior to the calibration,
t h e s e are made and documented also. Generally speaking, a l l instruments in a control
loop are calibrated and a final loop check is performed.
The work order and worksheet are returned to the Systems Engineer for disposition and
computer entry. The work order is then permanently filed per section 4.0
Aristech
Surfaces,
LLC
Instrument Calibration
Procedure
Date Revised:11/10/10
Authorized By:
Origination Date: 2/28/02
Page 5 of 18
SECTION 3.10 - TEMPERATURE
1. Following the Calibration Worksheet, use the RTD calibrator and send a
simulated RTD signal to the temperature transmitter.
2. Verify that the transmitter display is within 0.50 deg F of the simulated calibrator
temperature. Calibrate the transmitter as needed.
3. Verify that the DCS display is within 0.50 deg F of the simulated calibrator
temperature. Calibrate the transmitter and DCS controller as needed.
4. Recheck the loop by simulating the temperature and re-calibrate as needed.
5. Measure the temperature of the process with the RTD simulator. Connect the RTD
to the transmitter. Verify that the transmitter and DCS display are reading the actual
temperature correctly within 0.50 deg F.
53 | P a g e
Aristech
Surfaces,
LLC
Instrument
Calibration
Procedur
Date Revised:11/10/10
Authorized By:
Origination Date: 2/28/02
Page 6 of 18
SECTION 3.20 - LEVEL
1. Following the Calibration Worksheet.
2. Check the device(s) to insure the sensing area is free of material buildup. If
cleaning is required, be extremely careful not to damage the sensing area.
3. Fill the vessel to approximately 70% with was monomer to send a pressure
signal to the pressure transmitter.
4. Verify that the transmitter display is within 1.0 inches of the actual level.
Calibrate the transmitter as needed.
5. Verify that the DCS display is within 1.0 inches of the actual level. Calibrate the
transmitter and DCS controller as needed.
6. Check 35% and 0% level by transferring material out of the vessel.
7. Have the operator stroke. The valve ·at 0%, 50%, and 100% open or the open
And close position for a valve with on/off control. Control valve isolation using
Block valves may be necessary. Verify valve position in the field and feedback
to the DCS screen if available. Check for smooth stem movement. Perform a
visual inspection of the valve, actuator, 1/P converter and all other valve
accessories for proper operation.
8. There are a number of level indicating devices throughout the plant.
Be sure to familiarize yourself with the specific requirements for each device and
the method of checking necessary for each one
54 | P a g e
55 | P a g e
7.2 Equipment and Production Lines
Pigment Room – We produce our own pigment from pigment powders and pastes that are
purchased. The manufacturing equipment in this department is predominately high shear mixers
and roll mills. On specific pigments, a Hegman grind gage is used to measure particle size to assure
that the particles will not break through in the finished sheet.
Reactor Room – This is the dept where our batches are produced in a liquid form prior to pouring to
our casting machines. Manufacturing equipment involved in this area are pumps, automatic valves,
high shear mixers, flowmeters, pressure rated vessels between 500 and 1000 gallons, etc. The main
processes in this dept are the pre-polymerization of methylmethacrylate to syrup with 20% solids
which enable manageable flow to our casting equipment. Temperature and pressure are critical
parameters to manage during polymerization. The ATH dispersion process “feeds” this part of the
process for our solid surface production. Both of these areas are controlled by DCS. Quality
measures taken during the process are viscosity (Brookfield), agitation speed, temperatures,
pressures, and volumes (lbs). An additional piece of equipment measures the chemical structure of
specific chemicals to validate that the right material is being delivered.
Casting – The core of our operation is our 4 continuous casting machines. These machines are
controlled by Wonderware (PLC). The parameters of most importance to our final product are
speed, zone temps, caliper, and torque. As far as delivery, the casting department expects material
that has correct amounts of reaction chemicals and proper viscosity. Reactivity and viscosity are
quality checks measured on the front end of the casting machine before a batch begins to pour.
The casting machine team enters the time when the batch begins to pour, the sku and the pour
width.
Sawline – The main function of the sawline is to cut the sheets to the size required. In addition, the
sawcuts are measured 1 sheet of a lot for adherence to spec. The sawline time also provides an
extra set of eyes with which to identify defects before placing material onto the customers’ pallets.
Quality Assurance - The quality assurance team measures the following characteristics of all
batches produced: caliper is measured at predetermined distances across the width of the material,
color is measured on Spectrum 550 Data Color readout, and a hanging thermal is performed on
each batch to verify that the formability of the batch will be within specification. In addition, a 36”x
28”sheet is formed to detect for contamination, air, etc. A review of the material is visually
performed to detect defects and to prevent them from going to the customer. In addition, lot
numbers are automatically generated when a lot is created. Lot number generation is sequentially
generated.
Packaging – The packaging team assures the packaging material is correct and that all applicable
labels have been adhered to the outside of the package. In addition, when treated pallets are
required, this is another responsibility for the packaging team.
56 | P a g e
Shipping – Packaged material (whether 1st quality or scrap) are shipped to an outside
warehouse, about 3 miles from the plant where it is stored pending shipment. The shipping
department also has the ability to cut down material and create pallets for customers from
inventory.
All of the departments have the responsibility for entering all pertinent data into our database
that details the specific results of tests performed in their areas.
7.2 Equipment And Production Lines
Major Equipment
Continuous Casting Machines
Number of Lines/Eqt
4
Reactors
10
Promoters
19
ATH Silos
4
ATH Dispersion Mix Tanks
2
Sheet Cutting Saws
7
Sander and Sheet Moving Eqt
1
57 | P a g e
8.0 Labeling, Traceability, and Records
58 | P a g e
8.1 Policy of Traceable Label and Records
NO material is shipped from ASLLC without a label which includes a lot specific ID.
This lot specific ID is the lot number. This lot number tells us all that we need to
know for identification. With the lot number, we will be able to tell when the
material was produced, on which machine it was produced, the physical
dimensions of the sheet, the qty of the sheets, what raw materials were used,
what defects were encountered during casting, the yield of the batch and to
whom the lot was sent to.
All of this information is driven by the lot number. All of these records, which
make up the details about the lot, are kept in our database. Changes to a lot
number, i.e. sheets removed, are adjusted in the database and tracked by user
and date.
59 | P a g e
9.0 Policies and Instructions for
Third Party Inspections
60 | P a g e
9.1 Policies and Instructions for Third Party Inspections and
Listing Mark
A Third Party Inspection is defined as “Testing not performed by any parties who might
financially profit by 3rd Party Test outcome.”
Examples of testing we have had performed by outside testing organizations include
Underwriter’s Laboratory (UL), National Science Foundation (NSF), French VOC Regulations per
ISO 16000, and International Maritime Organization (IMO), to name a few.
A third party inspector may meet with an employee of the company from any of a number of
areas (R&D, Sales & Marketing, Production, Quality, etc.).
In third party inspections, a representative from a testing organization would review the focus
of the inspection with a member from the area about the subject at hand. Most of the
following items would be generally reviewed for most third party inspectors:
-
History of the organization
Review of product line and applications
Plant and Laboratory tour
Sources and internal testing of raw materials
Data acquisition within the process
Material traceability
Once the Third Party inspection was completed, samples may be tested on site or sent to a
testing facility. If the material tested, passes, then a Listing Mark may be authorized for use by
the organization requesting such certification. If the products did not pass the testing, a Listing
Mark would not be allowed to be used for that product and company.
61 | P a g e
9.2 Quality Control Manual Revisions and Inspections
The Quality Control Manual will be reviewed for revisions and additions on a two
year cycle. In addition, we will inspect the part of the process that is currently
being reviewed/updated in the same month. The plan is to have a group of 3-4
employees that will spend up to 1 day on each of these areas. With a team that is
knowledgeable about the focus area, we can divide and conquer the review and
revisions. The schedule will be as follows:
Section 2: General Information
Feb of 2014 Completed
Section 3: Incoming Materials
May of 2014 Completed
Section 4: Manufacturing Process
Aug of 2014 Completed
Section 5: Finished Products
Nov of 2014
Section 6: Disposition of NonConforming Material
Feb of 2015
Section 7: Measuring and Test
Equipment
May of 2015
Section 8: Labeling, Traceability,
And Records
Aug of 2015
Section 9: Policies and Instructions
For Third-Party Certifications
Nov of 2015
62 | P a g e
9.3 Reviews and Updates
Review Date
Subject
Participants
February’14
General Information
Sebastian Joseph
May ’14
Incoming Materials
Jim Cannoy
Aug ’14
Manufacturing Process
Mel Collins
63 | P a g e
LAST PAGE
64 | P a g e