Highfield boats Quality Presentation. Highfield 2014 World Conference

Transcription

1 Highfield boats Quality Presentation

2 1. Raw material qualification 1. Fabrics 2. Assemblies 3. Powder coating 4. Accessories 5. Aluminum 2. Quality control on production

3 Fabric 1) Tensile strength test (ISO 1421) 2) Tear strength test (ISO 4674) 3) Adhesion to textile strength test (ISO 2411)

4 ISO Tensile strength test Sample size: 50mm*200mm. Perform tensile test, after breaking record the maximum value. ISO 6185: 2000N / 5cm Mehler: 2500N / 5cm ORCA: 3000N / 5cm HF standard: 2200N / 5cm

5 ISO Tear strength test Sample is size is 50mm*200mm. Fabric sample needs to be cut in the center, 100mm long Do the tensile test, after tearing to termination record the maximum value. ISO 6185: 75N Mehler: 120N ORCA: 200N HF standard: 120N

6 ISO Adhesion to textile strength test Glue 50mm*200mm samples together. Let the assembly cure for 48 hours. Separate the coating layer with cutter and record the average value. Separate the coating layer with cutter ISO 6185: 80N / 5cm Mehler: 100N / 5cm ORCA: 150N / 5cm HF standard: 100N / 5cm

7 Assemblies 1) Bonding strength test (ISO 2411) 2) Seam strength test (ISO 6185) 3) Heat test (ISO 6185) 4) Air tightness test (ISO 6185) 5) Bonding of fabric to powder coated aluminium 6) Chemlock

8 ISO Bonding strength test Glue 50mm*200m samples together. Let the assembly cure for 48 hours. Do the peel test and record the average value. ISO 6185: 80N / 5cm HF standard: Mehler: 200N / 5cm ORCA: 170N / 5cm

9 ISO Seam strength test Join two pieces of material together in the same manner as used in the boat construction to form a 50 mm wide test piece. Apply a static load at 60 over a period of 4 h. Butt connection Single overlap connection

10 ISO Heat test Sample tube is inflated to 1.2 times working pressure. Placed in a heat chamber, set at 60, for a period of 6h. Test air tightness. There should be no slipping or other failure at any part of seam.

11 ISO Air tightness test The boat is inflated to a 1.2 times design working pressure for 30min. Pressure is reset to design working pressure for a further 30min period. Following a test period of 24h, the pressure drop shall not be greater than 20% in any compartment.

12 Bonding of fabric to hull Glue fabric to the aluminium powder coated panel. Do the peel test to measure the adhesion value. Record the average value. HF standard: 120N / 5cm

13 Chemlock Polish the aluminium panel and paint the aluminium with Chemlock. Let the Chemlock dry. Fabric and hull material are assembled by gluing using PVC or Hypalon glues. HF standard: 120N / 5cm

14 Powder coating 1) Coating thickness (ISO 2178) 2) Impact test (ISO 2409) 3) Cross cut test (ISO 2409) 4) Solvent resistence test (Qualicoat) 5) Salt water boiling test (BS EN )

15 ISO Coating thickness We use the gauge to make sure the thickness of powder coating is qualified. HF standard: 60-80um

16 ISO Impact test Test panel is placed under a die. A weight of 1kg is released from 50cm high. Impacted areas are examined for cracking.

17 ISO Cross cut test Scribe parallel lines. Apply sticky tape remove slowly. Results should be no lifting of the cured powder between scribe lines.

18 Solvent resistence test Apply petrol or solvents (MEK, toluene, acetone) on the test panels. After 10 minutes assess the test panels for blister, delamination or loss of gloss.

19 BS EN Salt water boiling test Test panels are longitudinally scribed and stand vertically in a pressure cooker. Keep heating for 2 hours at a pressure of 1 bar (100kPa). Examine samples for blisters, delamination.

20 Accessories 1) UV test (ISO 4892) 2) Salt spray test (ISO 9227) 3) Strength test of handle, rope and D-ring (ISO 6185)

21 ISO UV test Sample panel is exposed to a specific UV lamp for accelerating weathering test. A 1000 hours of exposure can simulate a natural exposure of a few years.

22 ISO Salt spray test This is an accelerated ageing test to check corrosion resistance. Sample panels are exposed to a salt spray machine during a defined period, temperature and humidity.

23 ISO Strength test of handle, rope and D-ring Assemble handles, rope and D-ring on the tube. After 3 days strength tests are performed. Record the maximum value after accessories separated from tube. ISO 6185: 1,500N HF standard: 2,000N

24 Aluminium 1) Chemical analysis of aluminium 2) Bending test

25 Chemical Analysis for aluminium A sample of aluminium is taken from every batch and sent to an independent lab for chemical decomposition.

26 Bending test The flexibility of the aluminium needs to be verified on every batch. We make sample 100*100mm. Press a 90 deg angle, then flatten. Repeat the process and record the number of times before cracking appears. With this simple process we can check the resilience of the material.

27 Quality inspection on production 1) Aluminium hull 2) Fabric tube 3) Whole boat 4) Water tightness 5) Packing

28 Aluminium hull Quality supervisor check the boat after each process (cutting, pressing, assembly, welding, sanding, treatment, powder coating). Record the result on the table. Hulls that pass inspection are stamped on the transom.

29 Aluminium hull A 200*50mm sample panel is attached together with the hull during the pretreatment and powder coated processes. Tests are performed on the sample panel to check the quality of the powder coating (impact test, cross cut test and solvent resistance). Record the result on the table for traceability. Keep the sample panel in archives.

30 Aluminium hull Measure the coating thickness on 12 different locations of the hull. Record the data on the table and get the average to check whether the coating thickness is satisfying

31 Fabric tube Tube can be made only if humidity is below 70% and temperature between 15 C. to 30 C. After the tube is completed each compartment is tested to verify the air tightness of the chambers and baffles. Tube air tightness test is performed. Tube is brushed with soapy water on the seams to check potential leaks.

32 Whole boat Quality supervisor checks every boat s quality about glue situation, taping, rubbing strake, accessories, packing and so on. Record the result on the table and signature on the program card. Program card is used for traceability. It records who and when did what on the boat.

33 Water tightness Boats are filled with water after the tube has been attached to the hull. Water is kept in the boat for at least 5 min to make sure there is no leak. Record the result on the table. If leaks are found, they are fixed and the boat is tested again.

34 Final QC Every boat is inspected following the quality inspection plan Quality Inspection Sheet for OM Date: Order number: Model: Hull/Serial NO.: NO. Description of inspection OK NG Remarks Hull 1 Quality of weld fillet and buffing 2 Color of powder coating 3 Presence of stains on the hull (glue, solvent) 4 Quality of powder coating (gloss, thickness, dust) 5 Deformation or damage on hull 6 Hull is flat 7 No drilling after painting 8 Quality of transom cheeks 9 Bow locker fit for tube 10 Quality of fuel tank 11 Fuel tank is secured to the hull poperly 12 Fuel outlet is not touching deck lid 13 Sender and connectors can be accessed from the small lids 14 Model of fuel filler 15 Installation of fuel hoses 16 Cover of fuel tank matching with deck 17 All screws are useful and have washers 18 Make sure strakes are flat and 5deg down angle 19 Transom welding 20 Fitting of accessories (positon, size) Tube 21 Material 22 Color 23 Stains 24 Scratches 25 Wrinkles on the seams 26 Regular cutting edges 27 Qualiy of the logo (flat) 28 Quality of adhesion/welded of the seams Rubbing strake 29 Model 30 Position 31 Damage / scratches 32 Stains 33 Regular cutting edges 34 Quality of adhesion to tube Accessories 35 Material and color 36 Model 37 Position and edge 38 Bubbles (air or stains) under the accessories 39 Stains 40 Damage / scratches 41 Quality of adhesion to tube 42 Nylon drain plug can be screwed and unscrewed 43 Quality of elephant trunk + rope and cleats 44 Motor plates (position, rivets) Anti skid 45 Position, edge, adhesion(no bubbles) on the hull Equipments 46 Consoles and seats' model and quality 47 Wooden shelf and foam for protecting 48 Position and adhesion of CE plate 49 All equipments are packed (oars, bags etc.) Date: Signat ure:

35 After packing After boats are packed, 5% of the boats will randomly be opened for inspection