Plastics : Simple guide for effective plastic factory visits

Below is a simple guide for effective plastic factory visits

Pre-Visit Planning:

Set Clear Objectives:

• We need to have specific inspection points
• What quality checks needed
• Process verification
• Have technical discussions with techniciens and engineers
• Check if the samples requirements are met

Documentation Needed:

• Go through the quality specifications
• Go through the process parameters
• Go through the tests requirements
• Check previous issues
• Go through the sample approval criteria

During Visit:

Production Check:

• Check the raw material storage
• Check material handling
• Check the processes settings
• Check the quality controls
• Have a look at the finished goods storage

Key Areas to Inspect:

 
Material Handling:

• Storage conditions
• The material segregation
• Contamination prevention
• Moisture control

Production Area:

• The conditions of the machines 
• Check the different processes parameters
• Run a quality checks
• Check the operator practices
• Go through the maintenance records of the machines

Quality Control:

• Test equipment
• Test procedures
• Keep records of quality control
• Sample retention
• Machine calibration records

Sample retention is the practice of keeping representative samples of manufactured products for a specified period, allowing future quality checks, comparisons, or problem investigations if needed.

Calibration records are documented proof that measuring and testing equipment has been regularly checked and adjusted to maintain accuracy against standard measurements, including dates, results, and next due dates.

Critical Questions:

Process Control:

• Check temperature settings
• Cycle times
• Quality checks
• Process changes
• Problem handling

Cycle time is the total time taken to complete one full production sequence including loading, processing, cooling, and ejection steps.

Quality System:

• Testing frequency of goods
• Documentation
• Traceability
• Reject handling
• Corrective actions

Reject handling is the process of identifying, segregating, documenting, and properly disposing of defective products, including analyzing the causes of defects and taking corrective actions to prevent recurrence.

Post-Visit Actions:

• Documentation:
• Write visit report
• Make a list of action items
• Follow-up needs
• Ask for sample submissions
• Test the results