MANUFACTURING PROCESS
ASSEMBLY SPECIFICATION
Production checklists have been developed for each procedure or related series of procedures, and are attached in the Appendices section of the Quality Control Manual.
Guerdon Enterprises will enforce a policy where all design/engineering operating, production methods, and control practices will meet or exceed Intertek’s Certification Policy with respect to required procedures and evidence of conformity to all applicable standards.
Plans and specification used in the production are produced by the own engineering staff. All plans are checked for applicable code compliance by the Quality Assurance Manager before being passed on to the production department. Drawings for manufactured structural components such as trusses, floor joists, beams columns and construction members and assemblies that fail outside of the Part 9 National Building Code shall be dealt with as per the latest standards and Intertek’s requirements. Specifications for manufactured structural components shall be reviewed by the Quality Assurance Manager for compliance to applicable requirements before production.
It is the responsibility of the Quality Assurance Manager in conjunction with the General Manager to provide all working drawings for production. It is also the responsibility of the Quality Assurance Manager to obtain and file engineered drawings for trusses, columns, beams floor systems and wall systems.
Other documents required for adequate quality control include this manual as well as the checklists. The documents that must be prepared and checked may consist of the following:
- Roof trusses / rafter engineered drawings;
- Floor joist system engineered drawings;
- Plumbing Schematics;
- Electrical circuits and outlet locations;
- Cross sectional construction details;
- Floor plans;
- Wall systems.
The purpose of document control is to ensure all essential documents affecting quality are reviewed for adequacy and approved for release to be used by the departments concerned.
The responsibility for the control of documents lies with the Quality Assurance Manager, who has been given the authority by the General Manager. He ensures that the following have been prepared, released and used:
- Quality Assurance Program Manual – used by all departments;
- Quality Assurance Program forms – used by Quality Assurance Program Department and Inspector;
- Procedures and work instructions – used by Production Department;
- Instructions to purchasing agent – used by purchasing agent and receiving agents;
- Engineering drawings, calculations and specifications – used by Production Department.
When documents are reviewed and revised, the revisions are re-issued to the departments concerned, and obsolete documents are removed from all points of use.
When documents are reviewed and revised, the revisions are re-issued to the departments concerned, and obsolete documents are removed from all points of use.
All inspection records shall be kept for a minimum period of 5 years. The records are referred to the quality program manger for evaluation and appropriate preventative action, which may involve consultation with other departments. Examples of such records are as follow:
- As build drawing;
- Engineered Stamped truss drawings and if applicable Engineered Stamped floor joist system;
- Technical check lists completed, dated and signed;
- Production checklists completed, dated and signed,
- Factory test results, dated and signed,
- Non conformance sheets and their corrected resolution,
- Letter to home owner with cc to local authority, updated floor plan showing foundation and utility connection points/details.
quality control inspections and tests
All plant purchasing is routed through the plant purchasing department, acting with the engineering department and foreman of the particular trade requiring the product. All items are ordered specifying, where relevant, that the recognized certification marking be applied to the product. Roof trusses and engineered floor joist are purchased with engineer stamped drawings.
The receiving inspector checks a random sampling of all incoming materials and components for damage, defect and compliance with the purchase order. All components used for: plumbing, gas, heating and electrical are checked for standard and code certification. Window and doors are checked to ensure they comply with the applicable standards.
If the incoming materials and components are found satisfactory as specified and in good condition, the receiving inspector makes the size of sample checked on a copy of the invoice and forwards this copy to the Quality Assurance Manager.
If the incoming materials and components are found to be questionable, the receiving inspector tags the entire shipment accordingly and forwards his/her comments to the Quality Assurance Manager for a decision as to the usage or non-usage of the goods.
Production checklists have been developed for each procedure or related series of procedures. It may be necessary to amend these checklists as problems arise. On each checklist a space is provided to outline corrective action for any deficiencies. The checklists shall not be signed, nor the product accepted until all deficiencies listed have been corrected. All checklists are filed by the Quality Assurance Manager upon final acceptance as well as all non-conformance reports to ensure a complete record of repair methods.
A production inspection is carried out by the Quality Assurance Manager in addition to that done by the production crew for the purpose of insuring that the modules are produced conform to the production drawings and specifications. The Quality Assurance Manager shall supervise and co-ordinate the inspection of the entire production. These checklists are to be initialed and dated by the person who completed the work and then signed off by the Quality Assurance Manager.
Any building going off line with deficiencies shall have a non conformance report initiated. A copy will be filed with the Quality Assurance Manager, the General Manager and the foreman responsible for repairs. The home will not be shipped until all deficiencies have been corrected, and the home re-inspected by the Quality Assurance Manager.
{For Production Checklists, see Quality Control Manual Appendix III}
On-Line Inspections
There is on-line product inspections carried out by the Quality Assurance Manager at each Work Station in addition to the inspection done by the production crew for the purpose of checking that the building segments are produced conform to the production drawing and specifications. The Quality Assurance Manager will supervise and coordinate the inspection of the entire product as well.
The Quality Assurance Manager, or a designate, makes regular inspections of each Work Station to verify adherence to approved plans and specifications. Some inspections will be conducted ones per each Work Station, i.e. electrical tests, plumbing tests, final Quality Control inspection, etc. Other inspections will be performed periodically to monitor compliance.
Upon completion of the manufacture, and inspection and testing of each unit, the personnel with designated authority shall perform a final inspection. Any deficiencies identified during final inspection will be cause for holding the unit until those deficiencies are satisfactorily resolved or remedied.
Final inspection activity will include physical review and verification that all records have been completed, and work has been approved or accepted by personnel with designated authority.
As part of final inspection, any and all non-conformance and corrective action reports will be checked and verified as having been completed. Verification will assure that all dispositions have been satisfactorily completed, rework of any sort has been completed, inspected, and accepted/approved, and all records have been filed.
As part of final inspection, all records for the specific unit will be checked to ensure that they are complete, located in the unit file, and that all records have been signed by personnel with designated authority.
Unit records will include all inspection and test records completed and closed, prints, and any other data deemed appropriate.
- Final Inspection I&T Checklist
- Manufacturer's Plate
- Stickers and Labels (as applicable)
- Unit Equipment List
- Unit Records (File or Binder)
(See Quality Control Manual for Inspection Checklists and Electrical, Plumbing and Gas typical Test)
finish product specifications
A “Modular Home Specification Name Plate” form shall be completed for each home, and placed beside the Intertek
label.
DISPOSITION OF NON-CONFORMING MATERIALS AND SUBASSEMBLIES
All products found to be non-conforming to the specifications defined in Sections 5 and 6 of this document will be segregated and clearly marked as non-conforming. The following procedure is in place to investigate the cause of non-conformances, fix the problem, and to re-evaluate materials before they are released as certified products.
Depending on the nature of defect, materials and components are to be reworked or replaced. The corrected system is then re-inspected according to the applicable requirements and must receive approval from the Quality Assurance Manager or his designated representative.
Defective materials or components which can not be reworked are scrapped or returned to supplier.
All defective materials and components shall be identified by “Rejected” (See below) which are to be removed only by the Quality Assurance Manager or his designated person. A designated quarantine area shall be used for materials with rejected tags. A report on the deposition will be given to the Quality Assurance Manager.
{For more information on Disposition of Non-Conforming Materials and Subassemblies, please see Guerdon Enterprises - Quality Control Manual Sections 7.1 and 7.2}
All measuring equipment used in the manufacturing and testing processes is calibrated and traceable to national standards, by means of an accredited outside calibration provider, or documented in-house procedures approved by Intertek.
{For more information on Measuring and Test Equipment, please see Guerdon Enterprises - Quality Control Manual Sections 8.1 to 8.3}
