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GES QUALITY INDUCTION

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GES – we manufacture wear plate kits, parts and welded assemblies for crushing and screening OEMs (Original Equipment Manufacturer’s).

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Everything we make needs to be made to certain specifications such as shape, size, thickness, material, colour etc.

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GES makes one piece of the jigsaw puzzle - it has to not only fit the shape and size, but it has to be the correct thickness, colour and material.

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CUSTOMER NEEDED BLUE

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WE PAINTED THE PART BLACK!

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  • The more parts we make right

= the happier our customers are,

= the happier they feel towards us,

= increased likelihood that they will place more orders.

  • Increased orders

= more work,

= increased turnover,

= more money to go round!

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Quality Dream:

OK to Great!

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  • The more parts we get wrong

= the more concerned the customer gets,

= increased attention/inspection of our parts,

= decreased likelihood that they will place more orders.

  • If we don’t continually inspect and aim to improve the quality of delivered goods the customer may withdraw certain work from GES.
  • Ultimately, losing contracts or tenders due to quality is a disaster, with the worse case scenario of losing all business with a customer.
  • Fortunately this has not happened, yet….

Quality Nightmare:

OK to Bad!

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Quality Certification

  • All GES customers have certification requirements that we must meet before any orders can be placed.
  • Like a restaurant has a food and hygiene rating, GES has similar quality ratings and certification:
    • ISO 9001 – Quality Management System
    • ISO 3834-2 – Welding Management System
  • To maintain these certifications, Quality and Engineering departments continually check parts and maintain documentation.
  • GES then undertakes annual audits by external certification bodies.
  • To keep these certifications it is essential to find any quality issues or mistakes BEFORE the part is delivered to the customer.
  • And FYI - its OK to make a mistake! Just ensure if you notice the mistake to report it.

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GES WORK CENTRES

PAINT

BAND SAW

VMC

KITTING

PLASMA

WELD

CHAMFER

RED TAG

ROBOTS

PRESS

RADIAL

DISPATCH

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RIGHT MATERIAL

    • Is the material and thickness correct?
    • e.g. thickness and grade (Wear plate/Mild Steel)

Does it look good

    • Does the part have nice clean edges? Are they square?

Dimensions

    • Does the part measure the same as the x and y dimensions on the nest?

ALWAYS double check nest before cutting to ensure correct material and thickness.

PLASMA CUTTING - So what does good quality look like for me?

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Not Flat = Bad

Flat = OK

Slightly bowed = OK

Smooth square edge = OK

Rippled edge = Possibly OK (check)

Big divets or not straight = Bad

Sometimes parts can be repaired

Ensure correct part number and sticker is attached after cutting – helps travel through factory correctly!

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Nest name – used for loading right programme

Amperage – changes depending on thickness

Material type

& Thickness

Size of the sheet

Part Number / Job number

Nested = quantity

The NEST

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Right side

    • Ensure the correct edge is chamfered.

Right angle

    • Ensure the correct angle is set as per the drawing.

Right Heat

    • Thicker parts require preheating before cutting to deliver a smooth quality chamfered edge.

ALWAYS Refer to drawing when chamfering!

CHAMFER- So what does good quality look like for me?

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ALWAYS refer to drawing and ensure correct size and length of section!

Right size

    • Ensure correct size of section is selected.

Right Length

    • Ensure the correct length is stated on the saw.

Right Set-up

    • Ensure the section is correctly set and clamped to achieve square cut.

BAND SAW - So what does good quality look like for me?

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ALWAYS refer to drawing and ensure correct size and length of section!

BAND SAW - So what does good quality look like for me?

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ALWAYS refer to drawing and notes when countersinking!

Right side

    • Ensure the correct side is counter sunk.

Right Size

    • Ensure the correct size tool is set as per the drawing (i.e. M10, M12, M20).

Right Depth

    • Ensure the hole is sunk to the correct depth – details are in the drawing.

Measuring Tool

RADIAL DRILL - So what does good quality look like for me?

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RADIAL DRILL - So what does good quality look like for me?

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LARGE PLATE COUNTERSUNK WRONG SIDE – CUSTOMER RECEIVED TWO LEFT HAND PARTS. A LOT OF OUR KITS HAVE A LH AND A RH.

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ALWAYS refer to drawing when folding - mark out fold line to ensure accuracy.

Right side

    • Ensure the correct side is folded.

Right Way

    • Ensure the part is either folded up or down, as shown in the drawing.

Right Angle

    • Ensure fold is to the correct angle.

Right Tools

  • Right tools (top tooling and bottom V).

BRAKE PRESS – FOLDING - So what does good quality look like for me?

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ALWAYS check your fold afterwards!

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Right setup

    • Ensure the correct edge to be machined.

Right tool

    • Ensure the correct tool is fitted.

Right Programme

    • Ensure that the correct programme is loaded and to the right revision.

ALWAYS refer to drawing / VMC Programme.

ALWAYS check your part afterwards, & re-write part number if missing.

VMC – Vertical Machining Centre - So what does good quality look like for me?

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Right parts

Right job number

Right revision

ALWAYS refer to drawing and kit list – ensure fully kitted before weld.

KITTING- So what does good quality look like for me?

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Right parts

Right job number

Tack Parts

Check Weld details

Check Finished Assembly

ALWAYS refer to drawing / weld assembly.

WELDING/FABRICATING - So what does good quality look like for me?

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Right parts for right pad

Right program

Right jig

All parts jigged

Check final pad

ALWAYS ensure jig is fully loaded to all back-stops and clamped.

ROBOT- So what does good quality look like for me?

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516 pads

883 pads

133 pads

126 pads

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Right colour

    • Ensure the correct RAL/colour is used.

Right mix

    • Ensure the equipment is working and paint is mixed fully.

Right coverage

    • Ensure the parts are fully covered by the coat of paint – no steel or primer showing.

ALWAYS ask and check correct colour if unsure.

ALWAYS check finished paint coverage under inspection lights.

PAINT- So what does good quality look like for me?

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X

YELLOW PRIMER VISIBLE!

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Right part

    • Kit lists and packing lists issued. Ensure right part and quantity is packed.

Right revision

    • Ensure the parts are correct revision – look up drawing if unsure.

Right packaging

    • Ensure parts are set safely and secured on pallets. Distribute weight. Do not overload pallet.

ALWAYS refer to the kit and packing list – ensure parts and quantities are correct.

DISPATCH - So what does good quality look like for me?

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TOP 5 QUALITY ISSUES IN GES

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  1. CUT QUALITY AT PLASMA / CHAMFER:

WRONG CONSUMABLES, WRONG AMPERAGE, WRONG SET-UP, WRONG MATERIAL, WRONG THICKNESS. 1 Tonne scrapped per month.

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2) MISSING PARTS ACROSS THE FACTORY

WRONG LABEL, WRONG MARKING, WRONG PALLET, WRONG RACK, WRONG DRAWING. 2 Tonne scrapped per month.

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3) RADIAL DRILL COUNTERSINK

WRONG SIDE, WRONG SIZE, WRONG HOLES, NO COUNTERSINK.

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4) PAINT ISSUES

WRONG COLOUR, POOR COVERAGE, LOW GLOSS, LOW THICKNESS.

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5) FAB / WELD / ROBOT ISSUES

POOR WELDING, MISSED WELDS, WRONG DIMENSIONS.

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5) FAB / WELD / ROBOT ISSUES

POOR WELDING, MISSED WELDS, WRONG DIMENSIONS.

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GES QUALITY CULTURE

  1. IT’S OK TO MAKE A MISTAKE.
  2. ALL PARTS WE MAKE CAN BE FIXED OR REPLACED.
  3. REPORT ANY MISTAKES – DO NOT SEND TO NEXT WORK CENTRE OR IGNORE THE ISSUE – MISTAKES CANNOT MAKE IT TO THE CUSTOMER.
  4. EVERYONE IS HERE TO HELP, JUST ASK IF UNSURE.
  5. BUT MOST IMPORTANTLY, LEARN FROM ANY MISTAKE – DO NOT REPEAT.