Quality System
Cast-Fab Technologies, Inc. is committed to being the Best Total Solution for our Customers. We do this by providing:
• A framework that establishes & reviews Quality Objectives
• Tools to support Continuous Improvement efforts
Committed to meeting customer requirements
Framework to establish and review Quality Objectives
Tools to support improvements to better serve the customer
The Quality Policy and Quality System are described in the Company Quality Assurance Manual.
Some of the highlights of our Quality System are described in this profile. If desired, we can provide an uncontrolled copy of our Quality Assurance Manual. Our Quality System has been certified to ISO 9001:2000 by an independent third party member of the Registrar Accreditation Board.
New Job Start-Up
All new jobs go through a start-up and testing process. This process includes dimensional testing and verification as well as chemical and physical analysis, depending upon customer requirements. Either destructive or non-destructive testing for soundness can be performed. Customers are requested to provide feedback on the machining results of the test lot prior to production. Any of the aforementioned can be tailored to meet customer needs.
Heat Date Codes
Castings are identified with a heat date and logo in a permanent unmachined area. Traceability of castings is critical for maintaining our quality level. It is essential to be able to investigate the conditions existing when the casting was produced. A computer database is used to track each serial number or heat date associated with a particular casting.
Non-Conforming Materials
Internal reviews take place daily by members of the Quality Organization and Supervision to discuss non-conforming materials. The review results in assigning cause and corrective action to the defects; feedback and follow-up ensure problem resolution.
Calibration and Testing of All Measuring Equipment
All testing and measuring equipment is routinely inspected and traceable to the NIST (National Institute of Standards & Technology).
Internal Quality Audits
Internal quality audits are conducted no less than twice per calendar year in order to assure compliance with the guidelines of our Quality Assurance Manual. These audits are performed by our Quality Department with assistance from designated manufacturing personnel. A checklist is used to determine compliance with each procedure. Written notification of noncompliance is given to the Department Supervisor.
Corrective actions are then taken and are approved by the Quality Assurance Manager. A follow-up audit is made to assure compliance.
Total Employee Involvement
As an element of Cast-Fab's corporate commitment to customer awareness, total teamwork, elimination of waste and participatory management, we encourage our employees to constantly think of ways to improve the company. We formally recognize their input in areas relating to quality, productivity and safety.
Continuous Improvement
Because improvement in quality, cost and innovation are necessary for world class leadership in today's marketplace, Cast-Fab is involved in a continuous improvement process. As part of this effort, we have implemented a Just-In-Time strategy to improve quality and reduce costs, lead times, work-in-process and inventory.
LABORATORY FACILITIES AND TESTING EQUIPMENT
Sand Laboratory
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Complete facilities for testing No-Bake or Green Sand
Chemistry Laboratory
- ARL/Fisons Optical Emission Spectrometer for measurement of up to 28 elements in cast irons or steels
- Leco Combustion Analyzer for Carbon and Sulfur simultaneously
- Leeds and Northrup Thermal Analysis (Cooling Curve) for Carbon and Silicon determination
Mechanical Testing Laboratory
- Tinius-Olsen Testing Machine for Tensile Strength, Yield Strength and % Elongation
- Brinell Hardness Testing Equipment
- Charpy Impact Testing (subcontracted when required)
Metallographic Laboratory
- Unimet Optical Microscope - magnification from 25X to 1000X
- Photomicrography of microstructure
- Sample preparation and specimen mounting
- Scanning Electron Microscopy (available by subcontract)
Non-Destructive Testing
- Ultrasonic Testing for flaw detection and velocity measurements; Krautkramer-Branson USL-42, Panametrics Epoch II
- Visible Dye Penetrant
- Hydrostatic Testing
- Radiographic Testing (subcontracted)
- Magnetic Particle Testing (subcontracted)
Dimensional Inspection
- Layout Table - 25' x 11' (7.5 x 3.4 meters)
- Romer Portable Coordinate Measuring Machine - Series 1000
- Various hand measuring equipment (calipers, micrometers, etc.)
- In-Process and Final - Visual Inspection
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