Quality problem or non-conformities can happen at any time. It can be cosmetic failure or functional defect, supplier process related, logistical damage or result of abrasion. The consequence is the same.
The damage of the quality starts a chain reaction: conform products aren’t present in the waited time and place. Your enterprise get a short and a long time lost: breakdown of production and loss of profit, scrap and compensations costs, extra delivery costs, loss of face.
The main issue in this case: how much will it all cost, and to whom?
We strive to get less!
Our services provide instant savings: It can be eliminated the standing in queue, extra delivery, the costs of reclamation and scrap. Furthermore we offer a solving on hide issues like own manpower (mostly engineers) to get transparent and transferable, to decrease the administrations costs, and in clarifying of the root causes. We send a daily report to the parties involved about failure rate and possible new defects.
Most of our activities are
Visual inspection, sorting
Selecting of the non-conform parts from the lot, and separated handling. According to determinate instruction and limit samples can be decided if the parts are conform to the quality criteria.
For Example:
- Electronic testing
- Surface and tampon printing failures
- Microscopic sorting
- Dimensional measurement
- Inspection of PCB-s
- ESD conformity check (packaging material)
Rework
If the quality defects of the parts can be subsequently corrected, the controlled way this repairing means rework
For Example:
- Grinding
- Aesthetic repair
- Burr removal
- Dimensional correction
- Repackaging, marking
We create opportunities for our clients to grate save own working capacity, and to use for other activity, to save significant costs.
Our process is as follows:
- Order and quotation.
- Receipt work instruction and limit samples, arrangement of activity.
- Training the job for the operators, validation of the results, and determination of the norm time.
- Receiving of parts, inspection, completing the rework, marking the ready parts.
- Handover the parts, documentation, conformity tests
- Performing reports and send
- Accounting, performing of invoice
In our plant, in the plant of the Client, or anywhere in…
The sorting in the plant of the customer is sometimes difficult, because the optimal environment is missing. The light, temperature or desks are often missing. It can happens, that the client has a customer’s quality audit in the time of the sorting. In this time is not lucky the performing of a quality inspection activity. For this case was planed our work-van.
The work-van was built to ensure the optimal light and climatic respectively material flow. We are able to service in every place, the work-van needs only electrical grid 230V 50Hz. There are ESD protected work places according to the needs of modern electronic parts.
The working in the work-van was audited at more customers.
We perform a comprehensive wage labor and pre assembly precise in high quality, with well trained, experienced manpower. We can help to the customer to bridge the gap on missing capacity and assure sewing time and costs.
Wage and preassembly:
- Preassembly of part which are usual in the automotive industry, more different pars from plastic and metal.
- Assembly of soldered parts
- Complex manufacturing and assembly operations
- Transport packaging, as prescribed
- If necessary, we develop and manufacture the tools and equipments for the assembly
Soldering:
Soldering electronic components or replace the non-conform part, rework soldering in ESD workplace.
- soldering according to the IPC-A-610 standard
- soldering miniature components
- soldering with leaded and lead-free alloys
- soldering under microscope
- 30 colleagues participate on a special soldering training inclusive theoretical and practical exam
X-ray material testing can give You a picture from inside, no damage, fast and accurate, from the hide manufacturing defects, damages, deviations, structural characteristics. So You can prevent the possible expensive reclamation costs.
This procedure is to use to final quality inspection but also to detect production non-conformities and to optimize the manufacturing technology.
Our industrial Y-Ray equipment from Phoenix is a high-resolution micro focus for 2D real-time tests. Particularly suitable for X-ray testing soldering (such as BGA, QFN, QFP for PTH, Flip Chip, CSP, soldering, etc.), respectively X-ray testing of electronics and mechanical components.
The important parameters
- 160 kV, 20 Watt, micro focus x-ray tube with removable collimators in order to get a clear image quality
- 2 megapixel-resolution digital image intensifier system
- The lowest resolution 0.5 µm
- Geometric zoom > zoom 2/100, total magnifying 23 000
- 5-axis manipulation system, 360 ° rotatable system
- Up to 70 ° slewable detector
- Maximum sample size: 410 mm x 410 mm, 5 kg
- External controlled manipulator to effective sample rotation
Typical inspections
- Individual testing, serial testing
- Conformity inspection of soldering
- Measurement and test of insulation, wall-thickness v
The inspection and control have to ensure the detection and separation of non-conform parts which are mixes by chance to the conform parts. The inspection happens after the official line end test according to a work- / inspection instruction and/or inspection plan. The inspection can be made at the supplier, in the plant of Alap Europa Ltd. or at the customer before receipts into the stock.
The main types of inspection are:
- 100% inspection
- sample check
- qualified sample check
CSL – 1 first types of controlled delivery
The customer defines to the supplier for limited time a double inspection with severe controlled delivery. The CSL1 delivery is prescribed by the customer, and the supplier must it perform according to aunt decision. The supplier can delegate this task to a servicing enterprise. The second 100-% inspection is made after the regularly line end final inspection
CSL – 2 second type of controlled delivery
The customer defines to the supplier for limited time a double inspection with severe controlled shipping. The inspection must order the supplier at a third party, at a servicing firm. An independent, to quality inspection specialized firm have to inspect the product in 100%.
Our three phases of the controlled shipping level
- Preparation, planning, contract and start work (3-sided “kick off meeting”).
- Controlled delivery operations.
- Closing the controlled shipping level, and evaluation of the finished work.
Our procedure is the next
- Purchase order.
- An official letter response the accept the job
- Trying the inspection job to clarify the feasibility
- Kick off meeting, clarifying technical, organization and responsibility issues.
- Writing the work instruction to define the inspection job.
- Staff training.
- Reporting CER to the supplier or the both, to the supplier and customer
- Final report and closing meeting.
- After accept the final report send the invoice
3D optical measurement service is based on the newest, high-tech GOM equipment. This technology enables a very high precision measurement of most complex geometry, also in manufacturing line conditions.
We can measure or digitalize (scanning) from the smallest (precision engineering) to the 1-2 m large parts, products, with all kind of material, color with high resolution. From the scanned parts we get full surface picture. The gathered points are more millions. The hide defects of the part (burr, brake, sinking, deformation etc.) are instantly visible.
The GOM ATOS system is able to scan all kind of technical products. The object can be from all kind of material, inclusive glass. The shiny object should be covered with a very fine powder, its thickness is <0.7µm, practically no effect on the measurement results.
The result of the scanning is a high resolution concentrated point cloud or a network layer from triangles (*.STL file). Optional can be performed a surface or solid state CAD model. The digitalized 3‑D file can be used for customer presentation, archiving, copying of part, final element analyzing, redesign or production and for quality inspection. The scanning of special broken or used up mold casting for reserve engineering or measurement and analyzing of free form plastic or metallic parts.
Mostly is it able for very complex geometrical forms, which are difficult on not to measure by traditional way (3D CCM)
The comparing of the result with the 3D-model can show the deviation in color code. So can be separate a non-conform from the OK parts.
The full 3D file can be exported in a standardized file format to the rework. The 3D files of GOM ATOS are usable for CAD/CAM computing. It is possible to export the model in general formats, like .IGES, .STEP or in special case in a parametric original formats, like SolidWorks .sldprt, Pro/E .prt, Siemens-UGS NX .prt. Mostly is the .iges file usable to export and editing in all kind of CAD/CAM systems.
Typical fields of application
- Measurement of initial samples: technical, mechanical and precision engineering components.
- Series measurements.
- Spare parts for digitalization and 3D CAD/CAM model comparison.
- 3D scanning of real parts and passing in GOM, in order to make visible any overlapping or shortage of material. You can see the differences between failures of assembly, part manufacturing or design.
- Back modeling: 3D CAD/CAM product model in the entire known file formats.
If required dimensioned 2D drawings, views, sectional drawing.
A main potency of our company is the daily administration, reporting and documentation which are very time-consuming for the customer. We can communicate with the customer and with its suppliers in three languages English, German and Hungarian. We can report with aids of our professional software support to the administration.
We have an individual developed software system (APS) for administration; it can support the data computing in a closed system. This system makes the whole administration from data collecting to reports, performing invoices and the appendixes, delivery notes.
- daily reports-direct and immediate cost control
- 8 d/5W2H analysis
- initial sample documentation
- PPAP documentation
- Control Plan
- P-FMEA
- Safe Design audit
- Run at rate audit
- R & R / MSA
- LLC / Lesson Learn Card
- 5S