QUALITY APPROACH OF OZBROS LTD
OZBROS LTD supplies products in a manufacturing facility with highly developed quality management and quality control systems with the implemented technology on their production systems, quality management system, and highly skilled team.
Aluminium Extrusion, Sheet Metal, PVC, and Roll Formed Products are used in diverse industries such as automotive, furniture, consumer electronics, marine, railway, construction, aeronautics, household appliances, and road transportation industries etc.
The Quality Control Process works from Incoming Material Control to Final Shipment. With our highly skilled technicians and engineers, we measure critical dimensions on site after each production step and control customer requirements.
Control Fixture and Tools used for necessary projects to measure critical dimensions on site and report to our customer in Automotive and other related Industries. We are experienced in preparing fixtures and tools for the quality control process. We design and manufacture our fixtures to provide detailed quality results.
The product’s Micro Structures and Destructive Testing Quality Controls completed in Laboratories to analyze results and ensure the quality standard from Casting to Final Mechanical Operation and Surface Treatment Operations
QUALITY CONTROL PROCESS FOR DEDICATED CUSTOMERS
OZBROS offers customized solutions to the automotive industry to satisfy their increasing demand for lightweight structures and all quality control requirements with PPAP and Cpk results after machining. By adding our knowledge and experience in the quality control process in Aluminium, PVC Extrusion, and Sheet Metal Products, OZBROS transforms aluminium, and PVC Extruded profiles and Sheet Metal Products into high precision machined, welded, and metal formed components with internationally certified precision tolerances and quality requirements.
As the six core principles, we provide Quality Management, Technical Support, Customer Care, Health & Safety, Environmental Sensitivity, and Positive Work Environment.
New Product Commissioning
While commissioning new products of our customers,
- FAI (Initial Sample Approval) process,
- Monitoring of test productions,
- Following the control gauge and fixture processes required for new products,
- Preparation of all necessary instruction procedures and adaptation to the system before mass production,
- Preparation of PPAP documentation,
- Informing the departments weekly about new product projects,
- Reviewing new product processes on existing project plans,
- Testing, equipment, and documentation of new products studies are carried out by our Quality Department.
Input Inspection and Process Quality
In line with the PPAP documents prepared during the new product commissioning process, input quality control plans are prepared for each of the critical materials used, and the results of the controls are entered and followed up in the SAP system.
In accordance with the requirements of industry 4.0, all production parameters are taken from the machines, and the process quality control data is processed into the SAP system; full traceability of the products from the raw material to the shipment stage is provided on the system.
With our fast and precise production, our Mechanical Processing Department designs and produces special fixtures and apparatuses for our customers to provide cost advantage, ensure the reproducibility of products with the same quality, and provide the fastest and most accurate control of the geometry of the products.
Quality Laboratories, having trained, knowledgeable and experienced personnel in their fields; the qualifications of the products are verified by performing many tests and applications such as:
- CMM Testing
- Macro control, boiling quality control
- Hardness test
- Tensile, compression, bending, tearing, and twisting test
- Bending test
- Visual inspection
- Microstructure control
- Ultrasonic inspection
- Penetration test
- Surface roughness test
- Conductivity measurement test
- Vibration test
- Preparation of heat treatment recipe
MACRO (ETCHING) TESTING
We control welding position, welding quality control, grain distribution, back end defects, block to block effect, and Transfer Welding Failures.
BENDING TEST – EN ISO 7438
Bending test performed with the sample received defined area of the profile.
CRUSH TEST – EN 13981-1
Crushing Process is applied to the extrusion welding area.
MICRO STRUCTURE INSPECTION – EN 13981-1 – ASTM E112, NF A 04-503
Prepared Samples are inspected by Microscope after samples are prepared on preparation device. The Laboratory team measure particle size and microstructure distribution.
Brinell , Vickers, Webster, Knoob Type Hardness Measurement Device are used in our Facility.
TENSILE TEST – EN ISO 6892-1 / EN 755-1
The measurement received and analysed carefully with our highly skilled Laboratory Team.
COMPRESSION TESTS – TL 116
Compression Test For Bumper Profiles. (Shock Absorber)
ULTRASONIC INSPECTION ASTM 594
PENETRATION INSPECTION EN 10228-3
CONDUCTIVITY TEST EN ISO 3452 – EN ISO 23277
SURFACE ROUGHNESS TEST EN ISO 4288 – EN ISO 4287
Transverse Tensile Test
Transverse Bend Test
PROCESS QUALITY CONTROL
With the quality approach of OZBROS, we manage all the risks and control our processes with Process Control Tools, FMEA Studies, Control Plans, VDA 6.3, and Product Audits.
We can perform SPC (Statistical Process Controls) and MSA (Measurement System Analysis) according to customer requirements to provide necessary Cpk results after machining operations and excellent results after Extrusion and Coating Processes.
CUSTOMER QUALITY PROCESS
OZBROS LTD follows the customer quality related concern in the UK and connects the production facility. With our engineering team in the UK, we measure and report all your concerns in detail and provide clear communications between teams.
The Quality Control Team is highly experienced in managing Root Cause Analysis, Corrective Actions, and Global 8D reports.
We are cooperative and responsive to all your questions and concerns related quality of our products.
Our products are manufactured with the company Environmental Management System, which is targetting to have a Zero Environmental Impact. To achieve we take many practical steps that include selecting alternative materials with less environmental impact, the maximum use of recycled materials, the minimal use of packaging, the removal of wastewater, and the management of all hazardous emissions.
CERTIFICATIONS AND QUALIFICATION OF THE MANUFACTURING FACILITY IN TURKEY
IATF 16949 – Quality Management System in Automotive Industry
ISO 22163 (IRIS) – Quality Management System – Railway Applications
ISO 9001 – Quality Management System
ISO 14001 – Environmental Management Systems
OHSAS 45001 (OHSAS 18001) – Occupational Health And Safety Management System
CE (EN 15088) – Aluminium And Aluminium Alloys. Structural Products For Construction Works. Technical Conditions For Inspection And delivery
DIN EN ISO 3834 – 2 – Quality Requirements For Fusion Welding Of Metallic Materials
EN 1090 – Fabrication and Assembly of Steel And Aluminium Structures
DIN EN 15085 – 2 – Welding of Railway Vehicles And Components
CE / EN 40-6 – Light Columns. Requirements for Aluminium Light Structures.
QUALICOAT – Specifications for a Quality Label for Liquid and Powder Organic Coatings on Aluminium for Architectural Applications
QUALANOD – Comprehensive Quality Requirements Maintaining And Promoting The Quality Of Anodised Aluminium
TS EN 14351 – 1 – CE Marking For Windows And Doors Product Standard
EN 12608 – (PVC-U) – Profiles For The Fabrication Of Windows And Doors
RAL-GZ 716/1 – 1 – Quality And Test Requirements For Plastic Window Profile Systems