Quality

Incoming Material Inspection

Perfect material analyzing laboratory will ensure all the material are compliance with international standard and European environmental protection requirement. Kemal uses the CMM for dimensions inspection.

Mold Processing QC

  • Mold Parts
  • Electrodes
  • Final Assembly
  • CMM
    CMM
  • Electrodes
    Electrodes
  • Mold parts QC
    Mold parts QC

Plastic Parts Production QC

Professional and experienced QC staff will ensure all the products completely meet your demands. Besides CMM, Kemal also uses Optical Projector, Hardness Tester & Height Gauge for inspection.

Visually
Visually QC
Plastic Parts Inspection
Plastics Parts Measurement
Color comparison
Color Comparison
Package Inspection
Package Inspection

Auto Parts Inspection

The Automotive industry has an enormous responsibility to guarantee vehicle safety and satisfaction for the billions of consumers who travel by road every day. Automotive parts are expected to have zero defects, without exception. Substandard products can endanger lives and damage a brand’s reputation, profit margins, and the ability to meet contractual obligations. Kemal has always implemented a rigorous quality management program.

Quality Reports& Certifications

Kemal’s QC team ensures that all orders are completed in accordance with Kemal’s Manufacturing Standards.

Ø Full dimensional inspection report

  • Dimensions are verified using a precision measuring instrument (caliper or gauge) and with a Coordinate Measuring Machine (CMM) when required. And Kemal’s QC team will check all critical dimensions as required.

Ø Material Certifications

  • These certifications include Certification of Steel and Components and Steel Heat Treatment Certification. And they will be provided before mold shipment for each project.

After-Sales Service

After sales service for US customer
After sales service for Germany customer
After sales service for Poland customer
After sales service for US customer
After sales service for US customer
After sales service for Mid-east customer

QUALITY ASSURANCE: THE ULTIMATE FAQ GUIDE

 

At Kemal, quality is considered as the foundation of our survival and development. With the scientific methods of quality control and advanced measurement facilities, we manage to ensure the quality of tools and goods within specification. Here you can find some FAQs about our quality assurance policies and views of quality management as below. If you have further questions, please feel free to contact us.

1.Are you ISO certified?
2.How do you define quality management in the molding industry?
3.What kind of QC equipment do you have?
4.Is steel material important for tool/mold quality?
5.How to control the material(steel and plastic) quality?
6.How do you control the sample/product quality?
7.How do you control the mold quality?
8.How to define the importance of mold structure design for mold quality?
9.How do you control the quality at the design phase?
10.How do you define the importance of mold manufacture for mold quality?
11.How do you control the quality at the manufacturing phase?
12.How do you control the quality in the manufacturing /production planning stage?
13.How do you define the importance of assembling for mold quality?
14.How do you define the importance of fitting for mold quality?
15.How do you control the quality at the assembling and debug phase?
16.How to define the importance of mold maintenance to mold quality?
17.How to define the importance of mold maintenance to mold quality?
18.How do you define the importance of cooling for mold quality?
19.How do you control the quality of outsourced mold components and secondary processing products?
20.Do you provide quality reports?
21.Do you provide a warranty?
22.Do you provide off-site after-sales service?

 

1.Are you ISO certified?

Yes, we are ISO9001:2015 Certified.

2.How do you define quality management in the molding industry?

Quality management is the act of overseeing all activities from design to manufacture, assembly and fabrication, through carrying out strict and complete quality policies with all staff involved to achieve the objective of building quality mold and producing quality products.

3.What kind of QC equipment do you have?

We have CMM machines with working size 1000*700MM, digital and manual caliper, projector, hardness tester, height gauge, we also use checking fixtures to test the parts when required.

 

4.Is steel material important for tool/mold quality?

Mold steel is one of the key factors for mold quality, and choosing the right mold steel is the top priority. If the plastic materials are different, and the corresponding mold steel materials will be different as well, such as the requirements for high polishing, corrosion resistance, and so on. We believe that not the most expensive steel is the best, the cost factor of the mold must be considered. It is best to choose the material based on the design life of the mold to avoid unnecessary waste. ”For plastic mold steel, the P20 generally has a useful life of 300,000, 1.2738 mold steel with about 500,000 and for H13 and 1.2344 mold steel, it’s usually more than 800,000 to 1 million, which can be selected according to the different situation.

5.How to control the material(steel and plastic) quality?

The material should be provided at the in-coming stage along with the material certificate, which involves material type, chemical composition, hardness, and other info.
In addition, the material hardness and size will also be tested in house. Only the qualified material will be sent for the next process.

6.How do you control the sample/product quality?

A good sample/product comes from a quality mold. As a result, we shall pay more attention to the mold quality.

7.How do you control the mold quality?

The mold quality is divided into 3 categories —design, manufacturing, assembly and debug.

8.How to define the importance of mold structure design for mold quality?

A sound mold structure design not only considers the product material properties, shrinkage rate, molding temperature, elastic tensile deformation coefficient, etc. but also considers the cooling water circuit and the speed of mold opening and closing. A reasonable mold structure can effectively extend the life of the mold and ensure the smooth production of the mold. And to improve efficiency and reduce costs.

9.How do you control the quality at the design phase?

The quality control at the designing phase is sorted into 3 phases—initial, mid, and final.
At the initial phase, our engineering team will have a thorough and productive discussion with the customer about basic part info, GD&T, Tolerance, etc.
In the middle phase, we will design according to customer requirements and modify our drawing according to their comments.
At the final phase, after the mold design is approved by the customer, we will follow the design to build the mold.

10.How do you define the importance of mold manufacture for mold quality?

To do a good job, an artisan needs the best tools. The reasonable arrangement of the mold processing technology is very important, which can not only speed up the production cycle, shorten the processing time, and effectively save costs, but more importantly, accurate and reasonable processing can ensure the stability of the mold in the production process and extend the life. Processing errors will cause mold welding, no matter how good the welding is, it is a loss to the mold; in addition, poor processing may also affect the mold operation, reduce mold life, and cause mold cracks or even cracks during the production process.

11.How do you control the quality at the manufacturing phase?

The production process is the key to quality control. So we should turn quality inspection after the event into prevention beforehand, and do a good job of control before the act to improve the effectiveness of quality management. This requires us to incorporate all stages of the production process into quality management and work out a reasonable manufacturing process.

12.How do you control the quality in the manufacturing /production planning stage?

It happens before manufacture/production, strengthen the communication between the marketing department, the technical department, manufacturing, production department, and purchase department, analyze the factors influencing mold and product processing quality, determine the production plan based on evaluation and demand, and communicate with suppliers in advance. Strengthen the verification of production equipment, and production processes to ensure that qualified molds and products are processed and produced.

13.How do you define the importance of assembling for mold quality?

The mold assembly is just like assembling a machine. Every component and every screw must not go wrong, otherwise, the consequences will be quite serious. In the slightest, it will cause product defects and affect production; in the worst case, it will completely damage the mold and cause scrap. So the assembly work must be very meticulous. Pay special attention to the cleaning of the mold during the assembly process, especially the waterway, screw holes, and the iron filings in the scene.

14.How do you define the importance of fitting for mold quality?

The fitting is mainly relying on the experience of toolmakers, which seems to be easy but the most technical job. The main focus of complex molds is this effort. The flat mold is the simplest, as long as the parting surface does not have a flash segment difference. However, automotive molds are very troublesome, not only the parting surface is relatively irregular, but also includes multiple sliders and ejector blocks. Meanwhile, other problems of the mold can be improved and perfected through the fitting. So it is a comprehensive job.

15.How do you control the quality at the assembling and debug phase?

All of the toolmakers should obey the operation manuals when assembling and debugging the mold. Pay more attention to details. Make sure the mold is built as per the drawings and to the standard.

 

16.How to define the importance of mold maintenance to mold quality?

The mold is like a car. If it is not used for a long time without maintenance, it may cause the mold to be scrapped. Therefore, every time the mold is used, comprehensive maintenance must be carried out, especially the rust prevention of the forming parts and the rust prevention of the main working parts. Since the mold is more or less exposed to water during the production process, especially water or sweat stains on the mold during installation or disassembly, it is necessary to ensure that the mold is dry when downtime is long. And after cleaning the mold. Be sure to brush with protective oil or anti-rust oil.

17.How do you define the importance of cooling for mold quality?

Cooling is very important for mold quality. Due to the increase in prices and labor cost, when doing mass production, the profit brought about by reducing the injection cycle by one second is unimaginable. However, speeding up the production cycle will cause the mold temperature to rise. If it is not effectively controlled, the mold will be too hot to form the product, and even cause the mold to deform and fail. Therefore, a reasonable waterway design is particularly important, including the arrangement density, diameter, and mutual links of the waterways.

18.How do you control the quality of outsourced mold components and secondary processing products?

All components and products for outsourcing will be re-inspected at the in-coming phase. The certificates will also be required when necessary. If there is any defects or problems, the components will be rejected.

19.Do you provide quality reports?

Sure. The reports we provide to our customers involve CPK Report, Full Dimension Report, FAI Report, CMM Report (PC DMIS), etc., which are based on customer requests.

 

20.Do you provide a warranty?

Yes, we provide 5 years warranty after delivery.

21.Do you provide off-site after-sales service?

Sure. Our technical engineers can go abroad to serve our overseas customers when required. So far, our engineers had provided this service for our customers in Iran, Mexico, Germany, France, etc.

 

 

 

 

 

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