Manufacturing and Product Inspections for Ventilation and Central Air Conditioning Equipment (Floor Convector, VAV/CAV, Heat Recovery Unit, Cellular Exhaust Fan, Air Damper, etc.), Air Handling Units Manufacturing Controls and Product Inspections
In manufacturing and product inspections, the determination is made as to whether a finished product, semi-finished product, part, or raw material’s dimensional quality or performance complies with pre-determined specifications.
During various stages of production;
Operational Sorting: Defective parts caused by inadequate manufacturing methods or machines are identified and separated. No corrective action is taken at this stage.
Corrective Sorting: Defective parts caused by avoidable errors such as workmanship and control frequency are identified. Immediate intervention may be made to resolve the sources of error.
Acceptance Sampling: Conducted at raw material receipt, during manufacturing, or at the entry of finished goods into stock, and based on the results, the group is either rejected or accepted. Corrective action is not necessary at this point.
Control Sampling: In case of negative results from sampling during manufacturing stages, immediate action is taken to correct the error caused by the machine or worker.
Sampling Techniques
Rational Sampling: The ideal sampling technique, where samples are taken under uniform conditions.
Random Sampling: Used when there are complex interrelations among multiple factors during processes.
Sequential Sampling: Used when samples are taken from different sources, ensuring each source is adequately represented within the sample group.
The technical documentation, standards, and technical drawings related to the product, and the customer’s specification (if applicable) are provided by the customer.
The Technical Manager reviews the documents and determines the intermediate control steps to be carried out.
The customer is informed about the certificates, reports, etc., that will be required during the manufacturing process.
The customer is informed about the intermediate control steps and a joint inspection plan with estimated dates for each inspection step is created.
The Technical Manager informs the inspection engineer about the scope of the inspection and the relevant technical documents are provided to the engineer.
The inspection engineer gathers the necessary documents and measuring tools for the inspection. The measuring tools are recorded on the device tracking list.
If subcontractors are used during the manufacturing phase, this information must be communicated to the Inspection Authority in advance.
The inspections of the production by subcontractors are performed at the subcontractor's site.
It is the customer's responsibility to inform the subcontractor about these inspections.
The control of the production process includes the following stages:
Review of the technical documents and drawings provided by the customer, evaluation of the manufacturing process stages, and determination of how the processes will be performed.
Prior to production, the subcontractor and suppliers used are informed about the preliminary studies conducted by the company.
Material Control: Verification that the material to be used for manufacturing complies with the project, relevant standards, and requirements. If necessary, the material certificates are also checked.
Control of Intermediate Manufacturing Processes: After cutting, the parts are checked for compliance with the project specifications in terms of equipment and dimensions before fixed connections are made.
After fixed connections, dimensional and visual inspections are conducted.
Accompanying destructive and non-destructive inspections, if any, are performed.
Monitoring the heat treatment and other processes related to the product.
Final control of the product (Painting, safety equipment, labeling, etc.).
If applicable, the relevant tests related to the product are performed.
Control and approval of the quality records kept for the above-mentioned processes.
Before starting the inspections at the customer’s site, the inspection engineer ensures that the necessary safety precautions have been taken.
During the inspection, the calibration certificate of the measuring devices provided by the customer is checked. If possible, the verification of the measuring device is also attended.
The inspection engineer records the measurements and checks conducted during the inspection.
The inspection engineer evaluates the conformity of the inspection results with relevant standards, directives, laws, and regulations and notes any discrepancies with their reasons in the inspection report.
The inspection report prepared by the inspection engineer is submitted to the Technical Manager for approval. After the necessary reviews and checks, the report is approved and sent to the customer via the courier company.
If discrepancies found during the inspection are corrected by the customer, an unscheduled intermediate inspection is performed to verify that the non-compliance has been resolved, and the inspection report is revised.
At the end of all inspection steps defined in the inspection plan, the inspection engineer prepares the final inspection report, summarizing the reports for each inspection step, and submits it for approval by the technical manager.
The technical manager reviews and approves the final inspection report, comparing it with the intermediate inspection reports. The final inspection report is sent to the customer via courier.