Total Quality Management

Total quality management at Ferriot

Total quality management applies to everything we do at Ferriot. The end goal is production readiness — parts optimized for functionality, consistency and ease of manufacturing.

Ferriot’s total quality-management process can take a product from concept to final assembly. We can step in at any stage, including in emergency transfers for any of our services, be it molding, painting and contract manufacturing.

The key steps in the quality management process for a molded part include

  • Mold qualification
  • Part qualification
  • Process qualification
  • Production quality

Call us or read on to learn more.

Part Development Process

Injection Mold Design
The first question, of course, is whether the mold already exist. If not, we work hand in hand with customers in mold design. Whether we’re developing simple or complex molds, the priorities are:

  • Ideal functionality of finished components and products
  • Ease and efficiency in manufacturing
  • Innovation in the application of engineered polymers to meet any need

Call us to learn about the range of our design capacity — from the engineering of America’s leading shake shingles that can withstand 200-miles-per-hour winds, to plastic components tough enough to replace metal on the boots of gasoline-pump nozzles.

Injection Mold Building
We offer maximum flexibility via our global network of mold makers. With a wide range of capabilities within our talent pool, we match each job to the right skill set for each mold design.

Qualifying the Mold
Regardless of where a mold is produced, its final qualification will be performed at Ferriot. Process engineers will establish the process window and test those boundaries. With a list of variables that affect each different part, they will identify the defining process parameters and zero in on where the part runs the best. Once the process is locked down, capability parts are run for qualification studies. Inspections include

  • Dimensional checks
  • Tolerance checks, including capability studies
  • Gauge repeatability and reproducibility (R&R) studies

Part Qualification

Failure Mode and Effect Analysis (FMEA)
This analysis is our first step in measuring the reliability of parts. In addition to following standard methodologies, our trained engineers and technicians add experience and instincts to the analysis of anticipating what can go wrong — and how to correct it before it does go wrong.

At this stage of analysis, the Ferriot team works closely with our original equipment manufacturers’ (OEMs’) counterparts. Ferriot assigns a lead tooling engineer to oversee each project from design to production readiness.

Testing EquipmentTesting equipment at Ferriot
Ferriot qualifies parts with the following equipment

  • Large coordinate measuring machine (CMM), running the latest version of PCDMIS
  • Spectrophotometer
  • Optical comparator
  • Variety of dimensional gauges, including Trimos height gauges
  • Electronic scales

When necessary, Ferriot can make custom tools for quality inspections.

Documentation
Ferriot documents each step in the qualification process, by using in-house forms or forms supplied by OEMs. Whatever the approval process, we will work with you.

Production Quality

Regularly Scheduled Quality-Control Audits
Ferriot follows critical-to-quality characteristics to ensure compliance to specifications and quality production. For each part, Ferriot conducts audits to ensure adherence to operator instructions and quality-control plans. Design standards are verified with drop tests, ductility tests, dimensional checks and other forms of analysis, depending on the part and its function. Ferriot is proud to be a certified ISO 9001: 2008 quality management system standards compliant.

Quality control audits.

Vendor Qualification
In addition to design and engineering services, Ferriot identifies and qualifies suppliers for each component required in your assemblies.

The process includes risk management, so that if we’re sourcing particular components for a finished assembly, we start by verifying the capacity and fiscal soundness of several potential suppliers. This can include on-site audits.

In making final selections, we seek bids from qualified vendors.

On-going supplier performance is tracked, measuring quality and on-time performance. Acceptable performance will earn a supplier a position on our Approved Vendor List.




Download the Case Study: Creating a plastic alternative to wood shake siding.