QA Display Information (Click on an image to zoom)

PPCP utilizes a system called QA Display to carefully manage all process steps, documentation, and training in our facility. This system is used by every production employee to show clearly how each individual part is to be made in each department of the process. The beauty of our system is the ease of use. Digital imagery is used to show images of the process along with written content. The system is used in real time on the shop floor. Specific customer expectations can be included for each part made. Customers have even emailed photographs of castings in use that we have included in our system.

The first screen for each casting made is the general screen. This screen shows an image of the casting along with important information. The screen displays the customer part number, our internal PPCP number, drawing number and revision, alloy, casting weight, and any revisions that have been made to the process. The revision tracking is extremely essential to ensuring that we have a frozen process in place that will not deviate from order to order. Any changes that are made are documented and dated with the reason for the change.

The next several screens document what needs to be accomplished in each department to move from raw materials to a completed casting.

In the wax room we document the wax weight, injection machine to be used, pressure and time settings, and any specialized instructions that need to be noted.

The assembly screens show employees the size and configuration of the set up as well as spacing requirements on the sprue. The assembly screens also show a photo of what the set up will look like when completed properly.

The Dip Department screens provide operators with information on the number of ceramic coats, dry times, and specific information about creating the shell for each specific part. The melting department provides the weight of metal that is poured in a shell, exact temperature the steel must be poured at, spacing of shells in the sand bed, and any customer defined chemistry ranges.

The Finishing Department screens show the sequence of operations from pouring through shipment. Specific imagery is utilized to show exactly how the customer wants the gates to be ground. This section also displays exact heat treating cycles, blast media to be used, and any additional information specified to create a sound casting.

The QA Screens allow us to track important information about the processes. Here we list any customer provided specifications that are called out on the purchase order. Employees access the specification directly from this screen. It truly eliminates error and places important data at the operator's fingertips. This screen is also the basis for creating the Chemical and Mechanical Test Reports (CMTRs) that most customers have sent along with the castings.

In short, QA Display separates of from our competitors. Very few foundries have a system even close in the scope of the ones used by PPCP. We have invested heavily in these systems to ensure we are always doing things right the first time. We look forward to demonstrating these systems in person if we have the opportunity to show you through our facility.