1. QP-S100 Quality Program Review

2. Quality Program Overview
Provide a framework as a basis for an IG fabricator specific program incorporating:
Process Control: detail best practice procedures and work instructions for process uniformity
Calibration: assure accuracy and uniformity of quality inspection equipment
Inspection & Testing: procedures for evaluation of incoming raw materials and components and outgoing finished goods
Non-Conforming Product & Corrective Action: handling of non-conforming product and materials and means to prevent reoccurrence.

3. Quality Program Overview
Storage & Handling: procedures for proper storage and handling of IG units
Field Service: gathering of customer information useful for improving manufacturing procedures (reports / visuals / audit forms, etc.)
Quality Audits: Ensure procedures in the quality manual are followed and determine effectiveness of the quality system.
Quality Control Forms: forms necessary to keep proper records from each area of inspection.
Training: appropriate personnel and frequency
Statistical Techniques: how used to organize and analyze information

4. Section 200 Process Control

5. 1.0 Purpose

6. 2.0 Procedure
Unit Assembly

7. 2.1 Unit Assembly Spacer assembly Glass Preparation
Primary Sealant Application
Glass Spacer Assembly

8. 3.0 Unit Sealing

9. 4.0 In Process Quality Checks
Sealant
Adhesion
Gunning vs. Toweling
Premature failure prevention
Glass breakage prevention
Material Parameters
Application Rate

10. 4.0 Process Quality Checks
Sealant bead shape
Sealant bead position
Pressing
Desiccant
Spacers
Glass
Visual Inspection

11. 4.1 Sealant Visual Inspection base & catalyst Ratio check for two part
Mixed Sealant
Quality control checks

12. 4.2 Adhesion
Quality control checks - Adhesion

13. 4.3 Gunning vs. Troweling

14. 4.4 Premature Failure Prevention
Voids or skips in sealant
Corner fill
Spacer / glass Alignment
Dirt / Contamination
Desiccant
Sealant Mix / Air
PIB Placement

15. 4.5 Glass Breakage Edge quality Spacer quality Corner Keys Muntin Bars
Spacer Profile
Lucor
Glass Deflection
Unit Separation

16. 4.6 Material Parameters
Amount of sealant
Temperatures
Pressures

17. 4.7 Application Rates
Spacer speed
Variations

18. 4.8 Shape of Sealant Bead
Shape
Cavities / Depressions

19. 4.9 Sealant Bead Position

20. 4.10 Pressing

21. 4.11 Desiccant Desiccant testing Spacer filling Storage
Desiccant Types
Front Points
Record Keeping

22. 4.12 Spacers
Accurate Cuts
Cleanlines
Handling
Coner Keys
Muntin Bars

23. 4.13. Glass Accuracy Edge quality Cleanliness Handling Stacking
Coated glass

24. 4.14 visual Inspection Spacer / Glass Alignment Corner Fill
Sealant appearance
Sealant depth
Entrapped Air
Sealant colorStacking Units

25. 5.0 Procedure Glass Washing Work Instructions
Hand Gunning Work Instructions
Additional Work Instructions

26. 5.1 Glass Washing Work Instructions
Purpose
Responsibility
Definitions
Safety Equipment
Quality Checks
Work Instructions

27. 5.2 Hand Gunning Work Instructions
Purpose
Responsibilities
Definitions
Safety equipment
Quality checks
Work Instructions

28. QP-S201 Calibration

29. 1.0 Purpose
The purpose of a calibration system is to assure the accuracy and maintenance of measuring and testing devices used to determine the acceptance of products and/or components.
At it's core, a calibration system is establishing traceability for an instrument with unknown accuracy to an instrument with a known accuracy.

30. 2.0 Responsibilities
A calibration system shall be implemented to insure adequate accuracy of the Measuring and Testing Devices (M&TD). Such a system as a minimum shall include:
(a) Clearly identified personnel responsibility
(b) Procedures or work instructions
(c) Master report of all M&TD for identification and status tracking
(d) Individual M&TD Identification labeling

31. 3.0 Definition of Measurement Standards
New M&TD - Policies and procedures shall exist to enter new devices into the calibration system prior to use.
Adequacy of Measurement Standards - Traceability shall exist for each M&TD. This traceability shall be to national or international standards, such as National Bureau of Standards (NBS) now National Institute of Standards And Technology (NIST). Consideration shall be given to accuracy, stability, range and resolution required for the intended use.
Environmental Controls - Calibration equipment should be located in an environment which assures the equipment is not degraded by environmental factors such as temperature, moisture, dust, vibration.

32. 4.0 Areas of Calibration Calipers Micrometer (Analog or Digital)
Gauge Blocks (Shim)
(d) Scales - Weight (Analog or Digital)
(e) Pressure Gauges (Air-Hydraulic-Gas-Water; Analog or Digital)
(f) Rulers and Tape Measures
(g) Vacuum Gauges (Analog or Digital)
(h) Temperature Displays and Thermometers (Analog or Digital)
Test Equipment (Hardness tester, multi-meter, etc)
The interval or frequency of calibration shall be determined by appropriate responsible parties in consideration of the calibration standard used, instrument manufacturer's recommendations, the intended use, instrument history, and any regulatory or contract requirement. In general calibration frequencies of 6 or 12 months are frequently used.

33. 5.0 Work Instructions
Procedures or written instructions shall exist for the calibration of M&TD. These procedures may be provided by equipment manufacturers, government agencies, published standard practices, outside calibration vendors, or company personnel. Procedures shall include as a minimum: (a) Manufacturer, model and ID number of the M&TD (b) Equipment necessary to perform the calibration (c) Acceptable tolerance of the M&TD (d) Acceptable accuracy of the measurement of calibration standard (e) Requirements of standards and equipment used and dates for recalibration (f) Written instruction of sufficient detail to assure a calibration specialist can perform the function. (g) Required data

34. 6.0 Out-of-Tolerance Conditions
Any M&TD suspected to be of an unacceptable accuracy shall be Tag and isolate, forwarded to appropriate personnel for corrective action, and then accepted, repaired or destroyed.
7.0 Outside Calibration Source
M&TD may be calibrated by the company or an outside source. An outside source shall provide traceable calibrations to national or international standards, such as NIST. Certificates, reports and/or calibration sheets must accompany the instrument and be maintained on file by the company.

35. 8.0 Calibration Status
All M&TD shall be labeled with a specific ID and indicate the devices status. If a label on the device is impractical alternate approaches may be used (label the device container). Labels shall include:
(a) A distinct ID number
(b) Calibration date
(c) Calibration due date
(d) Any limitations of the M&TD
(e) Initials or signature of the person responsible for the calibration
M&TD that are determined to be out-of-tolerance or defective must be clearly identified as such.

36. 9.0 Records (a) Description or ID of the device
Records shall be maintained for each M&TD and shall include:
(a) Description or ID of the device
(b) Calibration interval
(c) Date Calibrated
(d) Identification of the calibration source
(e) Calibration Procedure used
(f) Calibration results (report)
(g) Calibration action taken (returned to service, repaired, destroyed)
(h) Certificate or report number
(i) Date to be recalibrated

37. QP-S202 Inspection and Testing

38. S202a Inspection & Testing: Components & Raw Materials
1.0 Purpose:
Define the major components in the assembly
Outline means of inspection
2.0 Procedures address:
List of acceptable/approved components
Tolerance specifications and deviations
Statement of material conformance
Sampling of representative components for compliance evaluation

39. S202a Inspection & Testing: Components & Raw Materials
Components & Materials include:
Sealants: primary and secondary
Desiccant
Spacers and connectors
Glass
Insulating Gas
Not necessarily everything that could be inspected. Ie. muntins and other airspace material

40. S202b Inspection & Testing: Finished Product
Daily inspection for workmanship of:
Overall unit size & thickness
Alignment of glass lites
Cleanliness of airspace
Sealant bond to glass and at corners
Minimum vapor transmission path
Spacer position
Sealant uniformity
Sealant holes or underfills
Overall workmanship

41. S202b Inspection & Testing: Finished Product
Recommended sampling rate:
Daily Production
Number Inspected
Up to 25 1
26-100 5 10 15
Over 1000 20

42. S202a & b Inspection & Testing: General
In consideration of regulatory requirements a policy shall be established for the retention of quality control records.
All records to be made available to auditor upon request
Use Quality Control Forms to manage inspection records of component and finished product
Component Codes generic for IGCC/IGMA Certification; manufacturer specific for IGMAC

43. QP- 203 Non-Conforming Product and Corrective Action
1.0 Purpose
Specify how non-conforming materials are identified, documented, controlled and disposed
Corrective action is initiated to prevent recurrence
2.0 Scope
Materials purchased, manufactured or returned by customer
4.0 Procedures
Red-tagging for identification and disposition
Recording, Reporting and Review of findings
5.0 Corrective action to prevent recurrence
QP 203a Forms
I think this needs to be expanded and include the terms from section 3.

44. QP-S205 Field Service

46. QP-S206 Quality Audits

47. QP- 203 Non-Conforming Product and Corrective Action
1.0 Purpose
Specify how non-conforming materials are identified, documented, controlled and disposed
Corrective action is initiated to prevent recurrence
2.0 Scope
Materials purchased, manufactured or returned by customer
4.0 Procedures
Red-tagging for identification and disposition
Recording, Reporting and Review of findings
5.0 Corrective action to prevent recurrence
QP 203a Forms

48. QP- 206 Quality Audits 1.0 Purpose 2.0 Scope 4.0 Definition
To ensure the procedures in the Quality Manual are being followed and determine the adequacy of the Quality System and Procedures
2.0 Scope
All areas related to Quality, Procedures and Work Instructions
4.0 Definition
Quality Audit – documented activity performed in accordance with written procedures or check lists to verify by examination and evaluation of objective evidence that the program has been developed and implemented
5.0 Procedures
Selection of audit team
Training of auditors
Audit plan – Frequency and coverage
Audit reports and audit reviews
5.9 Forms

49. QP-S207 Quality Control Forms

50. The core concept of a quality system is: "Say what you do
The core concept of a quality system is: "Say what you do ... do what you say ... and be able to prove it." Quality Control Forms are the "and be able to prove it" portion of a quality system.

51. 1.0 Purpose
IGMA TM (07) provides examples of forms that can be used to document actions taken in the quality system (i.e. documentation of inspection and testing). The information to be listed on QC forms will vary with the application and specific details of the quality system. Other sections of TM-4000 contain specific requirements.

52. 2.0 List of Forms (a) Corrective Action Report QP-S203a
(b) QC Inspection Form QP (Two- Part Sealant)
(c) QC Inspection Form QP (Desiccant)
(d) QC Inspection Form QP-207-3
(Gas Fill Inspection)
(e) Customer Complaint Form

53. 3.0 Product and Component Inspection & Testing Forms
In general, the following information shall be included: (a) Company and Plant identifier (b) Production line (if applicable) (c) Date of Inspection or test (d) Initials or signature of responsible party (e) Batch, serial, pallet or lot number or identifier (f) Product or component description (g) Data to be taken (temperature, pressure, force, physical measurement, observation) (h) Acceptance criteria (what is pass and what is fail) (i) Conclusion and Disposition (pass/ fail and any action taken) (j) Comments and indication of supervisory review

54. Insulating Glass Manufacturing Quality Procedure Manual TM-4000-02(07)
Section: QP-S204
STORAGE AND HANDLING 54

55. QP-S204: STORAGE AND HANDLING
1.0 PURPOSE
1.1 Control the handling of products and materials
1.2 Ensure material is moved or handled in a safe manner
1.3 Provide secure storage areas to prevent damage or deterioration
1.4 Preserve product integrity and product identification
1.5 Ensure product protection:
after final inspection and test
through delivery to the customer (where required) 55

56. QP-S204: STORAGE AND HANDLING
2.0 SCOPE
Address all functional areas that have some responsibility for the movement, labeling or storage of materials 56

57. QP-S204: STORAGE AND HANDLING
3.0 GENERAL
Establish documented procedures and work instructions for:
Handling
Labeling
Storage
Packaging
Reservation
Delivery of product
To be in compliance with customer requirements or accepted commercial practice. 57

58. QP-S204: STORAGE AND HANDLING
4.0 PROCEDURES
4.1 Training
Employees to know how to handle and transport products as part of their job introduction.
4.2 Handling
Ensure against damage or degradation to:
Incoming materials
In-process materials
Finished goods
4.3 Labeling
Identity, source and date
Use consistent label format
Affix label securely 58

59. QP-S204: STORAGE AND HANDLING
4.0 PROCEDURES
4.4 Storage
Store in a manner that ensures that material and product integrit
Use designated storage areas (Bins, racks and shelves)
protects product
reduces damage
improves identification and location of materials
Document all procedures and work instructions
Inspect stored product for damage/deterioration.
(at least with each physical inventory)
4.5 Packaging
Establish packaging procedures and work instructions in accordance with:
contractual requirements
internal requirements
Use appropriate packaging materials to:
prevent handling damage
cushion normal transportation shock
ensure the integrity of the product. 59

60. QP-S204: STORAGE AND HANDLING
4.0 PROCEDURES
4.6 Preservation
Segregate and preserve materials/products against damage and deterioration
Meet internal or customer requirements for preserving
Control rotation of inventory to mantain appropriate shelf-life.
4.7 Delivery
Select delivery methods and carriers to optimize:
safe shipmen
on-time delivery.
Base transportation mode, carrier, and delivery instructions on:
customer requirements
other distribution requirements
(requested delivery date, transportation lead-time, size and weight).
select carriers who have proven records of on time delivery and damage free
Protection is extended unti receipt by the customer. 60

61. QP-S204: STORAGE AND HANDLING
4.0 PROCEDURES
4.8 Work Instruction documents (examples)
4.8.1 Raw material receipt and storage
4.8.2 Finished product labeling and storage
4.8.3 Warehouse organization
4.8.4 In-plant handling and operation of fork-lift equipment
4.8.5 Proper loading and unloading of trucks
4.8.6 Traffic planning and shipping 61

62. QP-S204: STORAGE AND HANDLING
4.0 PROCEDURES
4.9 Example document
4.9.1 Raw material receipt and storage
Inspect for material conformance, quality, damage, etc. according to established Quality Control procedures.
Label as required.
Add material to inventory as required.
Move to assigned storage area following established handling and safety procedures.
Assure that racks, shelving, etc. are in compliance to receive materials to prevent damage.
Example: Proper thickness and durometer rubber pads are in place to receive and protect glass. 62

63. Section 209 Training

64. 1.0 Purpose

65. 2.0 Scope

66. 3.0 Responsibility

67. 4.0 General

68. 5.0 Procedure
Training Requirements

69. 5.1Training Requirements
Managers and Supervisors
New requirements
Training Curriculum

70. 5.2 Training Mangers and Supervisor Role Work Experience Methods
Frequency
Qualification

71. 6.0 Evaluation
Managers and Supervisor evaluation
Training Records

72. 7.0 Training Records
Human Resources
Record Contents

73. 8.0 Reference Documents
Department Forms

74. QP-S209 Statistical Techniques

75. First Law of Statistics
Statistics Lie!
Is the sample size tested or inspected representative of daily production?
Is the data that is being collected relevant to your processes?
Collected data is not enough!
What is the data telling you?

76. What to Collect
Verbal reports: QC department, managers, line supervisors and plant personnel…but anecdotal is not enough!
Empirical evidence: Written reports, Inspection Forms, Statistical Analysis (variable control charts, spreadsheets, Pareto charts), Customer complaints.

77. Purpose
To ensure consistent quality and appropriate process control through the use of statistical techniques.
To collect, analyze and interpret data relating to product and process characteristics.
To identify problem areas to reduce returns and warranty claims.
Assist in conducting root cause analysis for problem areas.

78. General Approach Establish target specifications.
simply extract samples of a certain size from receiving, production, final inspection, shipping, in-field performance and customer feedback processes.
if samples fall outside pre-specified limits, then the process is deemed to be out of control and action is required to find the cause of the problem.

79. Tools
Verbal reports: QC department, managers, line supervisors and plant personnel…but anecdotal is not enough!
Variable control charts, spreadsheets, visual observations derived from data gathered from processes, testing and inspection.
Empirical evidence: Written reports, Inspection Forms, Statistical Analysis (variable control charts, spreadsheets, Pareto charts), Customer complaints.

80. Areas to Track Raw Material Receiving In-Process Inspections
Final Product Inspection
Field Performance
Customer Complaints

81. Test of Inspection Name
Responsibility
Data Type
Examples
Raw material receiving
QC or designated personnel
Test values
Visual
Components such as connectors, spacers, desiccant, sealants etc.
Damaged containers
In-Process evaluations
Water temperature, Cutting Wheels, Component Testing (ie sealant adhesion)
Final product
Skips and gaps in sealant
Field Performance
After Sales Service and QC
Written Inspection Reports
Verbal reports
Seal failure, volatile fogging
Customer Complaints
Verbal and electronic correspondence
Delivery delays, seal failures, volatile fogging, after sales service

82. Conclusion
It’s not enough to collect data! Data is meaningless unless it is reviewed, analyzed (what is it telling you) and acted upon.
Collect the right data and the right amount of data! One data point does not provide you with enough information to determine if a component or product conforms to specifications.
Don’t assume you know the cause of a problem!
Statistical analysis can help you control nonconforming components and products.

83. QP-S210 References

84. Quality Documents
ISO Quality Systems – Model for Quality Assurance in Design, Development, Production and Installation And Servicing
 ISO Quality Systems – Model for Quality Assurance in Production, Installation and Servicing
 ISO Quality Systems – Model for Quality Assurance in Final Inspection and Test
 ANSI/ASQO Q Quality Systems – Model for Quality Assurance in Final Inspection and Test
 IGCC-IGMA or IGMAC Certification Program Manual

85. IGMA Test Methods Test Methods for IG Unit Sealants
IGMA Recommended Voluntary In-Plant Test Methods And Performance Criteria for Desiccants for Sealed Insulating Glass Units
 IGMA Voluntary Test Methods and Voluntary Performance Quality Assurance Criteria for Spacers for Sealed Insulating Glass Units
 IGMA Voluntary Test Methods and Voluntary Performance Quality Assurance Criteria for Two Component Polysulfide Sealants Used in Manufacturing Sealed Insulating Glass Units

86. Related Documents
ASTM E2188 Standard Test Method for Insulating Glass Unit Performance
ASTM E2189 Standard Test Method for Testing Resistance to Fogging in Insulating Glass Units
ASTM E2190 Standard Specification for Insulating Glass Unit Performance and Evaluation
AAMA documents: Glazing Sealants
IGMA Sealant Siteline Survey