and then the glass should not be rejected · 3.5 all lux rating shall be measured using an extech...

[QUALITY MANAGEMENT SYSTEM - GLASS STANDARDS]

Document Type Document ID Version Page

QMS QMS-AMI-GLASS-001 1.1 1

1.0 Scope

1.1 This document defines the methods and quality criteria in which AMI establishes a

common basis for inspection that exceeds the industry’s and major manufacturers’

standards (ASTM C1036 Reference Standard). This document provides AMI

operations, suppliers and customers criteria for windows, sash, insulated glass (IG)

units, cut glass, and flat glass.

1.2 All glass consists of imperfections, as documented and standardized in the glass

industry. Provided these imperfections are not viewable under the defined

inspection method & lighting conditions AND do not exceed the acceptable limits

defined in this document, then the glass should not be rejected. The intent is to

create objective quality standards.

2.0 Table of Contents

1. Scope

2. Table Of Contents

3. Inspection Station Standards

4. Inspection Method

5. Spacer Standards

6. Grid Standards

7. Insulated Glass (IG) and Cut Glass Standards

8. Appendix

9. Revision Log

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3.0 Inspection Station Standards

3.1 Inspection stations must be designed to allow proper angle, distance and/or orientation

of the glass being inspected to the light source.

3.2 Reflective Lighting of 1000 +/- 400 LUX rating when measured using the criteria

listed in section 3.5 must be provided to the station to allow proper viewing of grid

and matrix defects.

3.2.1 The fixture shall support the required lamp T5HO Lamp, 85CRI 4100K,

recommended manufacturing model of HBL654HT5-L4.

3.2.2 The recommended lamps shall be T5HO Lamp, 85CRI 4100K

3.2.3 The reflective lighting fixture shall be placed 11 feet off of the floor and 5

feet back from the backboard where the transmissive lighting is

mounted.

3.2.4 The reflective lighting shall be angled at 25 +/- 5 degrees towards the

inspection station. The lighting angle shall cover the entire inspection

area where units will be placed.

3.3 Transmissive Lighting of 5000 +/- 800 LUX rating when measured using the criteria

listed in section 3.5.

3.3.1 The fixture shall be a channel strip single lamp fixture that supports the

required lamp F32T8, recommended manufacturing model of Z132MV or

SNF132UNV-EB81U.

3.3.2 The recommended lamp manufacturing model is F32T8/SP65/ECO.

3.3.3 Single fixture units shall be placed 10” center to center across the

inspection station area. This allows for consistent light output with no

peaks or valleys between lights. Fixture and lighting coverage shall be fit

to the inspection station size and usage.

3.4 Glass is NOT intended to be inspected under close-up scrutiny or held under direct

sunlight, as these conditions will almost always reveal tiny glass imperfections that

would otherwise be considered acceptable within AMI and industry standards.

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Table 3.4.1 – LUX Level by Lightning Conditions

3.5 All LUX rating shall be measured using an EXTECH Instruments 407026: Heavy Duty

Light Meter with PC Interface

3.5.1 Reflective lighting shall be tested with the light-meter facing up above

the belt (inspection area) at 4 feet above the floor.

3.5.2 Transmissive lighting shall be tested with the light-meter facing the

inspection station at 90 degrees and at 1 foot away from the lamps.

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4.0 Inspection Method

4.1 Glass shall be inspected per a standard process.

4.1.1 Windows, sash, IG units and cut glass shall be inspected at a distance of 3

feet as shown in example 4.4.2.

4.1.2 Glass shall be inspected visually for an appropriate time based on glass

size per table 4.1.2.1; if a unit has grids that inspection should also take

place during this allotted time. This inspection time does not include any

required measurements or validation if imperfections are seen.

Table 4.1.2.1 – Glass Visual Inspection Time

Glass Size Inspection Time

< 6 Square Feet 5 Seconds

6-35 Square Feet 10 Seconds

> 35 Square Feet 20 Seconds

4.1.3 If imperfections are viewable at 3 feet, the inspector shall step forward to

validate if the identified imperfections exceed the criteria listed in this

document. If the imperfections exceed the criteria, the unit should be

rejected or may be reworked per criteria listed at table 7.1.2.

4.1.4 Multiple imperfections clause: If a unit displays multiple imperfections

viewable from 3 feet, at a smaller size than the reject criteria listed on

table of 6.2.2, table 6.2.3 and table 7.1.2, the following shall apply: Any

units with 2 or more imperfections that are closer than 1” apart shall be

rejected regardless of the size of the imperfection, if they are viewable

from 3 feet. Any units with three or more imperfections shall be rejected

regardless of the size of the imperfection, if they are viewable from 3

feet.

4.2 AMI will require additional inspection for Field Remakes (units rejected by AMI’s

customers) as defined in the purchase order/download. AMI may also require

additional inspection in order to meet customer expectations in special

circumstances, which will be defined in the purchase order/download.

4.2.1 AMI may inspect for imperfections for field remakes at the distances that

represent the homeowner’s use of the finished product and their ability

to detect flaws in glass assemblies. Inspector shall inspect the field

remake at 90 degrees and at an angle of 45 degrees from the left and the

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right on each side. This inspection method supersedes the standard

process defined in this document.

5.0 Spacer Standards

5.1 Intercept standards shall be monitored and controlled through Statistical Process

Control (SPC) charts as documented in CP-10004-X.XX Intercept Spacer.

Table 5.1.1 – Intercept Spacer Requirements

Characteristic SPC Document Reject Criteria Tolerance

Spacer Width PCC-SWI- V_X.X See Table 5.1.2 +/- 0.005”

Spacer Tab Swage PCC-STI- V_X.X Spacer Width -0.025" +0.010" -0.005"

Spacer Splay PCC-SSI- V_X.X Spacer Width +0.010" -0.005"

Spacer Corner Flare PCC-CFI- V_X.X Spacer Width +0.010" -0.005"

Table 5.1.2 – Nominal Size – Decimal Equivalents

Nominal Size Decimal Equivalent

9/32” 0.2810

5/16” 0.3125

13/32” 0.4060

17/32” 0.5310

19/32” 0.5940

23/32” 0.7190

25/32” 0.7810

5.2 Super Spacer Placeholder

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6.0 Grid Standards

6.1 If present, grids shall be inspected visually from 3 feet for imperfections during glass

inspection. If the imperfections are viewable at 3 feet, the inspector shall step

forward to validate the identified imperfections exceed the criteria listed in table

6.2.1. If they exceed the criteria listed in table 6.2.1 or 6.2.3; the unit shall be

rejected.

6.1.1 If grids display multiple imperfections within the same unit which are

viewable from 3 feet, the multiple imperfections clause in 4.1.4 shall

apply, regardless of the size of the imperfections.

6.2 Spacer / Grid Gaps are inspected while using a profile gauge to simulate the

sightline. If the gap exceeds the criteria and is visible when the profile gauge is

applied, the unit shall be rejected.

Figure 6.2.1 – Grid Characteristic Examples

Table 6.2.2 – Interior Surface Grid Visual Quality Requirements

Characteristic Reject Criteria

Burrs / Shavings >1/32”

Fold-Overs / Dog Ears >1/32”

Paint Chips / Marks / Spots >1/32”

Dent / Crease >1/8”

Scratches (Length) >1/4”

Smudges / Fingerprints >1/4”

Grid Gap at Spacer inside of Sightline

>1/8”

Spacer Seam / Grid Gap at Mitered Corner

>1/16”

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Table 6.2.3 – Exterior Surface Grid Visual Quality Requirements


Burrs / Shavings >1/16”

Fold-Overs / Dog Ears >1/16”

Paint Chips / Marks / Spots >1/16”

Dent / Crease >1/8”

Scratches (Length) >1/4”

Smudges / Fingerprints >1/4”

Grid Gap at Spacer inside of Sightline

>1/8”

Spacer Seam / Grid Gap at Mitered Corner (See Figure 6.2.2)

>1/16”

6.3 The seam on the grids, by preference, but not required, should always be oriented

downwards on horizontal grids, and either left or right (not both) on vertical grids.

6.4 Grid straightness shall be inspected visually from 3 feet during glass inspection. Any

grid that appears out of alignment shall then be measured using a tape measure.

Measurements should be from the edge of the glass to the edge of each grid. Then

the maximum difference between the two measurements (e.g. C2-C1, A2-A1)

should meet the criteria listed in table 6.4.1.

Table 6.4.1 – Grid Straightness Quality Requirements

Length / Measurement Reject Criteria

< 4 Inches > +/- 1/32”

> 4 Inches > +/- 1/16”

Between Sashes / Units > +/- 1/8”

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Figure 6.4.2 – Grid Straightness Measurement Example

Examples

A2 – A1 (4 1/32”) – (4”) = 1/32”

B2 – B1 (8 1/8”) – (8”) = 1/8”

C2 – C1 (5 9/16”) – (5 1/2”) = 1/16”

Acceptable <=1/32”

Unacceptable >1/16”

Acceptable <=1/16”

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7.0 Insulated Glass (IG) and Cut Glass Standards

7.1 Glass shall be inspected visually from 3 feet for imperfections. If the imperfections

are viewable at 3 feet, the inspector shall step forward to validate the identified

imperfections exceed the criteria listed in table 7.1.2. If the imperfections exceed

the criteria, the unit should be rejected. For linear blemishes the intensity rating

shall be determined by the distance in which the imperfection is viewable under the

inspection station requirements in section 3.0

7.1.1 If glass displays multiple imperfections within the same unit which are

viewable from 3 feet, the multiple imperfections clause in 4.1.4 shall

apply, regardless of the size of the imperfections.

Table 7.1.2 – Coating and Visual Quality Requirements


Scuff / Streak > 1/16”

Debris > 1/16”

Spots > 1/16”

Bubbles > 1/16”

Hair / Lint > 1/16”

Butyl > 1/16”

Fingerprints > 1/16”

Linear Blemish (Scratch) Quality Requirements

Intensity Viewing Distance Reject Criteria Disposition if Rejected

Faint 0-8 Inches Allowed Pass

Light 8-36 Inches > 1” Rework

Medium: Visible/finger nail will not feel the depth of scratch

36-120 Inches > 1/2" Rework

Heavy: Very noticeable/ finger nail will feel the depth of scratch

120+ Inches None Allowed Scrap

7.2 Tempered glass can exhibit slight optical distortion, even more so when LOW-E is

involved. This distortion is accentuated when looking off-angle or against a dark

background. Relative “waviness” of glass should not be rejected, unless the glass

has obvious distortions when viewing under the inspection standard in section 3.0.

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7.3 Overall IG size shall not exceed a final size of > +/- 1/16” outside of the specific unit

size. This includes any variation in glass alignment and butyl squeeze-out.

7.3.1 Alignment of the cut pieces of glass shall not be offset > 1/16” and must

not allow the total unit size to increase beyond the specification in 7.3.

7.3.2 Butyl squeeze-out shall not extent > 1/16” the edge of the glass and must

not allow the total unit size to increase beyond the specification in 7.3.

7.4 Edge deletion shall occur no further than 7/16” from the edge of the glass.

7.5 Glass spacer or butyl should not be exposed more than 1/16” around the perimeter.

7.6 Matrix and Butyl imperfections in the Matrix on spacers are not cause for IG

rejection provided the blemish is outside the sightline. However, action should be

taken with the process control plan to minimize and monitor such properties.

Breaks in the matrix shall be reviewed by plant quality authority for acceptance, but

are not preferred.

7.7 Glass edge quality and the resulting glass edge strength are critical to the

performance of the glass under thermal loading and in applications where one or

more edges are not supported. AMI uses an industry standard specification defined

regard to rejecting edge damage. Guideline for Cut Edge Quality TD-119 can be

found at http://buyat.ppg.com/glasstechlib/60_TD119F.pdf OR

www.ppgideascapes.com

http://buyat.ppg.com/glasstechlib/60_TD119F.pdf

http://www.ppgideascapes.com/

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8.0 Appendix

8.1 Gauges

9.0 Revision Log

Date Revision Changes Approval

5/17/13 0.1 Document Creation PowellJE

8/22/13 0.2 Revised wording 3.2 for wording consistency PowellJE

9/18/13 0.3 Revised 7.1.2 to reflect new scratch standard to align with other glass defects

PowellJE

10/2/13 0.4 Revised wording in Table 6.2.1, Revised Figure 6.2.2 FerryKA

10/2/13 0.5 Added spacer information to section 5.0 Revised wording in 7.7 referencing wrong drawing

PowellJE

10/9/13 0.6 Revise 7.1.2, change glass scratch back to 1” LiangLI

08/12/14 0.7 Initial document review with engineering, manufacturing, quality and marketing Added Table 6.2.3 to include exterior grid defect criteria Added examples to grid measurement on Figure 6.4.2 Revised Table 6.2.2 Grid gap at spacer inside of sightline from 1/16” to 1/8" and exterior/interior specification differences. Revised Table 7.1.2 to include intensity scale for acceptable linear blemishes (scratches) and updated separation on clusters from ¼” to 1” minimum spacing Revised 4.1.4 to reference sections 6.2 and 7.1 in determining cluster criteria

PowellJE

08/22/14 0.8 Revised 7.1 to describe intensity ratings for linear blemishes Revised 7.1.2 to include viewing distance range for each intensity and allowable criteria for medium intensity Revised 7.2 to accurately reference section 3.0 for the inspection station standard

PowellJE

09/04/14 0.9 Revised Table 7.1.2 from >1/16” to >1/2” for medium intensity linear blemishes per discussion with engineering

PowellJE

9/17/14 1.0 Revised 4.1.3 to add rework; Revised 4.1.4 Max number of imperfection allowed per unit and none allowed for cluster; Revised 6.1.2 and 7.1.2 to reference Section 4.1.4. Revised 4.2.1 with inspection angle requirement; Revised Table 6.2.2 spec of Grid Gap; Revised Table 7.1.2 Scratch with definition of medium/heavy and add disposition guideline; Revise 7.7 to include industry standard PPG cut edge quality link; Revised Table 6.2.2,Table 6.2.3,Table 7.1.2

LiangLI

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removing Size separation column.

9/25/14 1.1 Added reference to the “Multiple imperfections clause” in 4.1.4, invoked in 6.1.1 and 7.1.1. Revised verbiage for spacer/grid gaps in 6.2

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and then the glass should not be rejected · 3.5 all lux rating shall be measured using an extech...

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