qacs-01 - vinyl and capstock extrusions and laminate ......uniform intensity lighting between 70 and...

Vinyl and Capstock Extrusions and

Laminate Cosmetic Standard

Nbr: QACS‐01

Revision B

Document Title

Terms, Abbreviations and Definitions

Document Nbr: QACS‐01 Revision: B Page 2 of 20

Originator: Keri Brookshire, Industrial /Aesthetic Designer

Revision History

REV DCN#

EFFECTIVE

DATE

INITIATED

BY DESCRIPTION OF CHANGE

A ‐ 3/15/19 K. Brookshire Initial Release

B 4/29/19 K. Brookshire Clarifications

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Table of Contents

JELD‐WEN Windows & Doors ........................................................................................................... 4

JELD‐WEN Values .............................................................................................................................. 4

Purpose ............................................................................................................................................. 4

Scope ................................................................................................................................................. 4

Reference Documents ....................................................................................................................... 5

Abbreviations / Definitions .............................................................................................................. 5

Roles and Responsibilities ................................................................................................................ 6

General .............................................................................................................................................. 6 8.1 Order of Precedence ..................................................................................................................................................... 6

Drawing Tolerances & Dimensions .................................................................................................. 7 9.1 Physical Tolerances ....................................................................................................................................................... 7 9.2 Critical Dimensions (CI) ................................................................................................................................................. 7 9.3 Reference Dimensions .................................................................................................................................................. 7 9.4 Dimensions.................................................................................................................................................................... 7 9.5 Coating .......................................................................................................................................................................... 7 9.6 Acceptance Criteria – Vinyl, Capstock, and Laminate Products .................................................................................. 7 9.7 Visual Inspection Guidelines ......................................................................................................................................... 8 9.8 Magnification ................................................................................................................................................................ 8

11.0 Coating ............................................................................................................................................ 11 11.1 Coating Requirements ................................................................................................................................................ 11 11.2 Adhesion (Tape) Testing ............................................................................................................................................. 11

13.0 Surfaces ........................................................................................................................................... 13 13.4 Sharp Edges ................................................................................................................................................................. 14 13.5 Dents, Dings, Gouge & Nicks ...................................................................................................................................... 14

14.0 Surfaces ........................................................................................................................................... 14 14.1 Through Holes ................................................................................................................................................................... 14 14.3 Countersinks ...................................................................................................................................................................... 14

15.0 General Defects .................................................................................................................................. 15

16.0 Control of Nonconforming Material .................................................................................................. 20

17.0 Records ............................................................................................................................................... 20

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JELD‐WEN Windows & Doors

JELD‐WEN is a pioneer in designing and manufacturing large opening door systems. Dedicated to

creating products that open spaces, our focus in developing and refining these products has

resulted in the most innovative and comprehensive range of doors and windows available. As the

pioneer in large openings, it is important that JELD‐WEN and it’s suppliers provide the highest‐level

quality products that merits being used in JELD‐WEN products. To learn more about JELD‐WEN,

please visit our website at https://www.jeld‐wen.com.

JELD‐WEN Values

Our Culture JELD‐WEN’s culture is our lifeblood ‐‐ it is the ongoing expression of our Purpose, Vision and Values, reflected in the behaviors and actions of our associates who genuinely understand and are committed to these principles.

Our Purpose We bring beauty and security to the spaces that touch our lives.

Our Purpose is our reason for being. At JELD‐WEN, we do much more than manufacture windows and doors. Our products and services afford us the opportunity to enter peoples’ workplaces, homes and daily lives. With this privilege comes great responsibility to ensure that the products we deliver are reliable and enrich the places and lives that they touch.

Our Vision To lead the global building products industry with great people creating superior products and delivering excellence in all that we do.

Purpose

The purpose of this standard is to ensure reliability and consistency in the manufacturing of products by or supplied to JELD‐WEN Inc. This standard shall be used as a guideline for engineering production (fabrication and assembly), quality personnel and suppliers. It may also be used as a training aid for assemblers and inspectors as its intent is to provide the means necessary to determine product quality and acceptability.

Scope

This document applies to all JELD‐WEN manufactured products and applicable products, materials supplied to JELD‐WEN. This includes, but is not limited to:

Vinyl and Composite extrusion, hardware materials used to manufacture JELD‐WEN products.

All materials that have been finished and or coated Note: This document does not apply to glass, wood, or any metal product.

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Reference Documents

5.1 AAMA 303 Voluntary Specification for Rigid Polyvinyl Chloride (PVC) Exterior Profiles

5.2 AAMA 309 Standard Specification for Classification of Rigid Thermoplastic/Cellulosic

composite Materials

5.3 AAMA 614 Voluntary Specification, Performance Requirements and Test Procedures for High

Performance Organic Coatings on Plastic Profiles

5.4 AAMA 615 Voluntary Specification, Performance Requirements and Test Procedures for

Superior Performance Organic Coatings on Plastic Profiles

5.5 ASTM D4726 Rigid Poly (Vinyl Chloride) (PVC) Exterior‐Profile Extrusions Used for Assembled

Windows and Doors

5.6 ASTM D3359 Standard Test Methods for Measuring Adhesion by Tape Test

5.7 ASTM E1753 Use of Qualitative Chemical Spot Test Kits for Detection of Lead in Dry Paint Films

5.8 ACT Orange Peel Standards

5.9 OP03 Control of Nonconforming Product

5.10 OP04 Supplier Corrective and Preventative Action

5.11 OP03‐F02 Nonconforming Material Report (NCMR)

5.12 OP05 Deviation Request

5.13 OP05‐F01 Deviation Request Form

Abbreviations / Definitions

6.1 AAMA American Architectural Manufacturers Association

6.2 Inspection Area(s) Area is defined as a section of 3 feet. Example: a part that is 12

6.3 Cosmetic Defect Any defect detected visually that detracts from the products aesthetic

appearance.

6.4 MRB Material Review Board

6.5 NCMR Nonconforming Material Report

6.6 DR Deviation Request

6.7 Sampling Refers to the practice of evaluating (inspecting) a portion ‐the sample ‐ of a lot

– the population – for the purpose of inferring information about the lot. An

accept/reject decision is normally made based on the results of the sample.

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Roles and Responsibilities

Role Responsibility

Employees Use this standard for guidance for acceptance criteria.

Engineering Assist with determining criteria to keep this document current.

Inspectors Conduct visual inspection using the guideline outlined in this standard.

Quality It is the responsibility of Quality and Engineering to keep this document current.

Production Disposition cosmetic non‐conformances' of defects defined within this standard.

Purchasing Use this standard for guidance for cosmetic acceptance criteria.

Materials Purchasing, in conjunction with Quality Dept. is responsible for disposition,

adjustments, and coordination of corrective action in the event that a non‐

conforming material is found.

Supplier Receiving materials and routing to Receiving Inspection. Receiving Personnel

verifies the shipment for damage. The material’s group also checks that the

purchase order information such as P/N, description, and quantity match with

the actual part and the packing list.

General The items list in this standard are not considered all‐inclusive. Flaws or defects not noted will be considered

on a case‐‐by‐‐case basis depending on the cosmetic surface classification and type of defect. Questionable

areas should be referred to the LCD Buyer or Quality Manager. The choice to accept/reject product outside

of specification is a JELD‐WEN business decision and that authority resides within the manufacturing facility.

It is recommended that the authorization for use of such material be given by the Production Manager,

General Manager, Coordinating General Manager, or Vice‐President.

8.1 Order of Precedence

Internal Supplier

1. Approved Deviation Request (OP05‐F01 Deviation Request)

1. JELD‐WEN/JELD‐WEN Purchase Order

2. Engineering Document, Drawing 2. Approved Deviation (OP05‐F01 Deviation Request)

3. Work Instruction 3. Cosmetic Standard

4. Cosmetic & Workmanship Standard(s) 4. Engineering Document, Drawing

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Drawing Tolerances & Dimensions

9.1 Physical Tolerances

Physical Tolerances include measurable, geometric dimensions such as hole‐to‐hole and form‐to‐form dimensions. Parts will be made to match print requirements. If the print requirements cannot be met, deviations (DRs) will be negotiated and documented prior to any work being accepted or started.

9.2 Critical Dimensions (CI)

Drawing dimensions or notes identified as "critical dimensions" are considered especially

important for fit, function, safety, or other reasons. Thus critical dimensions are subjected

to, but not limited to inspection. All drawing dimensions are subject to inspection.

Inspection records are to be readily available upon JELD‐WEN request.

9.3 Reference Dimensions

A reference dimension (REF or a dimension in parentheses e.g. (.125) is a dimension on an

engineering drawing provided for information only. Reference dimensions are provided

for a variety of reasons and are often an accumulation of other dimensions that are

defined elsewhere (e.g. on the drawing or other related documentation such as an

extrusion drawing).

9.4 Dimensions

All dimensions are considered to be finished dimensions aka after coating.

9.5 Coating

Unless, otherwise stated in a technical drawing, specification or purchase order.

9.6 Acceptance Criteria – Vinyl, Capstock, and Laminate Products

Due to the size of JELD‐WEN material, it is understandable that at times parts cannot be

completely defect free. It is required that at a minimum 90% (consecutive length) of the

material be useable.

Inspection

9.6.1 JELD‐WEN Assembled/Final Products (Inspection)

Inspection of JELD‐WEN assembled/final products are inspected for defects

identified within this standard utilizing QA02‐ JELD‐WEN Workmanship

standard.

9.6.2 Inspection Table Surface The inspection table surface shall be made of a non‐reflective, color surface to

avoid twilight conditions.

9.6.3 Light Source

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Inspection shall not be conducted using direct sunlight and must follow the

following guidelines:

9.6.4 Light Specification Bright white /cool white (3500K – 4100K), artificial office lighting (e.g.

fluorescent lights)

9.6.5 Light Intensity Uniform intensity lighting between 70 and 120 foot‐candles (750‐1250 Lux) shall

be used during inspections.

9.6.6 Light Position Lights shall be reflection‐free, non‐directional and positioned overhead. Lights

shall not be positioned directly above the inspection table.

9.7 Visual Inspection Guidelines

Variations in texture, color, transparency, reflectivity and finish should be observed and assessed while in a normal viewing position.

9.8 Magnification

Magnification shall not be used when inspecting for cosmetic defects.

9.8.1 Viewing Position Visual Inspection can initially be conducted by viewing the part on a flat surface

per the criteria outlined in this standard. However, the preferred position for

conducting visual inspection is to view the part in a vertical position, which is

closer to how the end customer will view the parts.

Never move the part at different angles as that is not how the part will be seen

by the end user.

Parts are not to be rotated to allow light to reflect at all possible angles.

Parts should be viewed using only up‐down and side to side visual movements.

Marking of the defect shall be not used to aid in finding the defect. This includes

circling, highlighting or taping of the defect in any way.

9.8.2 Viewing Method If product is inspected flat and a potential defect is found, it will need to be

inspected vertically or horizontally. Viewing the part vertically, will provide the

inspector the opportunity to inspect the material in the same manner that it will

be seen by the customer and allow the inspector to disposition the part based

on whether it will be visible to the end customer.

Note: Items 13ft or greater, may be viewed horizontally, using the same

guideline that are outlined within this standard.

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Correct Method The suspect defect is NOT to be marked until has been viewed vertically. The inspection is to be conducted by viewing the part using only up‐down and side to side eye movements. The same time per area and distance criteria defined in this standard apply.

Incorrect Viewing Method

Visually inspect by looking at the part straight

ahead

Use up and down and/ or side to side eye movements

Material is not to be continually moved to be

viewed at different angles.

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9.8.3 Viewing Time & Distance (applicable for parts, not completed panels)

9.9 Cosmetic Surface Classification

Cosmetic surface classifications are defined by three classes that can be applied to exterior and interior surfaces on the finished product. These surfaces will be identified on the applicable engineering drawing. *If the classifications cannot be found on the engineering drawing, please contact JELD‐WEN Buyer or Quality Manager to obtain a marked‐up print.

Time per Area Distance Class

Seconds Inches A ** B** C

3 ‐ 5 32" (1 meter) +/‐ 6"

X X

1 ‐ 2 X

**Exposed surfaces Class A is a critical, cosmetic surface, usually exterior of part most often viewed closely by the customer. Class B is a less‐critical cosmetic surface seldom viewed by the customer such as a side of the part. Class C is a non‐critical, non‐cosmetic surface that is never viewed by the customer.

9.10 Inspection Records Inspection records are to be maintained and be readily available when requested by JELD‐WEN.

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10.0 Color Match Specification

10.1 Color Difference The nonlinear relations for L*, a*, and b* are intended to mimic the nonlinear response of the eye. Furthermore, uniform changes of components in the L*a*b* color space aim to correspond to uniform changes in perceived color, so the relative perceptual differences between any two colors in L*a*b* can be approximated by treating each color as a point in a three dimensional space (with three components: L*, a*, b*) and taking the Euclidean Distance (E*) between them.

10.2 E* Total color difference between sample and standard, where: ∆𝐸 ∗

√∆𝐿∗ ∆𝑎∗ ∆𝑏∗ 10.3 Specular Gloss

The perception by an observer of the mirror‐like appearance of a surface. This appearance cannot be measured; only the specific reflectance characteristics of the surface are measured.

11.0 Coating

All coated parts must match JELD‐WEN approved color standards. The part is unacceptable if the color does not match the approved color standard or if the difference is easily detectable. Questionable conditions will be referred to the JELD‐WEN Quality Manager or designee for resolution.

11.1 Coating Requirements Coating will be conducted on clean surfaces, uniform in color and shall be defect‐free. It shall withstand the tape pull test.

11.2 Adhesion (Tape) Testing

Coating shall not come off when rubbed with a dry cloth or with fingers. A crosshatch pattern is made using appropriate tool (GARDCO cross hatch cutter is recommended) though the coating film to the substrate. Detached flakes of coating are removed by brushing with a soft brush. Pressure‐sensitive tape (Elcometer 99 tape or PA‐280630 tape) is recommended) for the pull test. The adhesion nearly matches the requirement specified in ASTM D3359: Measuring Adhesion by “Tape Test”, 36 ± 2.5 oz/in.

This test should be conducted ~2” from edge of part. And a minimum of 1 sampling per batch bases conducted by both supplier and JELD‐WEN. Cross‐hatch results matches 4B or above as per the below scale, it is accepted. Suppliers must maintain records of adhesion test results and be readily available to JELD‐WEN upon request.

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11.3 Extrusion, Capstock Defects

The defined requirements will be used by JELD‐WEN personnel and by suppliers to inspect product.

Color ‐ all coating shall be uniform in color (on same part and throughout the lot) and match the approved sample/coupon.

Coating touch‐up – can be performed as long as the touch up is not evident and meets all coating requirements.

Stains – parts shall be free of stains, fingerprints, water stains, and contamination stains etc.

Debris – parts shall be free of debris Contact/Rack Marks ‐ Contact marks are acceptable on interior (nonvisible

surfaces) or as defined in section 14 of this standard. If uncertain, contact JELD‐WEN Buyer or Quality Manager.

Racking shall be done in a manner that will not damage the parts. Suppliers will be responsible for any damage done to JELD‐WEN parts.

Surface finish – parts will be smooth and have a uniform finish and be free of any adhesion issues. Surfaces will be free of scratches, runs, cracks, defects etc. Refer to general defect list in section 16 of this standard.

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11.4 Lamination Requirements

The defined requirements will be used by JELD‐WEN personnel and by plating suppliers to inspect product.

Color ‐ all lineal shall be uniform in color (on same part and throughout the lot) and match the approved sample/coupon.

Plating Touch‐up ‐ is not to be performed without obtaining written authorization by a JELD‐WEN Quality Manager.

Stains – parts shall be free of stains, fingerprints, water stains, and contamination stains etc.

Debris – parts shall be free of debris Contact/Rack Marks ‐ Contact marks are acceptable on interior (nonvisible

surfaces) or as defined in section 14 of this standard. If uncertain, contact JELD‐WEN Buyer or Quality Manager.

Racking shall be done in a manner that will not damage the parts. Suppliers will be responsible for any damage done to JELD‐WEN parts.

Surface finish – Parts will be smooth and have uniform finish. Refer to general defect list in section 16 of this standard.

12.0 Contact/Rack Marks Contact/rack marks are not allowed on any Class A or B surfaces without written approval from JELD‐WEN. If there is no other option but to rack the parts from the ends, the marks may not exceed the first 1 inches of the ends of the sticks of material.

13.0 Surfaces

13.1 Surfaces Cleanliness All finished products must be clean and free of debris that can cause damage.

13.2 Surfaces Finish Surface finish also known as surface texture, is the characteristics of a surface. Surface finish shall meet the requirements specified on the drawing. If the drawing does not specify a surface finish, exterior surfaces shall be smooth, uniform and pass at a minimum a thumbnail test.

13.3 Thumbnail test

Manual test of scratch depth is performed by trying to catch a normal thumbnail in the

crevice of the defect. Failure is when the nail catches or as defined in section 16 of this standard.

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13.4 Sharp Edges

Sharp Edge is an edge having a thin cutting edge or a fine point well‐adapted for cutting or piercing. Sharp edges are reject‐able for rework because of potential safety concerns for

personnel handling the parts.

13.5 Dents, Dings, Gouge & Nicks

Visible Dents, Dings, Gouges and Nicks are not allowed on any Class A or B surfaces. These defects may be considered if they are on class C surfaces and do not impact function of the part.

14.0 Surfaces

14.1 Through Holes

Through holes are holes that do not have any threads. Holes must be free of burrs and

debris. Hole sizes are to be checked using the appropriate size pin gages.

14.2 Threaded holes

It is important that internal threads are manufactured that meet the defined

requirements in the drawings. Taper lock Thread Plug Gages are to be used to check the

internal threads of parts. Checking the internal threads assures assembly of mating parts,

checks the pitch diameter and the functional thread.

14.3 Countersinks

Countersinks are a conical hole cut into a manufactured object. The purpose is to allow

the head of a countersunk bolt or screw, when placed in the hole, to sit flush with or

below the surface of the surrounding material. Countersinks need to meet the

requirements identified in on product drawings and be checked using an appropriate

countersink gage.

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15.0 General Defects

The defects defined below are applicable to hardware, extrusions, and coated parts. The list is not all inclusive and only represent the more common defects that are likely to be seen by JELD‐WEN or JELD‐WEN’s customers. See section 11 for inspection methods and guidelines. Defects will be subject to rejection if the defect was detected when viewed per the guidelines (section 11) identified within this standard.

SURFACE CLASS

(A): Accept (R): Reject

DEFECT DEFECT DESCRIPTION DEFECT EXAMPLE A B C COMMENT

Abrasion

Surface imperfections where the coating is wearing away. Usually caused by items rubbing together.

R R A Must not effect fit, function or adhesion

Bubble Bubble, bister, bulge or protrusion, air pocket

A A A

A =0.010”‐ 0.025” One per 4”x4” B= 0.010”‐ 0.030” Two per 4”x4” (height & width)

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SURFACE CLASS



Burns

Yellow‐brown lines or marks on surface area caused by burnt material.

R R A

This observation shall be made in the QA Lab under Darkroom conditions.

Bowing Out of flatness.

Bow +/‐ 0.45" maximum allowable over a three‐foot sample on same extrusion placed on flat surface. At center point of extrusion use calipers or pin gauge to measure.

Buffmarks

Intermittent, dull / high gloss surface. Normally caused by two walls welding together where a hollow section should be present.

A A A

A= <0.125” Two per 4”x4” B= <0.375” Two per 4”x4”

Chatter or Rippling

Consistent ripples along the lineal usually due to centering problem.

R A A

B= <0.375” Two per 4”x4” Must not effect fit, function or adhesion

Contaminate

Contaminated by dirt, chemicals, or other mater making it dirty that cannot be cleaned.

R A A


Die line

Longitudinal depression or protrusion formed on the surface of the draw or extrusion.

A A A

A= <0.020” Two per surface B= <0.050” Four per surface

Delamination Separation of layers

R R R Not Allowed

"UV" light setting

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SURFACE CLASS



Discoloration Any change from original color

R A A

A= Must meet established tolerance per color B= <0.375” Two per 4”x4”must be within <2 DE* units

Dull Surface The lack of consistency of gloss across all sections of an extrusion.

A A A < 10 gloss units when measured on a Gardner 60º Gloss Meter.

Gouge

Small pit marks on the surface of the profile that is normally associated with foreign material in the compound.

R A A


Nicks Like gouges but smaller in size and no discoloration.

A A A

A= <0.020” Two per 4”x4” B= <0.375” Two per 4”x4” Must not effect fit, function or adhesion

Orange peel Irregular or rough surface resembling the peel of an orange.

R A A

B= <0.250” One per 4”x4” Must not effect fit, function or adhesion

Non-uniform texture

Surface texture changes within same surface area

R A A

B= <0.250” One per 4”x4” Must not effect fit, function or adhesion

Composite Non-uniform texture

Surface texture changes within same surface area

A A A

From edge of part inward A = <0.125” B= < .250 Per edge surface Must not effect fit, function or adhesion

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SURFACE CLASS



Scratch line Shallow groove in material, which can be seen and felt.

A A A

A&B= <0.250” One per 4”x4” Must not effect fit, function or adhesion

Scuff marks Minor scratches on surface of the finish that can be seen, NOT felt.

A A A

A&B= <0.250” One per 4”x4” Must not effect fit, function or adhesion

Shiny streaks High gloss lines on the surface causing Dull - Shiny affect.

R A A

B= <0.050” Two per surface Must not effect fit, function or adhesion

Composite shiny streaks

High gloss lines on the surface causing Dull - Shiny affect.

A A A A= 0.050" B= <0.125” Must not effect fit, function or adhesion

Sinkline

A consistent or intermittent dip that runs in the direction of the extrusion. Normally found here two walls intersect.

A A A

A=0.010”- 0.020” B= 0.020”- 0.050” Must not effect fit, function or adhesion

Stains Any discoloration due to foreign matter or chemical; a spot not easily removed.

A A A

A =0.010”- 0.025” One per 4”x4” B= 0.010”- 0.030” Two per 4”x4” Must not effect fit, function or adhesion

Streaking Non-uniform coverage leaving lineal marks

R A A B= 0.010”- 0.030” Must not effect fit, function or adhesion

Surface dent Depression or dips sinking inward on what should be a smooth surface.

R R R Not Allowed

Tear line A lack of radii, or undercut in the material

R R R Not Allowed

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SURFACE CLASS



Twist

Out of straightness, twist tolerance is the maximum permissible value of the twist deviation.

Twist total degrees of twist per foot 0.102" maximum allowable over a three-foot sample on same extrusion placed on flat surface. Place weight on left side, measure rotation on right side with pin gauge.

Unapproved touch-up

Defect made in efforts to cover up another defected surface and/or finish

R R R Not Allowed

Water spots Dull colored lines or spots that cannot clean off

R A A

B= 0.010”- 0.030”

Two per 4”x4”

Must not effect fit, function or adhesion

Watermark or fish eye

A blotchy appearance appearing as a smear on the surface.

R A A B = 0.010”- 0.030” Two per 4”x4” Must not effect fit, function or adhesion

Wave or ripples Fiberon; hour glassing

Dimensional variations or rippling of what should be a smooth surface for the full length

R R A


Composite Wavy/ ripples

Dimensional variations or rippling of what should be a smooth surface.

A A A

A= no more than 3 contact points over entire surface. Must met +/- tolerance for dimensional spec.


Woodgrain A patterned finish on the extrusion that gives the appearance of Woodgrain.

R R A Must not effect fit, function or adhesion

Worm line Wavy lines similar to a worm print.

R A A

B= <0.050”

Two per surface Must not effect fit, function or adhesion

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16.0 Control of Nonconforming Material

Material that does not meet the requirements identified in engineering specifications and or this cosmetic standard are to be identified and segregated to prevent them from being shipped to JELD‐WEN. If the supplier thinks that the product may still be useable, the supplier must follow the DR process as identified in this section.

16.1 Nonconforming Material Reports (NCMR) NCMR’s or an equivalent rejection report needs to be generated to document the nonconformance and disposition.

16.2 Deviation Request (DR) JELD‐WEN has defined specifications and or processes that must be adhered to. Sometimes circumstances occur that may cause material not to conform to defined specifications and processes. Suppliers can contact the JELD‐WEN Buyer to obtain a OP05‐F01 Deviation Request form and submit to JELD‐WEN for review. The submittal is not an approval and nothing is to ship to JELD‐WEN without the approved DR. If DR is approved, the supplier must identify the package with the DR # and attach a copy

of the DR.

17.0 Records

Records of inspection are to be maintained by JELD‐WEN suppliers and be readily available to JELD‐

WEN upon request. Records should be retained for a minimum of 5 years.