QUALITY RELATED SERVICES


ATSPL offers quality related services like testing, evaluations, inspection and validation by using in-house as well as outsourced resources.

ATSPL has NABL accredited laboratory in the discipline of Mechanical Testing of Polymers with NABL Certificate Number: T-4131.

Apart from the NABL accredited tests the ATSPL laboratory can also perform specialized testing and characterization owing to the in-house knowledge and expertise in the field of Science and Engineering.

Various Services offered are as below:

1. Polymeric Material Development-



  • Lab-scale and Pilot-scale Twin Screw Extruders set-up

    Polymer based materials are developed on the basis of the performance requirements of the part as well as the processing requirements of the part. Suitable polymer material can be suggested and the specifications of the materials can be suggested on the basis of performance requirements. On agreement of proposed specifications, material can be prepared and sample materials can be provided for testing. Pilot production material along with processing guidelines can be made available for production trials and monitoring of the processing trials cam be done by RTC executives is mutually agreed.

    Materials are also developed on the basis of desired specifications. RTC is capable of developing coloured material in a very short span of time on the basis of a component / standard colour plaque or RAL number.

    With a written agreement of usage of material, RTC can get the .udb file generated for carrying out Mold Flow Analysis helpful for mould design as well as for setting processing parameters.

2. Testing & Characterization of Polymeric Materials



  • Various testing and characterization of polymeric material possible is as below:

    A. Polymer Identification: Identification of polymer / polymers used in a component or material granules by physical and chemical testing and instrumental characterization.

    B. Physical Testing: Specific Gravity, hardness etc.

    C.Mechanical testing: Tensile, flexural and impact properties in temperature range -30o C to 150o C of ASTM and ISO specimen moulded as per the guidelines in these standards. The testing can be done for the specimen provided by the customers or by moulding the specimen as per relevant standards of the material sample provided by the customer.

    D.Thermal Properties: Heat Distortion temperature, Vicat softening point, Ash content.

    E. Burning Behaviour: UL flammability rating as per HB, V2, V0 etc. (Development testing in-house, certification testing – outsourced.)

    F. Flow Properties: MFI, spiral flow in comparison with a material with known flow characteristics for injection moulding.

    G. Shrinkage characteristics – Shrinkage in MD and TD as per ASTM and ISO standards.

    H. Fusion and Crystallization Behaviour – DSC scans with and without interpretation as per customer requirements

    I. Molecular Fingerprints - FTIR scans with and without interpretation as per customer requirements.

3. Components: Inspection, Evaluation and Testing-


  • UTM with temperatures -30o C to 150o C




    For approval of parts by Auto and other OEMs a number of requirements have to be fulfilled. RTC will help of define and propose the requirements if necessary and will support to fulfill the defined / agreed requirements.


    Dimension report and fitment checks:


    • Dimension reports can be generated on the basis of KPSs defined or with respect to the drawings or CAD files
    • Checking fixtures and can be designed and fabricated and the fitment check can be done with the help of checking fixtures
    • Part thickness measurement at desired locations can be done with the help of a profile projector.

    Part level mechanical tests:


    • Specimen can be prepared by cutting from the moulded parts as specified on the drawings / specs
    • Tensile, flexural, impact and HDT testing can be carried out on the specimen cut from the part at desired temperatures.
    • Falling weight impact testing can be carried out at desired locations of the part at desired temperatures.

    Part level chemical / oil resistance:


    • Testing the effect of chemicals, oils, artificial perspiration etc by rubbing on parts specified number of times and measuring gloss & colour before and after.

    Part Level Aesthetics:


    • Testing of scratch resistance by Taber five figure abrasion or Erikson Grid Test
    • Testing for Mar resistance by Erikson grid test; measuring gloss before and after indentation.
    • Colour and gloss at designated locations on the part

    Environmental cycling test:


    Form stability to temperature and/or humidity cycling as per specifications
    • Observing and monitoring changes on surface
    • Checking dimensions before and after cycling
    • Checking fitment before and after cycling.

    Heat Ageing test:


    • Exposing part to specified conditions and observing the part surface for changes.
    • Measuring changes in properties after exposing to desired conditions.

    Volatiles and Fogging:


    • Testing for fogging and VOC as per the desired specs.

    Weathering and changes after weathering:


    • Colour fastness to artificial light, Exposure in Xenon Arc WeatherOmeter, UV WeatherOmeter

    Tackiness development after exposing in oven or WeatherOmeter


    Durability testing:


    • Vibrational durability / Fatigue Testing as per specifications
    • Static and cyclic loading tests.

    4. Support to Quality System-


    • Support to documentation required for PART & Material Approvals - Production Part Approval Process (PPAP)
    • To ensure quality during regular supplies:
      • Control plans and quality system are required
      • Approved method and process of packaging and transportation is required.
    • Support for making Control Plans, Quality Systems etc.

    5. Consultancy: Polymers and Processing-

    • In Areas related to:
    • Polymer Selection for intended applications
      • Composites, Thermosets, Thermoplastics, rubbers...
    • Integration of Polymer based parts to the assembly
    • Finishing /decorating of Plastics based parts
    • Processing of plastics and overcoming processing defects
    • Overcoming defects in painted plastics parts

    6. Knowledge and Skill Enhancement-

    Training in:

    • Polymer (Plastics and Rubber) Materials:
    • Types, Availability, Relative costs
    • Properties relevant for designing & material Selection
    • Properties Relevant for Processing
    • Properties Relevant to Service life
    • Compounds, Blends and Composites

    • Polymer Processing:
    • Techniques for processing Thermoplastics, Thermosetting & Composites Joining Techniques
    • Polymer Testing

    • APQP-PPAP training-
    • Clause 7.3 of ISO / TS 16949 – Product and Process Development.
    • Introduction to Core Tools & AIAG Manuals – APQP, FMEA, MSA, SPC, PPAP.
    • Five Phases of APQP and sessions on each Phase of APQP.
    • Typical structure and reporting methods

    • Process Failure Mode and Effect Analysis-
    • Introduction to Clause 7.3 of ISO / TS 16949 – Product and Process Development, Core Tools (AIAG Manuals – APQP, FMEA, MSA, SPC, PPAP).
    • Brief introduction to each Phase of APQP and 3rd Phase of APQP.
    • Preparation of Process Flow Diagram
    • Preparation of PFMEA document
    • Evolving the Control Plan

    • Measurement System Analysis and Statistical Process Control-
    • Introduction to Clause 7.3 of ISO / TS 16949 – Product and Process Development, Core Tools (AIAG Manuals – APQP, FMEA, MSA, SPC, PPAP).
    • 4th Phase of APQP – Process and Product Validation; Introduction to principles of measurement (Precision, Accuracy, Uncertainty etc.)
    • Variable and Attribute Measurement System Analysis
    • Introduction to Statistics, Process characteristic, Variation, Types of Control chart etc.; Moving Range chart, X-bar – R chart

    • 7 QC Tools & Problem Solving Techniques-
    • Basics of Problem Solving methodologies
    • Discussion on Non-conformity, Correction, Root-cause analysis and Corrective & Preventive Actions
    • Basics of statistics
    • 7 QC Tools
    • A typical example

    • Awareness Training Course on QMS-
    • Evolution of QMS, up to ISO 9001: 2015;
    • 8 Principles of QMS, PDCA cycle,
    • Process Approach,
    • Terminology / Vocabulary and definitions
    • Detailed explanation of Clause Requirements, etc.

    • Awareness Training Course on EMS-
    • Evolution of EMS, up to ISO 14001: 2015;
    • EMS Terminology / Vocabulary and Definitions,
    • Concepts of Environmental Aspects & Impacts,
    • Applicable Legal Requirements – brief introduction,
    • PDCA cycle, Process Approach,
    • Detailed explanation of Clause Requirements, etc.