Majors Plastics, Inc

Quality Assurance

Ensuring superior quality and customer satisfaction through rigorous quality assurance practices and continuous improvement

Smartscope Optical Testing

At Majors Plastics, “we are committed to our ISO quality system with a goal of complete customer satisfaction through continuous improvement”.

Our ISO 9001 registration is proof of a disciplined adherence to a system of manufacturing within a quality framework. Utilizing a statistical sampling plan of C=0, we routinely meet or exceed our customer-imposed AQL levels as low as 0.040. To insure high process capabilities in production (Cpk>1.33), we thoroughly assess the critical-to-quality characteristics (CTQ) before a component’s production release.

Impact Testing

Due to our diverse customer base, we have become proficient in various methods of pre-production assessments:

  • PPAP [with control plans, PFMEA, process flow diagrams, warrants, run at rate analysis, etc.].
  • Once in production Installation/Operational/Performance qualifications or IQ/OQ/PQ validations [with sustained sample pilot runs from 8 hours to 3 weeks].
  • DOE studies [analyzing the effects of process variables on key product characteristics.].
  • Capability studies (Cpk, Ppk) of key product dimensions or attributes.
  • First article inspection reports (FAIR) involving multiple samples collected over time.
  • Gauge reproducibility (gauge R&R) studies.
  • Six-Sigma methodologies
A partial list of equipment employed in this effort is extensive:
  • Melt Flow Indicators
  • Moisture Analyzers
  • Ziess Coordinate Measuring Machines
  • OGP Smartscopes (Flash 500’s and desktop)
  • Optical Comparators
  • Spectrophotometers (Perkin Elmer and Hunter handheld)
  • Zeiss Digital Microscope System
  • Hazegard Transparency Testers
  • Gauge Blocks, Micrometers, Height Gauges, Calipers, Granite Plates and Angle Blocks

Particle Contamination Testing

Six-Sigma methodologies—Such methods of product and process assessment, performed early in a new component’s life, helps guarantee a successful product launch. Once volume manufacturing begins on an approved validated product, our statistic-based sampling plans assure that only quality components ship to our customer.

In-process audits of processing variables as well as critical to quality (Key) characteristics are regimentally conducted. Statistical process control (SPC) is employed as a tool to monitor production runs and react to variations before defects are produced. All gauges and measuring equipment used during production are calibrated and traceable to national standards.

High Quality Products

More important than the state-of-the-art equipment used in our operations is the skill of our employees that operate it all to ensure customer satisfaction. These dedicated and experienced individuals diligently check and recheck production in a tireless effort to please our customers.