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Posted on May 5, 2023, in Blogs

Managing the Quality Control Process

Consistent quality is an important part of the Flexiteek and Wilks production process. One that we try hard to maintain throughout the many stages of product production. A crucial factor that determines the quality we achieve is the teamwork amongst the different departments across the business. From sales to production, product development to stores and distribution, the people here play an important part in our business.

Our ATTENTION TO DETAIL

Each unique Wilks profile differs in terms of tolerance, cooling methods, packaging and the process used to ensure consistent quality throughout each and every order. Frequent checks during its production with a real eye on the detail are vital every time.

After an order is placed and processed, it is added to the schedule to be developed in an efficient and timely manner. This is in order to get it to our customers as quickly as possible. The production lines are set, started, and overseen by our setters. One of their main job responsibilities is to ensure that orders are started at a high level of quality. This starts right from the very first coil.

A metre of decking is taken over to the ‘linishing department’ to allow for quality checks on things like size, thickness, graining, and colour. If the requirements for that profile are not fulfilled, the metre is recycled, and then the machine is adjusted to improve the quality and checked again.

Once the extrusion process has started, our Production Operators then start their observations. Looking for any slips in quality, this includes any lumps or inconsistencies. If there are any, these are flagged to the setters, to correct it. Small samples are taken after every coil. This is measured and compared against the master sample, a small sample deemed to be the optimum standard.

Metre checks are conducted every hour and then more frequently for more complex products, to confirm that the quality we expect has not slipped.

TRANSPORTATION AND COMMUNICATION

Production operators also protect the coil for its cooling period and its short journey over the road to our second building to be finished. This is done by inserting cardboard so that the coils sitting on top do not perch on the lower ones resulting in potentially warped coils.

Another way that we ensure coils are undamaged is by ensuring that all coils are lined up and in a uniformed layout on the pallet.

These checks are communicated to other departments and to increase accountability we use a ‘Quality Report’. The Quality Report confirms if the coil has been checked and to what extent. It also creates an opportunity to write notes for potential concern to be passed on for people further down the production journey.

FINISHING THE PRODUCT

Once coiled, decking profiles are sent to the ‘linishing department’. This is where our expert linishers sand the product to create the wood like graining present on the finished product.

It is also where every coil is checked multiple times and in a variety of different ways. For example, we measure the width, caulking and the lip, and check the colour to master samples. Whilst also checking there is an appropriate level of wood grain and liveliness in the finish.

AND OUT THEY GO!

The last stage of a coils journey is in the stores department. This is where the last visual checks will take place and the products will be packaged carefully. This packing process can be different for each profile but all use high quality padding and other means of protection. This enables it to travel to warehouses, boat manufacturers and distributors around the world through our global distributor network.

As you can see from the sheer number of checks completed during the production process for both Wilks and Flexiteek products, we take quality very seriously. And we are, without a doubt, proud of the end results.

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