Incoming material control

Quality control begins on the receipt of raw materials such as adhesives and catalysts. The purchase order ordinarily defines the required quality properties of this material. This is accomplished by an actual statement of requirements, or by what is called out in the material specifications. The inspection requirements are normally specified in the material specifications as Quality Acceptance Tests or as Receiving Inspection Requirements.  

Containers The first inspection requirement is normally the condition of the container. The following items should be checked when inspecting the container. 

Damage Physical damage to a container of film adhesive can rupture its sealed wrapper, allowing moisture, dirt, etc., to reach and contantinate the adhesive. Damage can render a pail of liquid measure unusable in automatic measuring equipment. 

Leakage Leakage of liquid adhesive components can change the ratio of the catalyst to the base resin if premeasured kits are involved. It can also result in the receipt of less material than the purchaser needs and is paying for. 

Incoming adhesive material control includes two types of tests, physical properties, such as percent flow, gel time, and percent volatiles, which are 

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Verifying quantities of incoming raw materials Controlling ingredients to the proper proportions... 

Fiber-Optic Probes. Fiber-optic probes provide remote sampling capabilities to Raman instmmentation, are stable, and give reproducible signals. Their historical niche has been in environmental monitoring. More recently these probes have been used in chemical process control and related areas such as incoming materials inspection. 

Health-related institutions again show the future trend in a microcosm. Suitable incineration facilities may determine the ability of such institutions to function effectively in an urban environment. When adequate processes for solid waste and air pollution control by incineration are developed, the use of combustible, one-way trip disposables for all incoming materials can be expected to accelerate. This will result in a decrease in the need for a direct fuel supply. 

Laboratory controls commence with sampling and testing of incoming materials according to written procedures. Some aspects of the tests include identity, quantity, purity, activity, heterogeneity, stability, sterility, and safety. Intermediates and finished products are tested in accordance with preset... 

N. Smola and U. Urleb, Near infrared spectroscopy applied to quality control of incoming material in the pharmaceutical industry, Farmacevtski Vestnik, 50, 296-297 (1999). 

There are two primary methods to reduce the number of trial process conditions and at the same time gain more information from the experiments done. The first method to be discussed is based on design of experiments (DOE). The second method, process science, is an offshoot of attempts to improve quality control on incoming materials. Each has advantages and often they are combined. 

The first step in designing a QMS is determining business needs and the processes required to support the enterprise. Important consideration must be given to ensure that all processes are included in the assessment. The assessment must include all activities that affect product quality at corporate, business, manufacturing, distribution, contractors, or joint venture sites. Processes controlling incoming materials from vendors, laboratory services, contractual support, and other inputs should also be included in the initial assessment. 

Consideration is given to the control exercised at the source and documented evidence of quality conformance provided. All incoming materials are inspected or otherwise verified as to conforming to specified requirements before being released for use to production. This verification is in accordance with the quality plan or documented procedures. All incoming materials released for urgent production purposes are positively identified and recorded in order to permit immediate recall in the event of nonconformance. 

Quality assurance is concerned with maintaining the quality of products to set standards. This embraces the control of incoming materials, the control of compounds produced, the control of manufacturing processes and guaranteeing as far as possible the quality of the final product. Quality assurance schemes utilise physical testing methods as a most important part of their system. In fact most of the standardised test methods are principally... 

Receiving inspection is the first step in the total control program. This generally consists of comparison of what is received to the specification used in developing the purchase order. Acceptance tests on raw materials should be directed toward assurance that the incoming materials are correct and identical from lot to lot. 

Once identified and approved for receipt, all incoming material should be labeled with a receipt date. This date is prominently shown on the container or material while it is in inventory. The approved incoming material should then be stored in a controlled storage facility. Precautions must be taken to ensure that the oldest material is used first and that the shelf life of the product does not expire before it is used. The date stamp on the product is the most reliable method of doing this. 

As with the quality control plan for the formulator described above, acceptance tests on adhesives should be directed toward assurance that incoming materials are identical from lot to lot. However, this plan should also extend to the receipt and control of incoming adherends and other materials used in the bonding process. 

In addition to tests performed on the incoming materials, test specimens may be made to verify the strength of the adhesive joint. The quality control tests should be those that can quickly and accurately detect deficiencies in the adhesive s physical or chemical properties. ASTM lists various test methods that are commonly used for adhesive acceptance. 

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