Introduction
Ensuring consistent quality is paramount in the Deckfab production process. Our processes play an essential role in maintaining these high standards.
Attention to Processes
Each of the Deckfab profiles requires precise specifications regarding tolerance, cooling methods, and quality assurance. Rigorous attention to detail and built in quality checks are integral to our production process.
Orders are efficiently processed and scheduled to meet delivery timelines. Our setters oversee the production lines, ensuring that quality is upheld from the first coil. Initial quality checks in the linishing department assess size, thickness, graining, and colour. Profiles not meeting standards are recycled or reused, and machinery is adjusted as needed to achieve the desired quality.
Throughout the extrusion process, production operators vigilantly monitor for any quality deviations, such as lumps or inconsistencies. Any issues are promptly flagged and corrected. Samples are regularly measured against master samples to maintain our stringent quality benchmarks.
Hourly metre checks, and more frequent checks for complex products, ensure consistent adherence to our quality standards.
Transportation and Communication
During the cooling period and transportation to the linishing machines, production operators implement protective measures to prevent coil damage. Cardboard inserts and uniform pallet arrangements are used to maintain coil integrity.
Quality checks are meticulously documented which enhances accountability. This report details the extent of the quality checks performed and communicates any potential concerns to downstream departments
Finishing the Product
In the linishing department, our linishing machines coarse sand the product to create the characteristic wood-like deep graining. Each coil undergoes comprehensive checks, including measurements of width, caulking, and lip, and colour matching to master samples. We ensure the appropriate level of wood grain and maintain the product’s aesthetic and functional qualities
Stacking on Pallets
At the final stage, the stores department conducts thorough visual inspections and carefully stacks the coils onto pallets. each coil has a cardboard separator to protect the coil edges. This ensures that the PVC coils reach the warehouses and distributors worldwide in optimal condition, ready for use worldwide by deckmakers.