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QUALITY UPDATE

QUALITY UPDATE. Paul Newell Quality & Systems Manager. WINNERSH NOV 2011. WINNERSH NOV 2011. WINNERSH JULY 2012. 8 SEALED STAINLESS STEEL MIXING VESSELS MIXING VESSELS & RAW MATERIALS WITHIN BUND TO CONTAIN ANY SPILLAGE PUMPS, MOTORS, LIGHTING, FORK LIFT TRUCKS ALL EXD RATED.

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QUALITY UPDATE

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  1. QUALITY UPDATE Paul Newell Quality & Systems Manager

  2. WINNERSH NOV 2011

  3. WINNERSH NOV 2011

  4. WINNERSH JULY 2012 • 8 SEALED STAINLESS STEEL MIXING VESSELS • MIXING VESSELS & RAW MATERIALS WITHIN BUND TO CONTAIN ANY SPILLAGE • PUMPS, MOTORS, LIGHTING, FORK LIFT TRUCKS ALL EXD RATED

  5. MIXING VESSELS • LIQUIDS PUMPED INTO VESSEL FROM FLOOR LEVEL • FEED PIPE INSIDE VESSEL GIVES BOTTOM FILL • SOLID RAW MATERIALS ADDED VIA MANWEIGH HATCH

  6. FIRE TRIANGLE • ALL 3 ELEMENTS NEED TO BE PRESENT FOR A FIRE TO OCCUR • NITROGEN IS USED TO REMOVE OXYGEN FROM MIXING VESSEL & FEED PIPES • GROUNDING & BONDING ARE USED TO MINIMISE SPARK GENERATION • NO FREE-FALL OF SOLVENTS OR RAPID PUMPING

  7. SAFETY FEATURES • NITROGEN GAS USED TO PURGE PIPES & MIXING VESSEL • NITROGEN GENERATOR IN SEPARATE UNIT WITH COMPRESSORS

  8. GROUNDING & BONDING

  9. SAFETY FEATURES • EARTHING STRAPS CONNECTED TO RAW MATERIAL CONTAINERS • NITROGEN GAS ADDED TO RAW MATERIAL CONTAINERS

  10. SAFETY FEATURES • OVERFILL PROTECTION FITTED TO ALL VESSELS • AUDIBLE & VISIBLE ALARM IF NITROGEN PRESSURE IS TOO LOW

  11. ENVIRONMENT PROTECTION • EXTRACTED AIR FROM FACTORY & LABS IS PASSED THROUGH CARBON FILTERS • COMPLIES WITH ENVIRONMENTAL LEGISLATION

  12. ENVIRONMENT MONITORING • DAILY CHECKS ON VOC LEVELS INSIDE FACTORY

  13. CRITICAL SERVICES MONITORING • COMPRESSORS, NITROGEN GENERATOR & EXTRACTION CONTROLLERS LOCATED IN PURPOSE BUILT UNIT • ALL EQUIPMENT CHECKED X2 EACH DAY & RESULTS RECORDED

  14. SAFETY FEATURES • EMERGENCY SHOWER LOCATED ADJACENT TO MIXING AREA • SEPARATE EYEWASH STATION • CHECKED MONTHLY FOR OPERATION

  15. FINISHED GOODS & PACKING

  16. EXTERNAL STORAGE

  17. QC LABORATORY

  18. MAINTENANCE ROOM • STORAGE FOR EQUIPMENT SPARES & TOOLS • BENCHES FOR LIMITED AMOUNT OF REPAIR WORK

  19. STORAGE AREA FOR RETAINED SAMPLES • 1 LITRE SAMPLE OF ALL BATCHES • RETAINED FOR SHELF LIFE OF PRODUCT • GROUPED BY PRODUCT TYPE

  20. FINISHED GOODS STORAGE • ORDER PICKER USED TO REACH TOP OF RACKS • ORDER PICKER FITTED WITH VOC MONITOR • ELECTRONIC GUIDE LINES IN FLOOR TO MAINTAIN CENTRAL POSITION

  21. PALLET WRAPPING • AUTOMATIC STRETCH WRAPPING • WE CAN ALSO WEIGH FINISHED PALLETS ON THIS MACHINE

  22. RAW MATERIAL TESTING • WATER CONTENT OF RESINS & SOLVENTS

  23. RAW MATERIAL TESTING FTIR ON LIQUIDS & SOLIDS VS APPROVED REFERENCE SAMPLE

  24. RAW MATERIAL TESTING • SOLIDS CONTENT OF LIQUID RESINS

  25. RAW MATERIAL TESTING - VISCOSITY

  26. RAW MATERIAL GOODS-IN LABELLING AWAITING INSPECTION CLEARED FOR PRODUCTION USE

  27. MANUFACTURING CONTROLS MIXING VESSELS DEDICATED TO PRODUCT TYPES • TANK 1 – MISCELLANEOUS • TANK 2 – 1B51 FAMILY • TANK 3 – 1B73 FAMILY • TANK 4 – 1A33 FAMILY • TANK 5 – THINNERS & STRIPPERS • TANK 6 – UV40 FAMILY • TANK 7 - 1B31 FAMILY • TANK 8 – 1R32A-2 FAMILY

  28. MANUFACTURING CONTROLS MIXING VESSELS DEDICATED TO PRODUCT TYPES • DEDICATED MIXER FOR WATER BASED GRADES • DEDICATED MIXER FOR GELS • LOW VOLUME PRE-BLEND PRODUCTS MIXED IN DRUMS • FLUSHING REGIME USED FOR ALL MIXING VESSELS & DISPENSING PUMPS TO ELIMINATE POSSIBILITY OF CROSS CONTAMINATION • DEDICATED AREA FOR FILLING OF SYRINGES & CARTRIDGES

  29. MANUFACTURING CONTROLS • BATCH RECIPE SYSTEM UNIQUE TO HUMISEAL • RAW MATERIALS ADDED BY WEIGHT • MIXING VESSELS FITTED WITH LOAD CELLS • ALARM IF RM WEIGHT TARGET EXCEEDED • COMPREHENSIVE BATCH REPORT

  30. FINAL INSPECTION • VISCOSITY (cps @ 25C centipoises) • SOLIDS(% of non-volatiles by weight) • DENSITY OR SPECIFIC GRAVITY (grms/cc)

  31. FINAL INSPECTION • TACK FREE TIME (minutes before coating is touch dry) • APPEARANCE (clear of bits) • FLUORESCENCE (UV tracer is present - or absent if 1B73 LED)

  32. FINAL INSPECTION • PYMS (NEW) - PYROLOSIS MASS SPECTROSCOPY • SAMPLE IS HEATED TO RELEASE VOLATILE CONSTITUENTS • VOLATILES PASS THROUGH A COLUMN • RETENTION TIME IN COLUMN DEPENDS ON CHEMICAL TYPE • MASS SPECTROMETER ANALYSES CHEMICAL STRUCTURE OF EACH INGREDIENT AFTER IT LEAVES COLUMN • DETECTS IF CORRECT INGREDIENTS ARE PRESENT • DETECTS IF ROGUE INGREDIENTS ARE PRESENT

  33. KEY EVENTS 2012 • EXIT FROM CAMBERLEY -JAN • COMPLETION OF EQUIPMENT INSTALLATION – JAN • CREATION OF SOPs FOR MANUFACTURE, DISPENSING, LABELLING & DESPATCH – JAN /FEB • OPERATOR TRAINING – JAN/FEB • CLEANING & VALIDATION OF MANUFACTURING VESSELS - FEB • FIRST PRODN. BATCH – FEB. 1B31 HE8000 • US DOD MIL SPEC AUDIT - MAY • TRIAL BATCH UV40 - JULY • TRIAL BATCH UV40-250 - AUG

  34. WORLD CLASS PERFORMANCE MAXIMUM OF 3.4 DEFECTS PER MILLION (3.4 PPM)

  35. WORLD CLASS PERFORMANCE IF MANUFACTURE 40,000 LITRES PER MONTH, 6 SIGMA MEANS NO MORE THAN 3.4 LITRES REJECTED IN 25 MONTHS

  36. SUMMARY • SAFETY IS TOP PRIORITY • STATE OF THE ART FACILITY & EQUIPMENT • MODERN MANUFACTURING CONTROLS • INCREASED LEVELS OF RAW MATERIAL TESTING • ADDITIONAL PYMS TESTING AT FINAL INSPECTION • CONTINUE TO MONITOR KEY PERFORMANCE INDICATORS • AIM TO CONTINUALLY IMPROVE OUR BUSINESS PROCESSES • SETTING AMBITIOUS 6 SIGMA TARGETS

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