How can the yield of extrusion be improved? The following suggestions are provided for extrusion operators and quality inspectors for reference:
(1) Quality Inspection: Machine quality inspection must adopt a fast, accurate, and rigorous approach. 'Fast' means inspecting promptly and regularly; 'accurate' means being familiar with national standards, internal control standards, as well as the standards of different customers and surface treatments. If necessary, take samples for corresponding surface treatment tests. Misjudgments or acceptance of over-standard parts must be absolutely avoided. If a determination cannot be made under special circumstances, report immediately to the relevant person in charge; 'rigorous' means maintaining a strong stance and strictly enforcing the system.
(2) Extrusion Team Leader: Must not install the wrong mold or write the wrong tracking card; actively conduct quality self-checks, first inspections, and in-process inspections.
(3) Main Machine Operator (Deputy Team Leader): Actively cooperate with the team leader, verify each set of molds, control the three temperature settings, and flexibly manage material flow rates based on different model structures and surface treatments. Routinely check material quality, be responsible for wall thickness, molding precision, crushes or tearing, internal dragging, and accurately calculate whether the material remnants are long enough after cutting extrusions of different specifications into semi-finished products.
(4) Interruption Worker: The interruption worker is also a very important role. Quality problems must be reported immediately to the team leader or deputy team leader. For each set of molds, check the height of the lift on the material outlet, the condition of the graphite blocks, and the high-temperature rollers, as they directly affect the molding quality. Turn on the fans promptly, and check whether the conveyor is running smoothly and effectively. If there are bubbles, oil bubbles, or crushes/tears on the surface of the extrusion, mark them clearly to prevent them from entering the next process.
(5) Straightening Worker (Mixing Materials, Cutting to Fixed Length, Frame Assembly Worker):
Before straightening, each piece of material must be thoroughly inspected for surface quality. Profiles on the cold bed should not be piled too high to prevent scratches and dents. Hollow profiles should use appropriate end plugs to prevent excessive deformation from breakage. If there is an assembly relationship, the actual fitting should be done according to the sample of the corresponding surface treatment model from this batch order, in order to control the straightening elongation rate.
When consolidating materials, note that different surface-treated materials have different consolidation methods. For billets, oxidized sandblasted materials, and 'oxidized electrophoresis glossy materials,' try to place the non-decorative surface facing down or have non-decorative surfaces face each other. Maintain spacing between profiles to avoid rubbing, bumping, scraping, or scratching of the decorative surfaces.
Before cutting to length, consider whether the head and tail scraps are long enough. If a whole piece or batch is found to be too short, immediately notify to pause or halt the machine. After sawing, carefully inspect the profile ends for deformation; if deformation occurs due to saw cutting, the cutting speed can be appropriately slowed down.
For insulating materials (order-specific instructions regarding bending or twisting must be strictly inspected according to customer requirements; if not specified in the order, inspect according to high-precision standards), each piece must pass platform inspection before being framed. Profiles with complex shapes that are easily damaged by frame separators must have each layer separated by flattened tubes. Products requiring strict surface quality must use high-temperature felt to separate each piece, and separators must be placed neatly.
