Latex Special Process Appendix

• Document No. 0001

• Latex Special Process Appendix

• Supplier:

• Conducted on

  Date

• Prepared by: Jose Junior Naraval

• Location
  Address

General Requirements

• All tools used to verify product and process parameters are calibrated.

  Yes

  No

  N/A

• Calibration records of the tools are present, up-to-date and are properly documented.

  Yes

  No

  N/A

• For in-house calibration, workers doing calibration are trained/certified.

  Yes

  No

  N/A

Technical Data Sheet

• All critical to quality raw materials have their own TDS and/or MSDS

  Yes

  No

  N/A

• All TDS and MSDS are documented and filed properly.

  Yes

  No

  N/A

• All requirements stated in the TDS/MSDS are followed.

  Yes

  No

  N/A

• Workers handling the TDS/MSDS are trained to work with the documents and are well-versed in the handling and treatment of raw materials.

  Yes

  No

  N/A

Process Scheme

• Supplier has created a process scheme for each IKEA-produced products.

  Yes

  No

  N/A

• Process scheme are designed to address IKEA's CTQ requirements

  Yes

  No

  N/A

• Workers are trained and strictly adhere to the process scheme.

  Yes

  No

  N/A

Production Risk Assessment

• Supplier has a detailed PFMEA in place for each type of article and for each line/technology.

  Yes

  No

  N/A

• PFMEA are strictly followed and ahered to by everybody involved.

  Yes

  No

  N/A

• Workers are trained to handle potential failures as indicated in the PFMEA scheme.

  Yes

  No

  N/A

Data Collection and Control

Raw Materials

• SBR latex are checked according to the minimum CTQ requirements (%solids, pH and viscosity)

  Yes

  No

  N/A

• Natural latex deliveries are checked according to the minimum CTQ requirements (%solids, pH, viscosity and MST)

  Yes

  No

  N/A

• Soap deliveries or produced in-house are checked sccording to the minimum CTQ requirements (%solids and pH)

  Yes

  No

  N/A

• Vulcanisation system deliveries or produced in-house are checked according to the minimum CTQ requirements (%solids, pH and viscosity).

  Yes

  No

  N/A

• Gelling agent deliveries or produced in-house are checked according to the minimum CTQ requirements ( %solids and pH).

  Yes

  No

  N/A

• Every batch of raw materials delivered are checked and are properly recorded.

  Yes

  No

  N/A

• Workers tasked to receive incoming raw materials are trained on how to handle deliveries including non-conformances.

  Yes

  No

  N/A

Compounding Process

• Actual amounts of materials added in the compound are recorded and monitored.

  Yes

  No

  N/A

• Maturation time of every batch are stricly adhered and are properly recorded.

  Yes

  No

  N/A

• Compound CTQ requirements (%solids, pH and viscosity) are checked before use.

  Yes

  No

  N/A

• Procedures are in place to handle non-conforming compounds.

  Yes

  No

  N/A

• Compounders are trained to handle non-conforming compounds.

  Yes

  No

  N/A

• Actions taken to any non-conforming compounds are well-documented and have complete traceability.

  Yes

  No

  N/A

Foaming Process

• Compound temperature are being constantly monitored before and during production.<br><br>Note: Recording every 2 hours

  Yes

  No

  N/A

• Foaming machine minimum CTQ requirements are constantly monitored and are properly recorded.<br><br>1. Main pump output<br>2. Mixing head speed<br>3. Mixing head pressure<br>4. Additive pump dosage<br><br>Note: Every 2 hours

  Yes

  No

  N/A

• Wet foam density are regularly monitored and properly recorded.<br><br>Note: Every 2 hours

  Yes

  No

  N/A

• Gelling time at normal environment temperature is monitored and well-documented.

  Yes

  No

  N/A

• Machine line speed are regularly monitored and properly documented.<br><br>Note: Must be coincide with the requirements established in the process scheme.

  Yes

  No

  N/A

• Knife opening is properly set befire production and is well-documented.

  Yes

  No

  N/A

• Steam oven temperature is regularly monitored and is pripely recorded.

  Yes

  No

  N/A

• Drying oven temperature is regularly monitored and is properly recorded.

  Yes

  No

  N/A

• Foam shrinkage are regularly monitored, documented and available for the operators as reference for process control.

  Yes

  No

  N/A

• Final foam properties at the end of the line are monitored and are properly documented.<br><br>1. Thickness (every 2 hours)<br>2. Width (every 2 hours)<br>3. Length (every 2 hours)<br>4. Dry density (beginning, middle and end)

  Yes

  No

  N/A

• Foaming operators are trained to handle the line including troubleshooting production problems and handling non-conformances.

  Yes

  No

  N/A

Table. 2: IGC, CoA, TDS and PS

• Raw material article number (IGC, CoA, TDS/MSDS and PS)

  Yes

  No

  N/A

• Raw material batch number (IGC and CoA)

  Yes

  No

  N/A

• Expiry dates of raw materials (IGC)

  Yes

  No

  N/A

• Solid content of raw materials (IGC, CoA and TDS)

  Yes

  No

  N/A

• pH of all dispersions and solutions (IGC, CoA and TDS)

  Yes

  No

  N/A

• Viscosity of liquids (IGC, CoA and TDS)

  Yes

  No

  N/A

• MST of natural latex (IGC, CoA and TDS)

  Yes

  No

  N/A

• Storage and safety instructions of raw materials (TDS)

  Yes

  No

  N/A

• Cleaning instructions and materials used (TDS/MSDS and PS)

  Yes

  No

  N/A

• Compound recipe (PS)

  Yes

  No

  N/A

• Compound properties (PS)

  Yes

  No

  N/A

• Process parameters (PS)

  Yes

  No

  N/A

• Final foam properties (PS)

  Yes

  No

  N/A

Transport, Storage and Handling

• Raw materials are stored according to TDS requirement

  Yes

  No

  N/A

• Shelf life and FIFO are strictly followed

  Yes

  No

  N/A

• Treatment of non-conforming/expired materials are properly handled, well-documented and have full traceability.

  Yes

  No

  N/A

• Latex foam are stored in areas free of solvent-based materials that might contribute to increasing its VOCs or odour issues.

  Yes

  No

  N/A

• Latex foam are stored in areas where direct exposure to sunlight, heat and water are minimized.

  Yes

  No

  N/A

• Latex foam are stored and cured for 5 days

  Yes

  No

  N/A

• FIFO of latex foam products are stictly followed.

  Yes

  No

  N/A

Maintenance

• Maintenance plan for the machines and equipment are present.

  Yes

  No

  N/A

• Maintenance routines are well-documented.

  Yes

  No

  N/A

• Workers are trained to the adhere in thr maintenance plan.

  Yes

  No

  N/A