General Requirements

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

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

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

Technical Data Sheet

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

  • All TDS and MSDS are documented and filed properly.

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

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

Process Scheme

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

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

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

Production Risk Assessment

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

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

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

Data Collection and Control

Raw Materials

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

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

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

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

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

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

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

Compounding Process

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

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

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

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

  • Compounders are trained to handle non-conforming compounds.

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

Foaming Process

  • Compound temperature are being constantly monitored before and during production.

    Note: Recording every 2 hours

  • Foaming machine minimum CTQ requirements are constantly monitored and are properly recorded.

    1. Main pump output
    2. Mixing head speed
    3. Mixing head pressure
    4. Additive pump dosage

    Note: Every 2 hours

  • Wet foam density are regularly monitored and properly recorded.

    Note: Every 2 hours

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

  • Machine line speed are regularly monitored and properly documented.

    Note: Must be coincide with the requirements established in the process scheme.

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

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

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

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

  • Final foam properties at the end of the line are monitored and are properly documented.

    1. Thickness (every 2 hours)
    2. Width (every 2 hours)
    3. Length (every 2 hours)
    4. Dry density (beginning, middle and end)

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

Table. 2: IGC, CoA, TDS and PS

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

  • Raw material batch number (IGC and CoA)

  • Expiry dates of raw materials (IGC)

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

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

  • Viscosity of liquids (IGC, CoA and TDS)

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

  • Storage and safety instructions of raw materials (TDS)

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

  • Compound recipe (PS)

  • Compound properties (PS)

  • Process parameters (PS)

  • Final foam properties (PS)

Transport, Storage and Handling

  • Raw materials are stored according to TDS requirement

  • Shelf life and FIFO are strictly followed

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

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

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

  • Latex foam are stored and cured for 5 days

  • FIFO of latex foam products are stictly followed.

Maintenance

  • Maintenance plan for the machines and equipment are present.

  • Maintenance routines are well-documented.

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

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