Factory Production ontrol Manual: FP

CE MARKING WITHIN UK

Windows and External Doorsets

in accordance with EN 14351-1:2006 + A1:2010

Factory Production Control Manual

for

Finesse Windows Ltd

39 Melchett Road

Kings Norton Business Centre

Kings Norton

Birmingham

B30 3HP

• Factory Production Control Manual: FPC

Issued under the authority of the Management Representative:

Russell Bridge – Managing Director

__________________________

Date of issue: 15/04/2020

Document issue number: 7


1) Introduction

This Factory Production Control (FPC) manual documents the processes and procedures involved with the manufacture of win-dows and external pedestrian doorsets without resistance to fire and/or smoke leakage characteristics to meet the require-ments of EN 14351-1 for CE marking of the finished product.

The FPC is approved and issued under the responsibility of Russell Bridge Managing Director who shall ensure that it is availa-ble to staff where it is relevant to their work and that they are familiar with it.

2) Quality System

The FPC System comprises of the following documents:

Factory Production Control Manual

It is the responsibility of all staff to identify any errors or omissions in the FPC and notify Russell Bridge who will undertake a review and make amendments if required.

2.1) Control of documents

It is the responsibility of Russell Bridge ensure that all FPC system documents conform to the requirements of EN 14351-1.

Controlled copies of FPC Manual and any relevant procedures and standards are maintained on file, the distribution and loca-tions are referenced below:

Any changes to the FPC shall first be reviewed and approved by Russell Bridge. The updated FPC manual will be identified by the Document Issue No: in the header (sequential number starting at 1 for the first issue) and the relevant staff informed of the change.

Obsolete documents shall be removed from circulation and a copy retained for a minimum of 2 years.

No member of staff shall alter the FPC documents in any way. However, if they think that changes are required, they shall in-form Russell Bridge who shall consider the proposal and make any necessary changes.

File No Issue No Description Location

1 FPC Manual Russell Bridge Office







2.2) System review

An initial inspection of the factory and FPC was undertaken by Russell Bridge and the results recorded. This inspection verified that:

• relevant procedures as required by EN 14351-1 have been documented;

• suitably qualified personnel carry out the manufacturing and test processes;

• appropriate manufacturing and test equipment is available to ensure that products are manufactured in accordance with EN 14351-1 and FPC documented procedures;

• regular checks for accuracy are carried out on manufacturing and test equipment in accordance with the FPC documented proce-dures;

• processes are carried out in accordance with the FPC documented procedures;

• results from the ITT are available to establish compliance of performance with samples assessed during FPC;

• a procedure exists for dealing with non-conformity of components and products.

Continuous surveillance and regular internal reviews are undertaken of the FPC system to ensure that it continues to meet the requirements of EN 14351-1 and the needs of the business.

Internal reviews are conducted annually by Russell Bridge. The Managing Director shall allocate auditors who are the most appropriate to undertake reviews of the activities, areas and associated documents to be assessed. A record of the audit is written which identifies areas of non-conformance and observations with recommendations for improvement.

Where corrective and/or preventive action is required, this shall be recorded and actioned within an agreed period.

The internal reviews will as a minimum check and record that:

• Documented processes are being carried out in accordance with the documentation;

• Tests and/or inspections, in line with the ‘test plan’ for non-finished and finished products, demonstrate that the same values are achieved as the product(s) submitted to ITT;

• Random checks are carried out on the equivalence of the manufactured product with the product(s) submitted to ITT.

• Non-conformances, comments or recommendations from previous internal reviews have been satisfactorily resolved;

• Any significant changes in the FPC (including modifications to the manufacturing process) have been identified and their poten-tial effect on the conformity of the windows/doors has been assessed;

• Any change of the raw materials, component(s) or supplier(s) used has been identified and their effect on the conformity of the finished windows/doors has been assessed.


3) Organisation

3.1 Management representative

The manufacturer has appointed the Production Manager to be the Management Representative for the manufacturing unit at Finesse Windows Ltd. The Management Representative is responsible for the conduct and supervision of factory production control procedures.

The Management Representative is also responsible for implementation and maintenance of this manual.

3.2 Personnel Key personnel:

Managing Director: Responsible for overseeing the whole Factory Control Process, key responsibilities include:

Creating this version-controlled document and its distribution

Continual inspection and monitoring of process to ensure its relevance

Ensuring resources are made available to address any issues as they arise.

Production Manager: Responsible for eliminating instances of recurring problems, ensuring that all manufactured products conform to the latest version of ‘WINDOW & DOOR SPECIFICATIONS FINESSE V10 30/11/17’.

Factory Supervisor – responsible for continual quality control of manufactured products, for flagging up any issues resulting in non-conforming product to the Installation & Manufacturing Director. Ensuring that all machines critical to the manufacture of windows & doors are maintained to ensure that products are manufactured within our tolerances.


4) Scope of Products and Initial Type Testing

Windows & Doors covered within the scope of this factory control process:

Finesse Thermal Guard A casement windows

Tilt & Turn windows – window purchased but glazed by Finesse

Finesse Single resi and Double resi doors

Palladio Doors - door purchased but framed by Finesse

Patio doors - door purchased but glazed by Finesse

Bi-folding doors (Aluminium) door purchased but glazed by Finesse

Slide & Swing doors (UPVC) door purchased but glazed by Finesse

a) Safety Devices

Load-bearing capacity of safety devices – if used, the safety device will be able hold the leaf, casement or sash in place for 60 seconds when 350 N are applied. The threshold strength shall be demonstrated by Initial Type Testing (ITT) carried out by a test facility which is a Notified Body. See Project ref: W13207-2 carried out by notified body: Buildcheck.

b) Thermal Transmittance

Thermal transmittance shall be demonstrated by Initial Type Testing (ITT) of u-value either by calculation to EN ISO 10077-1 or EN ISO 10077-1 and EN ISO 10077-2, or hot box testing to EN ISO 12567-1 or EN ISO 12567-2. Calcula-tions/tests will be carried out by a Notified Body. Any changes to frame profile or glazing will require further ITT and any changes to frame material or weather stripping may require further ITT.

c) Dangerous Substances

All materials used in the window or doors listed above are not liable to emission or migration into the indoor environ-ment during normal use which is potentially dangerous to hygiene, health or environment. See supporting evidence containing declarations made by suppliers of components.

ITT reports will be retained for at least ten years after manufacturing of the product has finished.


5) Customer Ordering

The order processing for Finesse Windows Ltd is detailed below:

The process below demonstrates the method we follow to ensure the products that are specified at the point of sale are manu-factured and installed in the correct way. All the examples listed relate to real example Finesse Windows Contract Number: 16417 – customer name : Foster

Orders are received into the business via a printed contract (see appendix 1 – contract). The contract states clearly the specifica-tion of the product. Two copies of the contract are printed at point of sale – one is retained by the customer – the other is brought back to Finesse Windows Ltd and presented to Sarah Perry who controls Reception area.

The specification of product is stated by the salesman based upon the customer’s requirements.

1) “Elegance” specification. A-rated, fully steel reinforced.

• The exact component specification of Elegance products is dictated within document named ‘WINDOW & DOOR SPECIFICATIONS FINESSE V10 30/11/17’. (appendix 2) This is a version-controlled document which the Managing Director is responsible for maintaining & distributing.

• The production software we use is ‘Evolution’ provided by ‘Business Micros’. Evolution has been set up to reflect the specification detailed in ‘WINDOW & DOOR SPECIFICATIONS FINESSE V10 30/11/17. Therefore, when you choose a specification of window within ‘Evolution’ the correct manufacturing specification is automatically generated as well as the correct glass order to satisfy that build re-quirement. We only have one specification – A, therefore it is not possible to make a window destined for domestic use outside of this scope.

The order is processed by the accounts & management systems manager and it is then compiled into a brown file and passed to the Pro-duction processor who then double checks all items to be ordered or manufactured against the survey and the original sales contract. The nominated Production processor then releases the order to be manufactured and orders the glass accordingly from our approved list of glass suppliers named within Buildcheck’s audit process.

• The works order is passed to Production who are responsible to fulfil the order via the team in the factory. This is done by handing over a ‘batch’ of labels and a floppy disc. The floppy disc contains info to dictate the types and lengths of each piece of profile to be cut. The labels are applied to each piece of profile as they come off the saw. The labels describe the rating of each product:

Elegance A-rated spec = white label with Black writing.


6) Specification and verification of incoming materials / components

Goods in are received into the building by the Supervisor primarily, or any of his team in his absence. Goods are checked in terms of their specification against the purchase order by the Supervisor or his team. Visual checks are made at this stage to ensure that the quality of the goods is acceptable and if so, the delivery note is signed, and a copy is placed into the in-tray in the account’s office.

If goods are deemed to be faulty upon inspection, the delivery note is marked as such and a decision is made as to whether the goods should be returned immediately or placed in the Quarantine area at the rear of the factory – this area is clearly labelled ‘Quarantine’.

The Supervisor or a member of his team is responsible to visually check the labels on incoming glass sealed units to ensure that the correct specification of glass has been delivered. This is achieved by matching the glass spec to the type of window that is being manufactured.

For regular occurrence of faulty materials or components, FINSOP001 – Suppliers Non-Conformance report is issued and sent to supplier for their report. This is then monitored and reviewed after rectification of the problem or finding a root cause.

7) Manufacturing

Production Management “link” based master sheet is located on the shared drive, accessible for all Finesse Windows author-ised employees. This accommodates the control of Manufacturing Processes, Quality, Health & Safety and Equipment. All oper-ations are processed in accordance to specific SOP’s (Standard Operating Procedures).

S:\BGK BULLETPROOF GATEKEEPER PROCEDURES MASTER\PRODUCTION MANAGEMENT

Production planning and organization is done in accordance to FINQD010 - Factory Capacity workout and FINQD011 - Weekly Production Sheet. These documents are used to ensure smooth and trouble-free workflow to meet installation deadlines. FINQD011 gives the production supervisor planning and prioritizing opportunity to avoid any delays or missing products.

The manufacturing of Windows and/or Doorsets for Finesse Windows Ltd is detailed below:

The ‘Evolution’ software we use which is provided and maintained by Business Micros this holds the bill of materials for each type of window we manufacture. The Accounts & Management Systems Manager inputs the details recorded from the tech-nical survey into Evolution and a works order is created. A batch of works orders is collated, and floppy discs are produced con-taining all the instructions required to cut profile to fulfil that batch of window & doorsets. The floppy disc along with a corre-sponding batch of stickers is passed to Production to start the manufacturing process.

Ref. FINSOP002 – Job processing after survey

Ref. FINSOP003 – Batch labels and disk for production

See example of completed works order (appendix 3)


Manufacturing 1) FINSOP010 -Picking and Cutting. The floppy disc informs the types of profile and lengths of each that need to be cut. The Saw operative follows the instructions from the disc and cuts the batch of profile. Each window or door within the batch has an assigned bin number and the operative ensures that the profile cut is placed into the correct bin to facilitate moving on to the next stage of production. Crucially, each individual piece of profile will have a sticker applied to it before it is placed in the correct bin. The sticker holds all the information required to dictate the type of window that it is. At this stage a visual check of the profile quality is performed together with cut size check. Machine calibration at the beginning of cutting each week is FINQD005 – Cut piece calibration. Another operation performed is marking up profiles for transom or mullion placement, reference guides FINQD006 & FINQD007 for transom measuring guides.

Manufacturing stage 2) FINSOP011 & FINSOP014 – Sash and Frame Prepping.

Each section of profile that has been cut will need to be reinforced with steel and have drainage applied to it depending on the type of profile it is. The specification and location of steel is dictated by ‘WINDOW & DOOR SPECIFICATIONS FINESSE V10 30/11/17. Also, within this stage of production any reverse butt welds are made and cleaned in readiness for the next stage ref. FINSOP013 – Single Welding

Manufacturing stage 3) FINSOP012 - Welding. Each length of profile which has now been reinforced and had drainage applied to it and been reverse butt welded if necessary is joined to the other lengths in its bin via the process of fusion welding. A double or triple or Quad welder is used to fuse together the corners of the windows & doors forming a solid join.

Manufacturing stage 4) FINSOP014 – CNC Corner Cleaning. Each welded frame passes through the ‘corner cleaner’ to clean the welded joint and to apply a neat groove.

Manufacturing stage 5) FINSOP020 & FINSOP021 – Sash and Frame Hardware Assembly.

Each sash and frame have the following applied to it: Hinges, handles, locking mechanism, locking keep, restrictor. At this point the operator will add the correct BFRC label to the window. The production label dictates the type of window it is which informs the operator as to the correct BFRC label to apply.

Manufacturing stage 6) FINSOP022 – Beading Assembly. Each sash and frame is beaded individually so that a tight fit is guar-anteed between the internal rebate of the frame and the glazing bead. Top and bottom beads are cut straight, side beads are dressed over the straight cuts using a miller to form the featured ends.

Manufacturing stage 7) FINSOP023 – Final Assembly (Hanging). Each frame and sash is then finished by hanging the correct sashes in the correct frames.

Intermediate Inspection - Factory Boards: At each stage of production it is the operative’s responsibility to check the product for damage or non-conformity. If a product is found to be faulty a circle is drawn around the problematic area and the product is then removed from the workbench and placed into the rack for ‘intermediate inspection’ by the factory supervisor. At each stage Factory boards are in place to reflect current or prior quality issues. Each factory board contains Operation Title, Regular Inspection List, Visual Quality Awareness and Continuous Improvement Sheet. This is monitored on monthly basis and is part of Production Monthly Monitoring FINM001.


FINQD004 - Final Quality Inspection: At the end of the manufacturing process the factory supervisor or a member of his team is responsible to sign off each window or door set on the weekly production sheet. By doing so we are declaring that the product is fit to leave the factory and to be installed, it is also at this stage that the factory supervisor or a member of his team checks that the correct BFRC label has been affixed.

Each window with “PASSED” product will receive a label for clear recognition. Faulty products are returned to production for rectification into designated areas, depending on the extent and type of fault.

Control of Non-conforming manufacturing products Intermediate Inspection: at this stage – following the final quality inspection, The Factory Supervisor will make a decision as to

the seriousness of the problem. The product may be repaired / re-worked or re-made from the start.

Final Inspection: at this stage – The Factory Supervisor will decide as to the seriousness of the problem. The product may be repaired / re-worked or re-made from the start. We aim to have zero defects by this stage because any issues should have been eliminated during the ‘intermediate inspections’ taking place throughout the process.

On a quarterly basis – The factory supervisor reports any repeat issues of non-conforming products at either inspection stage. If an issue is repeatedly occurring, it is deemed to be a significant non-conformity problem and is elevated to be dealt with via a ‘FINQD003 - Internal Non-Conformance report’.

All significant non-conformances are reported to the Managing Director for completion of a management report. The following procedure outlines the process.

1. Where a problem is uncovered (including but not limited to a complaint and any other issue found during internal

auditing) or a deviation from the established practice it will be recorded on a management report form and retained for processing – FINQD003 – Internal Non-Conformance Report

2. Remedial action to resolve the immediate problem will be taken, where necessary, and any product that is still non-conforming will be identified and it will be ensured that it cannot be released.

3. The non-conformity will be processed appropriately, and a record kept of corrective actions required to clear the non-conformity and any preventative measures to prevent recurrence.

4. All non-conformities will be actioned in a timely manner.

5. A file of non-conformities will be maintained which identifies their status including highlighting those which are over-due. Regular review on non-closed non-conformance reports is implemented into monthly quality monitoring sheet FINM001. Those that are overdue will be progressed with the relevant person. The records will be kept for at least 5 years.

6. Scrap record – in a scenario where the finished product cannot be rectified and replacement profiles are necessary,

internal scrap record FINQD002 is filled and handed to Production Manager. The results of the scrap report are trans-ferred to scrap occurrence record – FINQD008 to identify problem areas for future improvements.

7. All internal non-conformance reports are kept in directory.


Equipment All equipment used at Finesse Windows Ltd is recorded on the main equipment list FINEQ100 – Equipment register. Each piece of equipment is identified with FINEQ number. This controls the equipment register together with necessary equipment servic-ing and maintenance procedures. Dedicated maintenance sheets FINMS are located within machining area and are filled in on a weekly basis. They are handed to the production manager monthly. Appropriate safety documents to use the hazardous ma-chinery reflect identification of all equipment.

Testing: Finesse Windows does not utilise testing equipment – inspections are made using digital reads on machines and visual inspections of finished goods.

Manufacturing: Double headed and triple headed welders are inspected daily to make sure they are operating within their optimum defined temperatures.

The overall widths and heights of finished window and doorsets are taken during and at the end of the manufacturing process. A tolerance of +/- 2mm per Weld is allowed in most areas, however tighter tolerances are in place in different circumstances. Any recurring issues are dealt with via the non-conformity process.

Labelling and marking

Windows: Each finished, energy-rated window will carry a label showing the following information:

Finesse Windows Ltd – BFRC license number – CE mark

This label is affixed to the rebate of the open sash in the window. If the window does not have a sash, the label will be applied to the internal glazing rebate.

Doors: Each finished door will carry the CE mark on the accompanying documentation e.g. within the receipt for payment.

The CE Mark shall:

Consist of the initials 'CE' taking the following form:

OR

If the CE conformity marking is reduced or enlarged the proportions given in the above graduated drawing must be respected.

The CE marking must have a height of at least 5mm.


Where the manufacturer does not have third party certification, the CE Mark shall include (where the manufacturer does have third party certification the certification body should supply the necessary information):

Name and registered address or identifying mark of the manufacturer;

Unique identification reference of the window/door;

Reference number of the declaration of performance;

Last two digits of the year in which the CE Mark was affixed;

Reference to the harmonised standard, ie EN 14351-1:2006+A1:2010;

Description of the product, including generic name, material, dimensions etc and intended use.

In addition, information on the relevant performance characteristics of the product will need to be included on the CE Mark. Where characteristics are not relevant, ‘npd’ (no performance determined) will be used.

Example CE marking information

When compliance with the conditions in Annex ZA of EN 14351-1 is achieved, the manufacturer is required to produce a Declara-tion of Performance (see Appendix for a template) which shall be either issued with the window/door or readily available. This shall include:

Reference number of the declaration of performance;

Name and address of the manufacturer, and place(s) of production;

CE Marking, consisting of the CE Marking symbol given in Directive 93/68/EEC

(Where manufacturer has third party certification, the certification body’s identification number will be in-

cluded under the CE Mark)

Company Name and Address

12

Name and registered address of the manufacturer

Last two digits of the year in which the marking was affixed

EN 14351-1:2006+A1:2010

Type XYZ

External pedestrian doorset intended to be used in do-mestic and commercial locations

Declaration of Performance: XXX

Load-bearing capacity of safety device: Threshold value

Thermal transmittance: XX W/m²K

Dangerous substances: None

Number of European Standard with year of publica-tion

Product ref/serial number/identifying name

Description of intended use

Issue/ref number of associated Declaration of Perfor-mance

Information on the level or class of the performance declared


Declared performance against the essential characteristics as determined in BS EN 14351-1;

Name and position of the person empowered to sign the declaration on behalf of the manufacturer.

For your procedure describe:

How each unit / batch is identifiable and traceable through documentation and/or marking/labelling.

The process for CE marking of the finished window or doorset. This should include how it is ensured the correct mark is applied to the right window/door and where it is to be applied (an example of the mark/label could be included).

Which information is accompanying the product when delivered to the client (label on product or adjoining paper work should as a minimum contain the following: information regarding intended use together with instructions for, handling, installa-tion, maintenance and care of the products). Include samples of delivery notes, accompanying instructions and or labels.

Training of personnel

All staff tasked with ensuring compliance with this factory control process will be trained in order to be able to fulfil their role.

Training for the process overall is facilitated by the Managing Director. This can take the form of a one to one meeting or via a structured session involving all relevant members of staff. Training for factory operatives is delivered by the factory supervisor.

Skills levels for production operators are recoded in FINQD050 – Skills Matrix.

Regardless of the trainer, all training details are recorded on a training form and kept for a minimum of 5 years in a ‘staff train-ing’ folder which is kept in the Managing Director’s office.


Appendices

Supporting evidence

The supporting evidence will be required as part of the FPC System. It is not a requirement to keep them with the FPC Manual and can therefore be kept separately.

Copies of Initial Type Testing reports for type tests/desktop assessments, proving compliance with EN 14351-1.

The standard lists the possible performances characteristics which can be declared against and Annex ZA of the Standard defines the essential characteristics which have to be included in the declaration of performance – there are eleven for doorsets and eight for windows (see Declaration of Performance templates).

However, within England and Wales there are 3 (or 4) characteristics that have to be declared against, they are:

1. Dangerous substances (COSSH)

2. Load-bearing capacity of safety devices*

3. Thermal transmittance (U-values)*

Ability to release (only required where panic devices are fitted to doorsets)*

* Initial type testing required which must be carried out by a Notified Body.

Letter(s) of permission to use any evidence/report in conjunction with the CE Marking which is not in your company name.

Training Records of relevant staff.

Equipment Calibration and Maintenance Records.

CE Mark and Declaration of Performance


EC DECLARATION OF PERFORMANCE

(System 3)

Issue No: XXX

XYZ Doors Ltd

XYZ XYZ

This document declares that the product:

XYZ door (identifying name/product references/serial numbers)

System Description: XXXXX

External pedestrian doorset intended to be used in domestic and commercial buildings, conforming to the product requirements of BS EN 14351-1:2006+A1:2010 Annex ZA

This declaration of performance is issued under the sole responsibility of XYZ Doors Ltd.

Signed on behalf of XYZ Doors Ltd:

Signature: ……………………………………

Name and Position: ………………………………………………..

Date: ….……………………..

Essential Character-istics

Performance Test Standards Name, Address and

Notified Body No of Test Laboratory

Test report reference and issue date

Watertightness npd BS EN 1027 N/A N/A

Dangerous substances None BS EN 14351-1: 2006+A1:2010

N/A In house declaration

Resistance to wind load npd BS EN 12211 N/A N/A

Impact resistance npd BS EN 13049 N/A N/A

Load-bearing capacity of safety devices

Pass BS EN 948 NB name, address &

number Ref XXXX1

Height (mm) npd BS EN 14351-1: 2006+A1:2010

N/A N/A

Ability to release npd BS EN 179 and BS EN

1125 N/A N/A

Acoustic performance npd BS EN ISO 140-3 N/A N/A

Thermal transmittance XX W/m².k

EN ISO 10077-1 & EN ISO 10077-2 (or EN ISO

12567-1 and prEN 12567-2)

NB name, address & number

Ref XXXX2

Radiation properties npd EN 410 N/A N/A

Air permeability npd BS EN 1026 N/A N/A


EC DECLARATION OF PERFORMANCE

(System 3)

Issue No: XXXX

XYZ Windows Ltd

XYZ XYZ

This document declares that the product:

XYZ window (identifying names/product references/serial numbers)

System Description: XXXXX

For domestic and commercial buildings, conforming to the product requirements of BS EN 14351-1:2006+A1:2010 Annex ZA

This declaration of performance is issued under the sole responsibility of XYZ Windows Ltd.

Signed on behalf of XYZ Windows Ltd:

Signature: ……………………………………

Name and Position: ………………………………………………..

Date: ….……………………..

Essential Charac-teristics

Performance Test Standards Name, Address and Notified Body No of

Test Laboratory

Test report reference and issue date

Watertightness npd BS EN 1027 N/A N/A

Dangerous substances None BS EN 14351-1: 2006+A1:2010

N/A In house declaration

Resistance to wind load

npd BS EN 12211 N/A N/A

Load-bearing capacity Pass BS EN 948 NB name, address & Ref XXXX

Acoustic performance npd BS EN ISO 140-3 N/A N/A

Thermal trans-mittance

XX W/m².k EN ISO 10077-1 & EN ISO 10077-2 (or EN

ISO 12567-1 and prEN

NB name, address & number

Ref XXXX

Radiation properties npd EN 410 N/A N/A

Air permeability npd BS EN 1026 N/A N/A

Factory Production ontrol Manual: FP

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