CE Approved

CE MARKING WITHIN UK FOR COMPOSITE DOORS      

External Doorsets in accordance with EN 14351-1:2006 + A1:2010 Factory Product Control Manual

for

              Rockdoor Ltd
              Partnership Way
              Shadsworth Industrial Estate
              Blackburn
              BB1 2PT

Issued under the authority of the Management Representative:

Darren Chesney         Company Founder

Date of issue: 1 July 2013, Document issue number: 1

  1. Introduction

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

The FPC is approved and issued under the responsibility of Quality manager who shall ensure that it is available to staff where it is relevant to their work and that they are familiar with it.

  1. 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 Quality manager who will undertake a review and make amendments if required.

2.1  Control of documents

It is the responsibility of Quality manager to 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 and stored on the server with open read only access. The quality manager only has editing permission to the FPC.

Any changes to the FPC shall first be reviewed and approved by Darren Chesney.  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.

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

2.2  System review

An initial inspection of the factory and FPC was undertaken by the Quality Manager 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 procedures;
  • 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. The Quality manger 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;
  • 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 potential 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.
  1. Organisation

3.1  Management representative

The manufacturer has appointed Pete Pollitt to be the Management Representative for the manufacturing unit at Rockdoor Partnership Way Blackburn.  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.

  1. Scope of Products and Initial Type Testing

French Door (Please click here for DOP - Declaration of Performance)

  • 50mm Thick slab
  • Carbon Fibre reinforcing
  • Planitherm Total +
  • 22mm Units
  • Argon Filled
  • Edgetherm Fs spacer bar
  • 70mm 5 chamber outer frame
  • Re cycled Pvc reinforcement
  • Aluminium Threshold
  • Aluminium centre trim
  • Thermal transmittance: 1.6 W/m²K
  • Dangerous substances: None

Ultimate Door (Please click here for DOP - Declaration of Performance)

  • 50mm Thick slab
  • Carbon Fibre reinforcing
  • Planitherm Total +
  • 22mm Units
  • Argon Filled
  • Edgetherm Fs spacer bar
  • 70mm 5 chamber outer frame
  • Re cycled Pvc reinforcement
  • Aluminium Threshold
  • Thermal transmittance: 1.6  W/m²K
  • Dangerous substances: None

Ultimate Classic Door (Please click here for DOP - Declaration of Performance)

  • 50mm Thick slab
  • Carbon Fibre reinforcing
  • Planitherm Total +
  • 22mm Units
  • Argon Filled
  • Edgetherm Fs spacer bar
  • 70mm 5 chamber outer frame
  • Re cycled Pvc reinforcement
  • Aluminium Threshold
  • Thermal transmittance: 1.6  W/m²K
  • Dangerous substances: None

Stable Door (Please click here for DOP - Declaration of Performance)

  • 50mm Thick slab
  • Carbon Fibre reinforcing
  • Planitherm Total +
  • 22mm Units
  • Argon Filled
  • Edgetherm Fs spacer bar
  • 70mm 5 chamber outer frame
  • Re cycled Pvc reinforcement
  • Aluminium Threshold
  • Aluminium and Rubber centre trim
  • Thermal transmittance: 1.6  W/m²K
  • Dangerous substances: None

S/E/C Door (Please click here for DOP - Declaration of Performance)

  • 44mm Thick slab
  • Aluminium reinforcing
  • Float
  • 18mm Units
  • Air Filled
  • Edgetherm Fs spacer bar
  • 70mm 5 chamber outer frame
  • Re cycled Pvc reinforcement
  • Aluminium Threshold
  • Thermal transmittance: 1.6  W/m²K
  • Dangerous substances: None

Glazing with NO DESIGN (Please click here for DOP - Declaration of Performance)

  • Double glazed
  • Thermo bar
  • Argon
  • Panabel A / Float glass
  • Thermal Transmittance: 1.5W/m2K
  • Dangerous substances: None

Glazing with DESIGN with Clear backing glass (Please click here for DOP - Declaration of Performance)

  • Double glazed
  • Thermo bar
  • Argon
  • Planabel A / Float glass
  • Thermal Transmittance: 1.5W/m2K
  • Dangerous substances: None

Glazing with DESIGN with a Patterned backing glass (Please click here for DOP - Declaration of Performance)

  • Triple  glazed
  • Thermo bar
  • Argon
  • Float / Planabel A / Float glass
  • Thermal Transmittance: 1.5W/m2K
  • Dangerous substances: None
  1. Customer Ordering

The order processing for Rockdoor is detailed below:

  • All orders are entered into the computer system either directly by our customer or by the sales office in both cases the customer receives a confirmation of the order which includes all the manufacturing details.
  • The computer system can only configure an approved door specification and a comprehensive bill of materials which relates directly to every component used in the final door is created.  Every door is issued with a unique Id number which is used for tracking. The Id number is stored on the computer system with the exact manufacturing details for the relevant door.        
  • The bill of material is used by the computer system to generate manufacturing instructions on labels to specific areas within the factory. The labels are bar coded and are stuck on to the relevant part of the door.
  • The computer also creates list which are used to assemble the parts together most assemblies are verified with a bar code scanner which then updates the lists.

    Specification and verification of incoming materials / components

Every component used within the manufacturing process has an agreed specification before it is entered onto the computer system. Purchase orders are generated by the computer system and on receipt of the goods at Rockdoor are placed into a quarantine area before they are checked for conformity. If accepted, the stock is then allocated to the relevant stock location. 

  1. Manufacturing

The manufacturing of Door sets for Rockdoor is detailed below:

  • All the processes and standards are maintained by the quality manager and are carried out within the scope of ISO 9001 which is audited by BSI every year.
  • The factory is driven by work to lists with specific details for the specific component to be manufactured.
  • The lists produce items for assembly in; Skin Vacuum forming, Glass assembly, Inner Frame and outer frame. The items then come together and are assembled by the drum press machine. The door is then cut to size by a CNC machine again all the details come directly from the computer system. The door then gets the unique door sticker applied and then has all the furniture fitted. The door gets a Q.C check and then goes into the relevant delivery stillage of final delivery to the customer.
  • At each stage of production the items are checked by the operator against the internal standards document to ensure they are to the documented standard.
  • The final Q.C. is carried out by a specific department and when the door has passed the standard a photograph of the door is taken and is stored on file against the unique Id for future reference.
     
  1. Control of Non-conforming products

All significant non-conformances are reported to Pete Pollitt for completion of a Rockdoor Quality tracker 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 Rockdoor Quality tracker and retained for processing.

2.       Remedial action to resolve the immediate problem will be taken, items that don’t conform are removed from the shop floor and the computer system is updated which in turn re issues the relevant items to be produced.

4.       All non-conformities are dealt with in the daily quality meeting.

5.       The quality tracker is kept on the server.

  1. Equipment

        It is the Engineering Managers responsibility to ensure that adequate means is available for the verification of measuring equipment and that equipment is calibrated on a scheduled basis.

        Individual pieces of measuring equipment used in the monitoring and verification of processes and finished products are uniquely identified and recorded in the equipment register.

        Each piece of equipment tested will have a record in which the frequency of checks and the level of accuracy required will be stated.  The subsequent test results will be recorded. 

        All measuring equipment included in the calibration scheme will be marked to indicate its calibration status.

        Equipment found to be outside of the accuracy tolerances given on the record sheet will be repaired or replaced.  It will be removed from production until the Engineering Manager confirms its re-calibration.

  1. Labelling and marking

All doors are marked with a permanent label which is for the Range of doors and shows the worst case U-value. The Permanent label is positioned under the top hinge on the door edge.  As every label is the same we can ensure that every door is correctly marked.

The packaging label will also show the CE marking but this will be Series specific. This can be achieved as all the information to identify which series the door is from is held on the computer system and the information is generated from a bar code scan taken from the door.

 The following Templates show how the Label will be printed with the relevant information for each specific series;

 

Rockdoor

Partnership Way Blackburn

2013

 

EN 14351-1:2006+A1:2010

FRENCH DOOR SERIES

External pedestrian doorset intended to be used in domestic and commercial locations

 

Declaration of Performance:  CU13312-6

 

Thermal transmittance: 1.3 W/m2K

Dangerous substances: None

 

Rockdoor

Partnership Way Blackburn

2013

EN 14351-1:2006+A1:2010

ULTIMATE DOOR SERIES

External pedestrian doorset intended to be used in domestic and commercial locations

Declaration of Performance:  CU13312-1

Thermal transmittance: 1.1 W/m2K

Dangerous substances: None

 

Rockdoor

Partnership Way Blackburn

2013

EN 14351-1:2006+A1:2010

ULTIMATE CLASSIC DOOR SERIES

External pedestrian doorset intended to be used in domestic and commercial locations

Declaration of Performance:  CU13312-2

Thermal transmittance: 1.2 W/m2K

Dangerous substances: None

 

Rockdoor

Partnership Way Blackburn

2013

EN 14351-1:2006+A1:2010

STABLE DOOR SERIES

External pedestrian doorset intended to be used in domestic and commercial locations

Declaration of Performance:  CU13312-5

Thermal transmittance: 1.1 W/m2K

Dangerous substances: None

 

 

Rockdoor

Partnership Way Blackburn

2013

EN 14351-1:2006+A1:2010

S/E/C DOOR SERIES

External pedestrian doorset intended to be used in domestic and commercial locations

Declaration of Performance:   CU13312-4

Thermal transmittance: 1.8 W/m2K

Dangerous substances: None

 

 

 

  1. Training of personnel

 On the first day of employment the new employee will be given his induction training and will have his training record initiated. The induction training will be conducted by a representative of the Operations Manager and will include:

        a) Detailed study of the policies and procedures contained in the starter pack.

        b) Overview of company handbook (employee receives copy)

        c) Video on manual handling

        d) Explanation of the safety signs applicable to the operation.

        e) Walk through of the fire safety arrangements and alarm points.

        f)  Introduction to the first aiders and their stations.

        g) Walk through of the welfare facilities and clocking points.

A training record (Doc Ref: TR/1) is initiated for each shop floor employee. This record will document experience and relevant training already undertaken. Subsequent training will be recorded thereon.

On going Training and Development

A training matrix will be created to cross reference all shop floor personnel with current method statements. The training matrix will be updated on an on-going basis

Training can be undertaken in one of three ways:
a)     The Manufacturing Manager instructs the trainer to provide an individual with training in a specific skill or area of work.
b)     Employee requests to be trained in a certain area.
c)      The Team Leader partners the employee with a fully skilled work mate, training is undertaken on the job.

In all of the above situations the trainer will issue the appropriate method statement and demonstrate how the skill can be performed correctly and safely.

In all cases the training representative will assess the employee performance against the method statement and general safety procedures before the training matrix is updated. Both the employee and the trainer will sign the training record.

 

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All Rockdoors are certified by independent testing specialist Build Check.

For extra information the GGF Frequently Asked Questions are a useful resource.