2012-08-20 SKN_N0106_AnnexE_R0

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SOLAR KEYMARK SPECIFIC SCHEME RULES
ANNEX E: FACTORY PRODUCTION CONTROL
INFORMATIVE
BASED ON ISO 9001 STANDARD COVERING THE PRODUCTION LINE

1. General

This annex specifies the requirements for the Factory Production Control (hereafter FPC) and the
quality management system covering the production line of collectors.

2. Organisation

2.1 General

The FPC shall be operated according to a documented quality system. The manufacturer shall
establish, document and maintain the FPC system to ensure that the products placed on the market
comply with the declared performance of the characteristics. The records must be kept at least for a
period of 3 years. All quality documentation shall be kept up to date.

2.2 Responsibility and authority

The responsibility, authority, and the interrelationships between all personnel who manage, perform, or
verify work affecting quality or product conformity, shall be defined. This applies particularly to
personnel who need the organizational freedom and authority to:

a) Identify procedures to demonstrate conformity of the product at appropriate stages
b) Initiate action to prevent the use and production of non-conforming product
c) Identify and record any product quality problems or non-conformities

2.3 Management representative for the FPC

At every place of production, a representative with the appropriate knowledge and production
experience shall be appointed by the manufacturer and given responsibility for managing and
supervising of the FPC procedures and for ensuring that the requirements of this annex are
implemented and maintained.

2.4 Quality Objectives

Top management shall ensure that quality objectives regarding the production process are established
at relevant functions and levels within the organization. The quality objectives shall be measurable.

At least one example of a quality objective could be to lower the number of non-conforming products
from year to year.

2.5 Management review

Management shall review at least every year the FPC system to ensure its continuing suitability,
adequacy and effectiveness. Records of such reviews shall be maintained. The minimum input for
management review shall be at least related to the conformity of the product and include the following:

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a) Status of corrective and preventive actions
b) Status of complains
c) Follow up from previous management reviews
d) Follow up of quality objectives
e) Results of audits

2.6 Training of personnel

The manufacturer shall establish and maintain procedures for the training (with a training plan and
training records) of all personnel in activities affecting quality or product conformity.
Personnel performing work affecting product conformity shall be qualified on the basis of appropriate
education, training and/or experience, as required.
3. Quality Documentation

The manufacturers documentation and procedures shall be relevant or appropriate to the production
and process control used during manufacture of the product, and shall provide at least the following
items:

a) Quality aims or policy, the organizational structure, responsibilities and authority of the
management with regard to product conformity;
b) Procedures for specifying and verifying the raw materials and other constituent materials;
c) Manufacturers production control and other techniques, processes and systematic actions
that will be used;
d) Inspections and tests to be carried out before, during and after manufacture, together with
their frequency and possible retest procedures;
e) Procedures for handling, storage, packaging, marking and labelling the product;
f) Procedures for all personnel to receive training in the activities affecting quality or
conformity of the product
g) A procedure that will specify how non-complying products shall be dealt with. Any event
of this kind shall be recorded as they occur and these records shall be kept for the period
defined in the manufacturers written procedures.
h) A procedure for corrective actions that instigates action to eliminate the cause of non-
conformities in order to prevent recurrence.
i) A procedure shall be established to define the responsibilities and requirements for planning
and conducting internal audits, establishing records and reporting results
j) The manufacturer shall have written procedures ensuring that processes related to affixing
traceability codes and/or markings are inspected regularly.

4. Inspection and testing

4.1 General

All necessary facilities, equipment and personnel shall be available to carry out the inspections and
tests. The manufacturer may employ, under contract, a subcontractor who has the facilities, equipment
and personnel to carry out the inspection and tests on behalf of the manufacturer. The manufacturer
shall be responsible for control, calibration, and maintenance of testing, measuring, and inspection
equipment, whether owned by or on loan to the manufacturer or a subcontractor.

Inspection and testing shall be performed by personnel qualified for such tasks on the basis of
documented appropriate education, training and/or experience.

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4.2 Test equipment

Tests to demonstrate conformity of the finished product to the relevant product standard shall be
performed using appropriate testing equipment and documented working instructions.
The test equipment shall be controlled regularly by calibration or verification following the
manufacturers own instructions.

4.3 Inspection and testing of raw materials and other constituent materials

The manufacturer shall ensure that raw materials and other constituent materials conform to his
specified requirements. In determining the checks necessary consideration shall be given to the control
exercised by the supplier and the documented evidence of conformity supplied (often referred to as
supplier certified components or certified raw materials). There should be a proper traceability to the
suppliers documentation.

This table shows the minimum checks to be carried out on incoming goods. All checks and tests shall
be recorded:

Material Method Requirement Frequency
Pipe
Visual check and
documentation check
No damage

Each delivery
Measurement
Purchase specificatnoion: pipe
dimensions within tolerance
Each delivery
(1)

Absorber sheet
Visual inspection No damage
Each delivery
Document check
Purchase specification:
Parameters of optical characteristics
(solar absorbance and thermal
emittance)
Absorber
Visual inspection No damage Each delivery
Document check
Purchase specification:
Parameters of optical characteristics
(solar absorbance and thermal
emittance)
and proper connection between absorber
sheet and pipes (this may be a
mechanical test also)
Pressure/leakage test
shall be done on
100% of absorbers-
by supplier or
manufacturer.
Pipe grid
Visual inspection No damage Each delivery
Document check

Purchase specification

Pressure/leakage test
shall be done on
100% of absorbers-
by supplier or
manufacturer.

Reflector
material,
reflector shape (if
the finished
Document check or direct test
for shape (eg: master shape )
Purchase specification:
Solar reflectance, shape
Each delivery
(document check) or
less frequency if it is
tested
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reflector is
delivered)
Heat pipes
Test for check performance
(may be done by heat pipe
manufacturer)

Purchase specification Variable
Glass
tubes(assembly of
absorber and
glass cover)
Specific test method Purchase specification Variable
Glazing
Measurement
Purchase specification: dimensions and
optical characteristics(solar
transmittance)
Each delivery
(1)


Document check or direct test
If only a document check is done, then
there must be a special agreement to
assure optical characteristics
Insulation
Visual Damage Each delivery
Document check
Purchase specification: density and
thermal conductivity
Each delivery
Weight measurement
Manufacturers method

Each delivery
(1)

Dimension measurement
Outgasing test (only for flat
plate collectors)
Casing

Material of frame
elements
Visual check
Purchase specification Each delivery
(1)

Measurement (verify product is
inside tolerance)
Material of rear
panel
Visual check
Purchase specification Each delivery
(1)

Measurement (verify product is
inside tolerance)
Hydraulic
connections
Visual Check

Measurement (verify product is
inside tolerance)
Purchase specification Each delivery
(1)

Sealant
Documentation and Visual
check
Purchase specification Each delivery
(1)


Note 1: In this case, the frequency of checks may be decreased in result of reliability of the supplier
(ISO 9001 certificate etc.) and history of deliveries (no complains, no non-conformities). In this case a
written procedure shall exist, describing the rules for decreasing the frequency and return to full-check
in case of non-conformities.

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4.4 Inspection and testing during manufacture and on finished product

In order to manufacture products which conform to the product standard the manufacturer shall control
his process and perform inspection and tests as described in his manual, and complying at least with
the following table.

Process Method Requirement Frequency
Cutting of pipe Measurement
Manufacturer
specification for
dimensions
At the beginning of
each production
order
(2)

Cutting of absorber
sheet
Measurement
Manufacturer
specification for
dimensions
At the beginning of
Each production
order
(2)

Cutting of frames Measurement
Manufacturer
specification for
dimensions
At the beginning of
Each production
order
(2)

Connection of pipe
to absorber
Visual
Proper welding
Each absorber
(Recommended but not obligatory)
mechanical test with
manufacturers method
Manufacturers
specification

Absorber Visual check No damage Each absorber
Reflector material
Visual

No damage Each collector
Assembly Visual Proper assembly Each collector
Sealing Visual Proper sealing Each collector
Leakage
Manufacturer method for pressure
test
Manufacturer method Each collector
Release of each collector Visual or manufacturers method Manufacturer method Each collector

Note 2: In this case, the frequency of checks may be decreased in result of reliability of previous
experience. In this case a written procedure shall exist, describing the rules for decreasing the
frequency and return to full-check in case of non-conformities.


4.5 Inspection and test records

The results of products inspection and testing shall be recorded
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The record shall contain the product identification, the date and time of manufacture and for each
property the test methods, the test results, the inspection result and the identification of the person
carrying out the inspection.

5. Actions in the case of non-conforming products

If the result of a test or the inspection of a product is a failure, the manufacturer shall immediately take
the steps necessary to rectify the deficiency. Products which do not conform to the requirements of the
product standard, shall be marked, isolated or controlled accordingly. When the deficiency has been
identified and rectified, the test or inspection in question shall be repeated without delay accordingly to
the quality documentation, to provide the evidence that the defects have been overcome. Corrective
and preventive actions taken in case of non-conforming products shall be documented.

6. Handling, storage, packaging and marking of products

In accordance with the quality documentation the manufacturer shall:

a) Provide methods of handling that prevent damage or deterioration;
b) Provide suitable storage areas or stock rooms or prevent damage or deterioration of the
product;
c) Control the packaging, storage and the marking processes

7. Traceability of products

Individual collectors and their main components (if applicable) (cover sheet, absorber, insulation,
reflector, polymer sealing and gaskets and heat pipes) shall be identifiable and traceable with regard to
their production origin.

8. Internal audit

The organization shall conduct internal audits at planned intervals of at least once a year to determine
whether the quality management system

a) Conforms to the quality documentation
b) Is effectively implemented and maintained

In case of internal audit, an audit programme shall be planned, taking into consideration the status and
importance of the processes and areas to be audited, as well as the results of previous audits. The audit
criteria, scope, frequency and methods shall be defined. The selection of auditors and conduct of audits
shall ensure objectivity and impartiality of the audit process. Auditors shall not audit their own work.

A document procedure shall be established to define the responsibilities and requirements for planning
and conducting audits, establishing records and reporting results.

Records of the audits and their results shall be maintained.

The management responsible for the area being audited shall ensure that any necessary corrections and
corrective actions are taken without undue delay to eliminate detected nonconformities and their
causes.
Follow up activities shall include the verification of the actions taken and the reporting of verification
results.