Hubei CAILONEN Intelligent Technology Co., Ltd
Our company adheres to the tenet of "Quality First, Continuous Improvement, and Customer Satisfaction", and is committed to providing excellent service to every customer. Looking ahead, we will keep
As a key equipment in industrial production, the quality of industrial furnaces directly affects many aspects such as production efficiency, product quality, and energy consumption. In order to ensure the stable and efficient operation of industrial furnaces, our company has a complete and strict quality control system that covers the entire process from raw material procurement to product shipment.
The lining materials of industrial furnaces need to have good thermal insulation performance, high-temperature resistance, and mechanical strength. For example, ceramic fiber products are often selected due to their characteristics such as low thermal conductivity and high refractoriness. For heating elements, such as resistance wires, they are required to have a high resistance coefficient, good oxidation resistance, and a relatively high operating temperature. Nickel-chromium alloy wires are commonly used materials. When it comes to the materials for the metal shell, factors such as strength and corrosion resistance need to be considered, and high-quality carbon steel or stainless steel is usually selected.
A strict supplier evaluation system is established to examine aspects such as the supplier's production capacity, quality control system, product quality stability, and reputation. Sampling inspection is carried out on the raw materials of potential suppliers to ensure that they meet the quality standards. For example, for furnace lining materials, indicators such as density, thermal conductivity, and refractoriness are tested; for metal materials, their chemical composition and mechanical properties are tested. Only suppliers who pass the strict evaluation can be included in the list of qualified suppliers.
When each batch of raw materials enters the factory, strict inspection is required. A special raw material inspection area is set up, and professional testing equipment and personnel are equipped. First, check whether the specifications, models, and quantities of the raw materials are consistent with the purchase order. Then, conduct a visual inspection to check for defects, deformation, corrosion, and other problems. For key materials, such as heating elements, electrical performance tests are carried out to ensure that the resistance value is within the specified range; for furnace lining materials, physical and chemical performance tests are conducted, such as testing their refractoriness through a high-temperature furnace, and the pressure vessel provides parameter reports.
Once unqualified raw materials are found, they are immediately labeled and stored in isolation. Communicate with the supplier in a timely manner and request them to return or replace the goods. A detailed record is made of problems such as production delays that may be caused by unqualified raw materials, and the impact on production costs and the production plan is evaluated. At the same time, traceability and evaluation are carried out on semi-finished products that have used this batch of unqualified raw materials, and rework or scrapping treatment is carried out if necessary.
According to the design requirements of industrial furnaces, detailed production process documents are formulated, including assembly processes, welding processes, heat treatment processes, etc. For example, when welding the furnace body, the welding method (such as argon arc welding), welding parameters (current, voltage, welding speed, etc.), and weld quality standards are clearly defined. For complex assembly links, detailed assembly drawings and assembly instructions are drawn to guide the workers' operations.
Professional training is provided for production workers to make them familiar with the production process and quality standards. Regular skill assessments are organized to motivate workers to improve their operation skills. When new employees join the company, experienced masters are arranged to provide guidance and assistance to ensure that new employees can quickly master the production process. For example, welding skill training courses are carried out, and professional welding engineers are invited to give lectures and provide on-site guidance to improve the workers' welding level.
In the production process, multiple inspection nodes are set up. After the processing of components is completed, the first-piece inspection is carried out to ensure that the processing dimensions, shapes, etc. meet the design requirements. During the assembly process of the furnace body, intermediate inspection is carried out to check the assembly quality, welding quality, etc. For example, check whether the connection of each component of the furnace body is firm and whether there are defects such as pores and cracks in the weld. After the overall assembly of the product is completed, the final inspection is carried out, and a comprehensive performance test of the heating furnace is carried out.
Sensors and other equipment are used to monitor key parameters in the production process in real time, such as the welding temperature and the pressure during the assembly process of the furnace body. The monitoring data is recorded and analyzed. Once the parameters are found to be abnormal, the production is immediately stopped, the cause is found, and adjustments are made. For example, the temperature change during the welding process is monitored through a temperature sensor to ensure the stability of the welding quality. At the same time, record the relevant data of each production link, including the operator, production time, inspection results, etc., for traceability and analysis.
A comprehensive performance test is carried out on the industrial furnace that has been assembled and debugged. The test items include the heating-up rate, temperature uniformity, heating power, etc. For example, thermocouples are placed at different positions in the furnace to measure the temperature distribution during the heating process and calculate the temperature uniformity. The time required for the heating furnace to rise from room temperature to the set temperature is tested to evaluate the heating-up rate. Ensure that all performance indicators meet the design requirements and relevant standards.
Check whether the appearance of the industrial furnace is clean and whether there are scratches, deformation, and other problems. An adhesion test is carried out on the coating on the surface of the furnace body to ensure that the coating is firm. At the same time, check whether the product packaging meets the requirements and whether the packaging materials can effectively protect the product from damage during transportation. For example, check whether the packaging is firm and whether there are shock-proof and moisture-proof measures.
A unique quality traceability code is established for each industrial furnace, and all information from raw material procurement to the production process and then to shipment is recorded. When customers feedback product quality problems, the root cause of the problem can be quickly found through the traceability code. For example, through the traceability code, you can query the batch of raw materials used in the heating furnace, the operator in the production process, and the inspection results of each inspection node.
Respond to the quality problems feedback by customers in a timely manner and establish a special after-sales quality handling team. Conduct an in-depth analysis of the problems, formulate solutions, and feedback them to customers in a timely manner. For product recalls or repairs caused by quality problems, actively communicate with customers to reduce the impact on their production. At the same time, use the quality problems feedback by customers as an important basis for improving product quality, and optimize the production process, quality control system, etc.
