Technical Certification Checklist

Section 1

GENERAL INFORMATION
Company Information
COMPANY

Ittihad Glass P.O. Box 22230, Amman 11181 Amman

CERTIFICATION DATE 19

Oct 2009

ADDRESS

CITY

COUNTRY

Jordan

PHONE

+ 962 6 479 00 50
Key Contact

FAX

+ 962 6 479 00 55
Title

WEBSITE

Customer Representatives
Email hisham@ittihadglass.com sales@ittihadglass.com Mr. Hisham Arnaout Mr. Walid Kheetan Factory Manager Commercial Manager

Guardian Representatives
Phone
FIELD SALES

Rashad Abu Daraj

00 962 79 55 30 523

COMMERCIAL SALES

TECHNICAL SERVICES EXECUTIVE

Patabandige Senaka

00 971 50 74 00 254

OTHER

Certification Information
Visit Type Pre-Cert Phone Screen Pre-Audit Visit Certification Audit Follow-up Audit Comments Comments

Audit went on 17 Oct & 19 Oct

Products Used in Certification

SG Series Solar High Performance Super Neutral Green 35 Products Used

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

Section 2

RECEIVING RE CEIVING AND STORAGE

Yes No Inspection Criteria Indoor unloading ** Environmentally controlled area (no roof leaks, open doors, ventilation for proper air circulation, etc.) ** Located proper distance (greater than 15.25 meters or 50 feet) from outside doors, glass washers and corrosive chemicals ** Comments

Passed Failed

TECHNICAL CERTIFICATION CHECKLIST

General Comments

Did cert. glass arrive undamaged? Tag Number(s): Couldnt find Visible Guardian case tags on newly received product Is there a system in place to track and Rqnt: Incorporate the manufactures tag manage the rotation of glass inventory (First- number to the inventory. Mention the in-first-out FIFO system? oldest tags in the work order. Do they re-wrap unused lites when placing Rcnd: them back into storage after running a job? Every case in the inventory was given an Ittihad tag with basic information. No tag numbers available in partially used cases. Even in the partially used case from which sample glass were taken, had not a tag number. ** This criteria is strict to follow for High Performance and Super Neutral products

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

Section 3

GLASS CUTTING AND AUTOMATED AU TOMATED EDGE DELETION DELETIO N

Yes No Inspection Criteria Use of clean dry gloves Coated surface verified Proper handling procedure used TPF remains on surface during cutting* Cutting equipment in good working condition (felt, drives, etc.) Is there an active Preventive Maintenance program in place and how often is it performed? Properly maintained suction cups Suction cup drop to table maintained Tilt table in good working condition Guardian case tag information recorded Guardian approved cutting fluid used in moderation Good quality cut edge transferred Lites tr ansferred individually from table to rack Automated edge deletion? Coated side pickup? Is there a system in place to train operators and if so how is it documented? documented? Are there any procedures in place to help the operators troubleshoot if a problem occurs? Cutting operator tried to pick the glass by suction frame placed on coated side. Comments Supported gloves Rqnt : No detectors are used

Passed Failed

TECHNICAL CERTIFICATION CHECKLIST

Spacer usage was started at cutting. Gantry, tilt table, cutting table, lami cutting and edge deletion. Rcnd : A PM program is required

Rqnt : Cutting opr has to mention tag number used for each orders done.

General Comments

* TPF is on SuperNatural HT products only

Important Cutting and Automated Edge Deletion Information Cutting Table BILLCO PTC LISEC Manufa HEGLA BOTTERO BYSTRONIC Manufacturer Approximate Vintage (Year Built/Rebuilt) GFB 60 / 30 12E S 007 Cutting Wheel Angle Cutting Wheel Pressure Cutting Speed Cutting Fluid Automated Edge Edge Deletion Wheel Type Automated Edge Edge Deletion Speed As recommended by Lisec 2.1 bar 2.3 bar ACPE 5250 GRENZEN GED Other

Automated Edge Edge Deletion Pressur Pressure Data Table for Thickness wise Selections No

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

* Temporary protective film (TPF) is applied only to SunGuard SuperNeutral HT coatings. Many of the critical handling steps outlined in this checklist were developed for handling split-silver products without TPF. If the TPF is undamaged and remains on the surface during processing, many of the special handling considerations outlined in this checklist that relate to potential surface damage will not be applicable to TPF coated glass. However, for annealed SuperNeutral or SuperNeutral HT coatings where the TPF has been removed, all aspects of this checklist are relevant and should be followed. TPF should remain on the surface of the coated glass during all fabrication processes and removed just before the glass enters the furnace.

TECHNICAL CERTIFICATION CHECKLIST

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

Section 4

SEAMING
Yes No Inspection Criteria Seaming process: wet dry Synthetic rubber Rqnt: No detectors are used. Use of clean dry gloves Coated surface verified Proper handling procedure used TPF remains on surface during seaming* Seaming equipment in good working condition (roller balls, felt, belts, etc.) Are the belts changed on a regular basis and if so, how often are they changed? Is there an active Preventive Maintenance program in place? Lists areas in the PM program and frequency Lites traceable to Guardian case tags Good quality seamed edge Does seamer feed directly to washer? Are there inspection criteria in place to make sure that the edges are properly seamed (example: posted photos showing acceptable and unacceptable edges)? Is there a system in place to train operators and if so how is it documented? documented? General Comments Comments

Passed Failed

TECHNICAL CERTIFICATION CHECKLIST

Based on the performance. Rcnd: Rcnd: Rcnd:

Funace operator inspect before feeding to the furnace. No special instructions or display materials.

* TPF is on SuperNeutral HT only

Important Seaming Information Type of Table Roller Ball V-Belt Type of Seamer If Wet Seaming, What Is the Fluid Used? Felt/Air Transfer Auto In-Line Water Combination Edge Grinding Other: Other:

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

Section 5

PREPRE - HEAT TREAT WASHING (HT ( HT COATINGS COATING S ONLY)

Yes No Inspection Criteria Use of clean dry gloves Coated surface verified Proper handling procedure used TPF remains on surface during washing* Treated water used: RO DI Softened Washer manufacturer: BILLCO Other: Triulzi Washer clean and maintained to OEM/ Preventive Maintenance criteria Is there a functional pre-rinse? Are spray/rinse bar nozzles positioned correctly and directed into brushes with good pressure? owAre low -E brushes installed and how often are they changed and replaced? replaced? Are brushes in good working condition? (not worn, touching the glass, balanced) Pinch rolls clean and adjusted correctly Is wash water clean? Are wash tanks drained regularly? Water temperature of 4960C (120140F) Wash pH of 68 pH: No Rinse pH of 68 pH: No Soap used Type: Washer chemical free (except for soap) Is rinse water clean? Total Dissolved Solids in Rinse Tanks Properly functioning air nozzles Is there an active Preventive Maintenance program in place? Lists areas in the program and frequency Lites traceable to Guardian case tags Equipment in place to do inspection in transmission Equipment in place to do inspection in reflection Customer trained to do inspection in both transmission and reflection Glass is clean and dry (no spots/streaks) Does washer feed directly into furnace? General Comments Comments Supported gloves Direct feeding from the seaming

Passed Failed N/A

TECHNICAL CERTIFICATION CHECKLIST

Cleaning schedule: Weekly (No documents)

One low E brush with 2 hard brushes. Rqnt: Only low E brushes should be used.

Rqnt: Pinch rolls need frequent cleaning Schedule: Daily Set Temp: 50C

Actual Temp: 42C (just after draining) Rcnd: Water quality has to be monitored Rcnd: Water quality has to be monitored

Amount: < 70 ppm. Target <200 ppm. Filter cleaning was done. Rqnt : Rqnt : Rqnt : Rqnt : Lighting needs to be provided at washer exit or furnace entry Adequate roof lighting is available.

Some removable marks observed.

* TPF is on SuperNeutral HT only

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

A certification audit will be conducted at all fabricators working with Guardian heattreatable SunGuard solar control & low-E coatings. The audit will consist of a low-level production simulation consisting of the lite sizes and quantities outlined in the table below. SunGuard Heat-Treatable Coating Low-Level Production Simulation Requirements
Number of Lites to be Run #1 #2 #3 2 6 12 Size of Lites 1605 mm x 2250 mm 1000 mm x 2000 mm 500 mm x 1000 mm Stock Sheets Required Required 2 2 1

TECHNICAL CERTIFICATION CHECKLIST

The fabricator must achieve 85% yield (by total number of lites) within a targeted 1-hour time frame to receive certification. The low-level production simulation should be successfully accomplished within 1 hour and is designed to ensure that the fabricators process is optimized for consistent quality output across a range of sizes. The fabricator may use the drops after cutting the trial-sized lites to prepare for the audit, but the actual production run must take place in the presence of a Guardian Technical Services Executive and utilize the sizes indicated. In addition, if the fabricator does not have a reliable quality system in place to inspect the glass before and after heat-treatment, the certification engineer can provide a suitable load-end quality check and final quality check inspection system as outlined in the Guardian documents Heat-Treating Load-End Quality Control Guidelines, and HeatTreating Final Quality Control Guidelines. These documents can be obtained by contacting your local Guardian Technical Services Executive. For recertifications, the same process flow will be followed, except for the size protocol listed above. Recertification efforts will utilize one of the following approaches: 1. Observe an actual production run involving the most currently used SunGuard product. 2. Product used from the customers inventory and cut to a standard production size for the fabricator.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

Section 6

HEAT STRENGTHENING & TEMPERING TEMPER ING

Yes No Inspection Criteria Use of clean dry gloves Coated surface verified Proper handling procedure used TPF removed correctly before furnace* Coating inspected before heat treatment Furnace in good working condition Furnace maintained to OEM/PM specs Is there an active preventive maintenance program in place? Lists areas in the PM program and frequency SO2 turned off 30 min. prior to processing Aspiration on Rqnt : Comments

Passed Failed N/A

TECHNICAL CERTIFICATION CHECKLIST

Rqnt : Each lite has to be verified. Rcnd: Glass cleaning after washing has to be done w/ standard glass cleaning practices.

Rqnt : The existing PM has to systemized. Rcnd : Convection furnace

Temperature not exceeding 700C (12 (1292F) Set points (bottom) are above 700 C Can the operator make furnace adjustments? Temp. Line Speed Aspiration Other Tempered load test meets Guardian protocol outlined in Heat Treat PAN** HeatHeat -strength load test meets Guardian protocol outlined outlined in Heat Heat Treat PAN** Lites traceable to Guardian case tags Zebra board in place online Equipment in place to do inspection in transmission Customer trained to do inspection in transmission Equipment in place to do inspection in reflection Customer trained to do inspection in reflection Is there a system in place to train operators and if so how is it documented? documented? Are there any procedures in place to help the operators troubleshoot if a problem occurs? Coating inspected after heat-treatment Coating damage noted Do they have an online inspection system and if so is the data recorded? Using foam tabs, cork tabs or polyfoam for separating lites Glass temperature below 50C (122F) before packing or further processing Do they monitor yields and what are they? General Comments Rqnt :

Rqnt :

This requirement is managed by means of roof lighting. Special lighting is required.

Rcnd : Rcnd :

Rcnd : On line quality inspection records are useful for process control.

* TPF is on SuperNeutral HT only ** Heat-treating PAN outlines production simulation required to be completed by the fabricator for certification

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

Section 7

FURNACE INFORMATION AND BASE PROFILES

Furnace Information Furnace Manufacturer Manufacturer Furnace Vintage (Year Built/Rebuilt) Number of Bays Type of Heating Largest Piece that can be Processed Fuel Operators Operator s Name HHH GLASSTECH IANUA UNIGLASS TAMGLASS GLASSROBOTS HTF 2860 R 2007 Pro E 1 Radiation Convection Other: Air Assist Combination 2800 mm X 6000 mm Gas Electric Other:

TECHNICAL CERTIFICATION CHECKLIST

Base Furnace Profile Information (Required) Product: Green 35 A B C D E F G H I J K L M N Guardian Tag Number Product Thickness Substrate Color Stored Recipe Name Total Cycle Time Zone Cycle Time Aspiration Settings (TOP) Aspiration Settings (Bottom) Zone 1 Upper Zone Temperature(s) Zone 1 Lower Zone Temperature(s) Zone 2 Upper Zone Temperature(s) Zone 2 Lower Zone Temperature(s) Primary Quench Settings Secondary Quench Settings Heat Strengthened 6 mm Green Guardian Green 35 310 s A (0,50) > B (60, 50) > C (85,0) 690 C 720 C 1700 Pa 2000 Pa A.Bal - 55%, N.Dis 25 mm / 45 mm ( for 6 pcs of 1000 x 1200) Tempered

Additional Furnace Data

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

Section 8

OFFLINE HEAT TREATMENT TREATME NT QUALITY/INSPECTION QUALITY/INSPECTIO N

Yes No Inspection Criteria Comments

Passed Failed N/A

TECHNICAL CERTIFICATION CHECKLIST

Flat inspection table/inspection station Scale / 50X50mm Aperture(break QC equipment readily available: Tape measure Aperture(break test) Micrometer Feeler guide StraightStraight-edge Roll gauge calibrated No roller wave gauge G.A.S.P. unit calibrated No GASP available Zebra board available offline Inspection light stand Equipment in place to do inspection in transmission ssion transmi Customer trained to do inspection in transmission Equipment in place to do inspection in reflection Customer trained to do inspection in reflection Is a valid quality system in place and Rcnd : This needs to be implemented. how often do they perform checks? Roll gauge G.A.S.P. Are the operators trained to use the following QC equipment: Tape measure Scale / 50 X 50 mm Aperture (break test) Micrometer Feeler gauge StraightStraight-edge recorded Rqnt : Inspection data re corded (see below) This will follow the off line QC system. Past QC data reviewed and analyzed Tempered product meets approved Users Guide standards HeatHeat -strengthened product meets approved Users Guide standards Do they have any SPC processes in place for analysis of their furnace data This will follow the off line QC system and/or use statistical tools to correlate their quality data? General Comments

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

10

Section 9

HEATHEAT - TREATING FINAL QUALITY QUALI TY CHECK

Task Record date/shift/time Record line item/tag number Record product type Heat-strengthened or tempered? Record squareness Record thickness Check logo Break test data if tempered G.A.S.P. average Check bow & warp
These items must be checked checked and data recorded at the beginning of the shift and then once an hour. hour. They must also be checked whenever a product or thickness change is made. made. (see Heat Treatment Treatment

Passed Failed N/A

Comments

TECHNICAL CERTIFICATION CHECKLIST

Required Required Frequency

Actual Frequency

(see Heat Treatment Check roll distortion PAN for details) Check surface quality Sign off approval optical QC Rcnd : This needs to be implemented with necessary instruments. General Comments

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

11

Section 10

RANDOM SAMPLE OPTICAL OPTICA L MEASUREMENTS

Attributes Protocol Protocol Size Roll Wave Surface Pressure Center Kink Flatness (Warp or Bow) Break Test
1600mm 1600mm x 2250 2250mm 250mm

Passed Failed

TECHNICAL CERTIFICATION CHECKLIST

Temper
1200mm 200mm x 1000mm 1000mm 500 mm x 1000 mm

Tolerance

< 0.06

< 0.04

< 0.04

Target .07 mm (0.00276 in.) Max .13 mm (0.00512 in.)

> 10,000 psi

No center kink or no crease (white) marks 6 mm. (can be improved) -

0.02 mm max (0.00079 in.)

2 mm

1 mm

+/ 1/16 in./linear ft. max

> 80

> 80

Number of largest pieces in 50 X 50 mm area > ??

General Comments

Due to project requirements more 1200 x 1000 sizes were tested. When it was running with full bed, breakages at chiller (single piece) observed for lower cycle time.

Attributes Protocol Size Roll Wave Surface Pressure Center Kink Flatness (Warp or Bow) General Comments
1829mm x 2438mm

HeatHeat-Strengthened Tolerance
1175mm x 1908mm 610 mm x 914 mm Target .07 mm (0.00276 in.) Max .13 mm (0.00512 in.) 3,5007,500 psi 0.02 mm max (0.00079 in.)

+/ 1/16 in. per linear ft.

No HS trials performed.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

12

Section 11

E DGE DELETION
Type Yes No Auto. on Cutting Table (see p. 3) Auto. on IG Line

Pre-Furnace Pre-Insulating
Manual (Hand Style) Comments Supported gloves Rqnt : No detectors are used Other:

Passed Failed

TECHNICAL CERTIFICATION CHECKLIST

Inspection Criteria Use of clean dry gloves Coated surface verified Proper Pro per handling procedure used Edge deletion equipment properly maintained Is there an active Preventive Maintenance program in place? Lists areas in the PM program and frequency Guardian Heat Treatable coatings edge deleted post-furnace Stand-alone process Appropriate grinding wheel used Deleted edge is straight and continuous Deleted edge has all coating removed Do they produce any offset IGUs? Lites traceable to Guardian case tags Is there a system in place to train operators and if so how is it documented? documented? Rcnd :

If yes, make sure that the coated surface for the SunGuard High Performance and SuperNeutral products is edge-deleted from the offset edge to the sightline. Rqnt : Rcnd :

General Comments Comments

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

13

Section 12

INSULATING GLASS WASHING WAS HING

Yes No Inspection Criteria Use of clean dry gloves Coated surface verified Proper handling procedure used Is the coating edge deleted? Treated water used: RO DI Softened Washer manufacturer: BILLCO Other: Lisec Washer clean and maintained to OEM/ Preventive Maintenance criteria Is there a functional pre-rinse? Are spray/rinse bar nozzles positioned correctly and directed into brushes with good pressure? low owAre l ow -E brushes installed and how often are they changed? changed? Are brushes in good working condition? (not worn, touching the glass, balanced) Pinch rolls clean and adjusted correctly Is wash water clean? Are wash tanks drained regularly? Water temperature of 4960C (120140F) Wash pH of 68 pH: No Rinse pH of 68 pH: No Soap used Type: Washer chemical free (except for soap) Is rinse water clean? Properly functioning air nozzles Total Dissolved Solids in Rinse Tanks Is there an active preventive maintenance program in place? Lists areas in the program and frequency Lites traceable to Guardian case tags Equipment in place to do inspection in transmission Equipment in place to do inspection in reflection reflection Customer trained to do inspection in both transmission and reflection Coating inspected after washing Coating damage noted Glass is clean and dry (no spots/streaks) Out put has no issues. Amount: < 70 ppm. Target <200 ppm. Rqnt : Rcnd : Rqnt : Comments Supported gloves Rqnt : No detectors are used

Passed Failed

TECHNICAL CERTIFICATION CHECKLIST

Cleaning schedule: Weekly. (No ) ( documents)

Based on the quality of washing

There no abnormalities observed Schedule: Twice a day Set Temp: ?

Actual Temp: This needs to be in range. Rcnd: Water quality has to be monitored Rcnd: Water quality has to be monitored

Rqnt: Lighting needs to be provided at washer exit or furnace entry This requirement is managed with roof lighting. Special lighting is required.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

14

Section 13

INSULATING GLASS ASSEMBLY ASS EMBLY

Type of Insulating Line: Vertical IG Line

Passed Failed

TECHNICAL CERTIFICATION CHECKLIST

Horizontal IG Line * See comments after section 14

Note: Guardian requires that all SunGuard SunGuard coatings be used in a dual seal seal IGU for commercial applications. Yes No Inspection Criteria Use of clean dry gloves Coated surface verified Proper handling procedure used Lites traceable to Guardian case tags Comments Supported gloves Rqnt : No coating detectors are used Rqnt :

Is there a system in place to train operators and if Training is done on the job. so how is it documented? documented? Do they have a preventive maintenance program in place to monitor various areas of the insulating Rqnt : process (for example: the sealant pump and system and press area)? If so, list areas. Spacer System Spacer Type: Frame Type: Aluminum Cut Bent

Is the spacer system processed in a way in which it maintains its original shape (no deformation)? Are corners or joints continuous (no gaps or breaks)? Desiccant Fill Is the desiccant stored in a cool dry place per OEM recommendations? Is the spacer being filled according to OEM specifications? Does the customer test for the active life of the desiccant (i.e. boil test) and record the results on a daily frequency? Primary Sealant Application Polyisobutylene (PIB) Type: Is the PIB applied continuous with no skips or breaks? Spacer and Glass Assembly Is the coated surface checked in order to make sure the coating is facing inward before assembly? Is the spacer applied uniformly to the sightline to prevent sag or bow? Is there a quality system in place that specifies what is acceptable and unacceptable for defects (voids, pinholes, clusters)? Are the operators properly trained on how to inspect the units for defects? Equipment in place to do inspection in transmission transmission Equipment in place to do inspection in reflection Customer trained to do inspection in both transmission and reflection How is the pressure monitored in the press area for the IG? Boil test is done No records

LJF - M Rcnd :

Rqnt : Detectors have to be used

Rqnt : Adequate lighting needs to be provided

This is done by observing the primary sealant layer. System can be adjusted.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

15

Is there a calibration process that helps assure that the correct pressure is being applied to the unit? Does the customer use capillary tubes in their process? Secondary Sealant Application Type of Sealants Used: Sealant Name and Lot#: Does the customer track the sealant type and lot number through specific jobs? Is there a quality system in place to test for conformation of proper sealant characteristics (mix ratio and sealant cure time)? time)? If there is a system in place, what tests are performed? Is the test data recorded and at what frequency is the test performed? Are the operators trained on how to perform the various tests and do they understand the results? Is the space between the back of the spacer and the edge of the glass filled completely, with no voids, air pockets, or bubbles? Does the customer check a finished IGU outside using natural light? If so, at what frequency? Does the customer have the capability to gas fill and if so what type of gas is used?

Based on the settings, required pressure can be obtained. Breathing tubes. (moisture pass is controlled) One-part Two-part Both Dow Corning 993 (Base/Curing Agent) LJF-M (3189/2 A&B)

TECHNICAL CERTIFICATION CHECKLIST

Butterfly Both

Stick Life

During batch change over.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

16

Section 14

POST INSULATING QUALITY QUAL ITY INSPECTION

Task Coating location verified Is there visible glass offset? Is sightline consistent? No edge deletion encroachment Inspect primary sealant skips Inspect secondary skips Are units concave/convex? Visual inspection in transmission
These items must be checked checked and data recorded at the beginning of each shift

Passed Failed
Comments

TECHNICAL CERTIFICATION CHECKLIST

Required Frequency

Actual Frequency

Visual inspection in reflection This needs to be implemented having provided necessary infrastructure. General Comments

*Note to TSE: If the fabricator is utilizing a horizontal IG line, you must relay the following information to the GM/Owner, Production Manager, Production Supervisor, and Lead IG Operator during the audit and during the audit debrief. TSE is responsible for conveying this message exactly as written below. Fabricators with horizontal horizontal insulating lines should be extremely cautious regarding potential glass deflection. During horizontal glass insulation, the unsupported upper lite can sag under its own weight, creating a concave effect in the unit. The resulting deflection creates creates an observable concave or collapsed appearance on the units exterior. The amount of deflection is solely a function of the horizontal insulating process and the weight of the glass. In fact, this appearance has been cause for rejection on project sites. sites. The deflection is caused by a combination of the shape, size, weight and thickness of glass. As an example, a horizontal insulating process involving a 1,200 mm X 1,200 mm (1.44 m2)square unit could produce a 6 mm ( ) deflection in the center. However, a rectangular unit of the same area (e.g., 600 mm X 2,440 mm ) may exhibit no deflection. Aspect ratio is critical; squares will always be at greater risk than rectangles. As an interim guideline, Guardian recommends that the insulation crew measure measure deflection on square units and on any unit greater than 1.44 m2. The concave appearance may be reduced by placing the units #1 surface against a solid base for support during sealant application. Deflection is easily measured by attaching string diagonally diagonally from opposing corners. The deflection should be measured where the two strings intersect. Units exhibiting any measurable gap between the string intersection and glass surface should not be shipped if any optical distortion is visibly apparent. Quality control of the final product is a fabricator responsibility. The fabricator must ensure that the performance and optical requirements of the project can be met with the available capabilities at the factory. Guardian recommends that inspection for for deflection be added to the insulators daily quality routine. As a final check, representative units should be spot checked outdoors to confirm acceptable optics.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

17

Section 15

INSULATING INSULAT ING CERTIFICATIONS

Yes No Inspection Criteria Third party certification information (organization name) Certification Number(s) Issue Date Copies of certification provided General Comments Comments Comments

Passed Failed N/A

TECHNICAL CERTIFICATION CHECKLIST

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

18

Section 16

AUDIT INITIAL REPORT

Section Receiving and Storage Glass Cutting Seaming Pre-Heat Treat Washing Heat Treatment Process/Load QC Offline Heat-Treat, Quality/Final QC Actual Base-Line Optical MM Interleaving Edge Deletion Insulating Glass Washing Insulating Glass Assembly Post-Insulating QA Inspection Insulating Certifications Pass Fail N/A Comments

TECHNICAL CERTIFICATION CHECKLIST

Commendable Activities 1. Shop floor is well organized. 2. Maintaining the cleanliness of the production floor.

3. Concept of in house labeling is a positive action in terms of operation. 4. Enthusiasm and the support for the assessment is good.

5. 6. 7. 8.

9. 10.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

19

Required Required Corrections Prior to Awarding Certification 1. The oldest tag number of the inventory has to be mentioned in the job order for cutting.

TECHNICAL CERTIFICATION CHECKLIST

2. After opening the case tag has to be remained till completely consumed. Cutting operator has to mention the tag number used for completing each order.

3. Coated side detectors have to be used in each key point such as cutting loading end, seaming, furnace entry, IG line entry.

4. Pinch rolls have to be cleaned thoroughly. This has to be done frequently. All the possibilities which can dirt pinch rolls have to be controlled (e.g. stickers, ink marks on the glass)

5. A proper PM program has to be defined for washers, furnace and sealant systems based on the equipment manufacturers recommendations.

6. Inspection (transmission/reflection) lighting has to be provided at significant places such as furnace entry, furnace exit, IG washer exit, IG line end.

7. Offline quality of the tempered products and finished IGs has to be checked for optical quality, dimensional accuracy, flatness and quality of tempering.

8. Off line quality checking results have to be recorded in order to meet the requirements indicated in section 9 and 14.

9. All the material test results (desiccant, sealants, etc) have to be documented. Sealant tests need to be done after long holds and change over of batches.

10. IG records should show the batch number of each material used for the jobs completed.

11. Pre furnace washer has only one low E brush. At least one more hard brush has to be replaced with a low E brush and the hard brush has to be pulled out while low E products are washed.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

20

Recommendations for Improvement 1. (a) Define a serial number to the Ittihad tag number (b) Incorporate the Manufactures tag number to the Ittihad tag number

TECHNICAL CERTIFICATION CHECKLIST

2. Opened coated products have to be well covered, in case those are not going to be used for a long time.

3. Inventory has to be updated based on the tag consumption information of the cutting operator.

4. Preventive maintenance programs have to be defined for each machine based on equipment manufacturers recommendation. Main elements are item to be checked, frequency, faults, corrective actions

5. When manual cleaning is required, use appropriate cleaning liquid and material which is not harmful to coating during tempering operation. (Refer the section 8 of Processor Users Guide Commercial Products)

6. Each equipment should have a preventive maintenance program which is derived with equipment manufacturers guidelines.

7. Its better to have a well defined training program which defines the expectation of each operator, dos and dont s of each operation and trouble shooting guides.

8. On line inspection results of the furnace output can be recorded for process control purposes and calculation of the furnace efficiency.

9. Uniformity of the primary sealant layer has to be maintained.

10. LJF secondary sealant is not in the Guardians approved material list.

11. Water quality (pH, TDS, temperature) has to be measured and documented in specific intervals. Heating facilities have to be ensured in both washing machines.

12. All the requirements for the off line quality checking has to be fulfilled for the completion of off line QC.

13. For low E product washing, only low E (soft) brushes have to be used.

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

21

Section 17

CERTIFICATION STATUS
Certification Recommended Certification Pending Certification Denied
Documentation and Verification Bold items in this certification checklist are critical for successful successful product fabrication and good quality control Verification: The signature below verifies that the fabricator has read and understands the full contents of this Checklist and the following SunGuard fabrication documents: Fabricator Users Guide SunGuard Limited Warranty Heat-Treatment Guidelines Product Application Note. Edge Deletion Guidelines Product Application Note. Laminating Guidelines Product Application Note. Bending Requirements Product Application Note. Temporary Protective Film (TPF) Guidelines Product Application Note. Insulating Glass Guidelines Product Application Note. Thermal Breakage Guidelines Product Application Note. Heat Soaking Guidelines Product Application Note.
CUSTOMER REPRESENTATIVE NAME COMPANY

TECHNICAL CERTIFICATION CHECKLIST

CUSTOMER REPRESENTATIVE SIGNATURE

TITLE

GUARDIAN EXECUTIVE SIGNATURE

DATE

TECHNICAL CERT. CHECKLIST EDITION 1.0 February 2009 RAK

22