Once the materials have passed through these testing procedures, they are passed on to the product development department.
Material Quality Control : The Material QC team receives material for mass production and conducts their tests to ensure the articles are ready to be released. This team checks for:
During the lamination process, the material is tested for weight, adhesion strength and humidity.
Each production order has a corresponding work order that is generated by the production office. The work order mentions the appropriate cutting to be used on any particular work order.
Cutting tools are properly stored with their corresponding labels so that appropriate tools are used in the production process for a particular order.
After the laminated sheets have been gone through panel cutting, they move over to the printing department. Along with the cut panels, the printing team is provided with the approved artwork (CAD {Computet Aided Design}) and an approved sample ball for the corresponding work order.
Ink shades are mixed and double checked by implementing on raw panels, to ensure correct color is printed. A few balls are printed as pre-production samples which are then subject to the approval of the QC inspector. Once the QC inspector gives his/her green signal, printing on the order starts.
Once the printing is in process, our Director himself performs random checks to ensure that there aren’t any issues in the quality of the printing on the panels. After a batch order has been completed, a QC inspector performs an inspection on an AQL basis. If the batch order is within set standards, it is passed on to the next department: panel sorting.
After the printing process, panels are moved to a sorting department where a team sorts panels according to the complete final product configuration while also looking for any faults on the panel such as
The panels are then batched together and sent to the stitching department.
After the sorting department has sorted the panels and prepared panel kits, the panels move to the stitching department. PRO BALLONSTAR performs various kinds of stitching: Hand stitching, simple machine stitching and hybrid.
Placement of every panel at the correct location. Machine setting is as per recommendation
For the hybrid ball, after the casing is completed (in the same way as the machine stitching process)
Hand Sewn balls are stitched in a separate hall where the labor is provide with suitable equipment and environment. Stitching department head makes sure all balls are sewn in a correct way with suitable thread, ensuring equal number of stitches are there on each panel.
Once the casing is completed, the bladder is attached with the casing. The QC inspector randomly checks that bladders are properly bonded with the casing of the ball.
During the stitching process, an in-line QC inspector is responsible for making sure that products are properly stitched. Once the products have been stitched, there is a second layer of quality control to check products at the end-of-the-line.
The job of this QC team is to check that products were properly stitched, there are no uneven panels, stitching is not loose, all panels are stitched at their proper location, and products are properly cleaned so that they are ready for packing.
For balls, they are inflated and put on hold for 24 hours to check if there is any leakage in them. After 24 hours, a QC inspector checks the air pressure in each ball with a digital air pressure gauge. All the balls which have air pressure within the set standard are passed over to the packing department, which as a precautionary method, again physically checks the balls before packing them in the boxes.
