Quality Control

The key to Kerox' outstanding reputation is its multi-stage quality control system that tracks each product through the entire production process.

These stages include:

  • Incoming inspection for outsourced cartridge components
  • thorough inspection and press trials of mold tooling before being
    approved for production use.
  • Testing of individual components prior to assembly
  • Testing at sub-assembly stages
  • Final testing of completed cartridges (100%)

These basic quality guidelines are then carefully applied to the following specific components and assemblies:

Ceramic Discs: The discs, made from select European raw material, are 100% inspected with an Automatic Optical Inspection (AOI) system, providing exacting analysis of all surfaces, edges and main dimensions.

Process Control techniques are used throughout the manufacturing processes to carefully monitor and keep under control such product characteristics as surface roughness, flatness and contact surface area ratio. These steps are critical in assuring leak resistance, low torque, low operating forces, and long term reliability in every Kerox cartridge.

Plastic Components - dimensional exactness is assured by computer controlled injection molding processes, as well as thorough inspection procedures.

Outsourced Components - a strict incoming inspection procedure allows only dimensionally correct parts to enter the production flow.

Tooling - Kerox maintains an on-going monitoring of the condition of its tooling to guard against possible degradation of quality. Tooling is kept in first-rate condition at all times.

Sub-assembly testing - each cartridge is checked in every sub-assembly stage and approved before being allowed to enter the next production phase. Before leaving the plant each Kerox cartridges goes through a last inspection.

Final Testing - After assembly, each cartridge is tested to be leak-free using a pneumatic process that provides far greater sensitivity than water. After successful testing, cartridges are stamped with a confirming serial number that can be used for future tracing in the event of a field problem.

Laboratory Samplings of Finished Cartridges - In addition to 100% pneumatic testing on the production line, the company's state-of-the-art laboratory is used to perform even more stringent periodic tests of production samples, based on various worldwide standards.

Packaging - finished cartridges are carefully and securely packed to assure protection against shipping damage and contamination.

The above processes are supported by professional procedures and equipments that include:

  • Quality planning, and quality goals
  • Quality Control Procedures
  • Preventive maintenance of molds
  • Supplier assessment
  • Statistical Process Control studies
  • Quality Control Plans
  • Design of Experiments
  • PPAP familiarity
  • Production process FMEA's; and internal reports to support manufacturing and supervising
  • Separate procedure for handling of non-conforming products
  • Professional equipment, such as computer-controlled test benches used for hydraulic testing under a wide range of temperature and pressure variables and extended life cycle testing.
  • Monitored and calibrated tools and measuring equipment

Kerox compliance with worldwide standards is fully supported by relevant certification. In addition to documentation concerning such certification, laboratory reports of company-conducted testing are readily available.

Kerox cartridges meet the most demanding test and certification requirements worldwide, complying with relevant standards of EN, NF, ASME/CSA, ASSE, GB, and water-contact parts are approved by DVGW, WRC, NSF, ACS and ASNZS4020. Most models designed for primary use with potable drinking water are NSF listed (including all single-lever models).