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Stage 1: Formulation Development

Acetone extraction tests verify the post cure volatility of the phenolic resin (residual uncured). Industry standard is <2% after post-bake (secondary cure) is acceptable. The ABS "low resin content" formulations perform on average at <0.5% without the need for the post-bake process.

Reacting to our customer's needs, ABS conducts Dynamometer testing for research and development of existing and new formulations.

ABS Friction is a manufacturer that performs in-house BEEP testing (Brake Effectiveness Evaluation Procedure) based on the SAE J2430 test, which then parallels the FMVSS 135 test (the O.E. Standard). ABS has passed BEEP vehicle testing requirements.

Stage 2: Steel Plate Processing

Manufacturing is scheduled by Distribution to meet incoming customer orders quickly and efficiently.

Our ISO/TS16949 registered suppliers guarantee reliability of their backing plate fit & function.

These suppliers certify the quality of the materials they provide with each and every shipment.

Certification lot numbers are recorded into manufacturing documents for tracking purposes.

What is ISO/TS16949?

The aim of ISO/TS16949 is the development of a quality management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain. TS16949 applies to the design/development, production and, when relevant, installation and servicing of automotive-related products. It is based on ISO9000.

Stage 3: Quality Board

All ABS employees undergo extensive quality training and are tested to verify their abilities prior to working in our manufacturing facility.

Boundary samples are displayed in our facilities to assist our employees in quality decisions.

Stage 4: Mixing

A controlled list of specified ingredients ensures all ABS formulations are made with premium quality materials.

ABS materials are purchased on performance over cost considerations. No compromises are ever made to affect performance adversely.

Using Statistical Process Control (SPC), ABS charts and monitors the trend results of the raw material supplier's performance measurements.

The supplier's certification date is recorded into the formulation document enabling for tracking purposes.

Stage 5: Repeatability Testing

For each batch mix, destructive testing (molding, shear and specific gravity) verifies a product's integrity prior to production use. Established upper/lower tolerances must be met before being approved.

Baseline results have been determined at an independent lab for comparison to ongoing in-house performance repeatability testing (Friction Assessment Screening Test - FAST). The coefficient of friction outcome indicates proper formulation performance.

Stage 6: Preform

Production will only use formulation batches that have Quality Assurance authorized approvals.

Batch numbers are recorded onto work orders for precise tracking purposes.

Preforms not meeting acceptable weight and dispersion criteria are reprocessed to prevent incomplete molding.

Stage 7: Molding

Routine monitoring (pressure and temperature checks) using calibrated measuring equipment controls the conditions of our most important molding process.

ABS high tonnage molding presses allow us to manufacture better performing "low resin content" formulations.

When maximum density is reached in the molding cavity, excess material escapes into the flash ring, thus allowing for the preform weight variation without negative effect on the density of other cavities.

Stage 8: Preclean and Paint

Product de-burring and flash removal is essential for the aesthetic and functional performance of paint finish.

ABS achieves a very durable paint finish with tandem cleaning and electrostatic paint processes to yield a premium powder coat finish for superior protection and appearance.

Stage 9: Inline Diamond Grinding

Grind thickness and flatness specifications are critical in our manufacturing process. Our centrally controlled electronic Bill of Materials and Parts References secures reliability of engineering specifications.

Our inline progressive cut grinding equipment uses diamond wheel stones that consistently achieve the flattest surface grind tolerance.

ABS inline grinding equipment meets or exceeds OE slot and chamfer features without extra processing.

Stage 10: Visual Inspection

Prior to transfer to distribution, every ABS part must pass a 100% visual inspection for defects according to one of the most stringent acceptance criteria in the industry

Stage 11: Orbital Hardware & Applied Shims

All hardware is attached with orbital equipment that secures the hardware with minimal force during assembly, thus preventing friction material damage.

Based on customer's requests, ABS offers shimmed programs. ABS offers only secured shim attachments  such as "Stake On", "Click On", "Drift Lock" and then "Bend Tab".

Stage 12: Customer Specific Final Inspection 

ABS Pack Line Operators perform many checks for proper packaging, set assembly and the quality of each ABS pad before it goes to the customer.

Final inspection audits are performed at a high proportional frequency to finished product shipments. The pass rate and concerns (if any) are reported back to the Packaging Teams to ensure we continuously and constantly improve upon performance.

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