More about Beckmann Converting!
A customer Needs Assessment is created and kept current on each and every existing product and new product development project through interviews and dialogue with our customer. It serves as a guide and communication tool for both parties on what is deemed to be most important to the customer.
What is the typical development process through Beckmann Converting from concept to a finished laminate ready for customer use?
Hand sample trials > Experimental roll trials > Validation Production Roll Trials > Customer Acceptance as a product > Commercial Production.
Hand sample trials: Hand size pieces that are approximately 12" wide by 20" long of each layer are ultrasonically bonded with the appropriate roll to confirm the ability to laminate the layers. This is where the dialog starts so we understand what you need to be successful.
Experimental roll trials. Short runs of roll goods are typically billed at an hourly rate ($/hr instead of $/ly or lm). Often used to develop or confirm specification values for bonding or other performance criteria. Materials need to be on 3” cores or 6" cores or 6.75 " cores.
Validation Production Roll Trials. Run with full size rolls using issued specification. Most customers have one to three qualification production runs before the product is accepted. Charges may be as a trial ($/hr) or as production ($/ly or $/lm) depending on volume.
Customer Acceptance as a product. Customer issues a formal statement that product as produced to their specification is accepted. Final pricing is confirmed for minimum quantity with defined testing frequency and packaging requirements.
Commercial Production. A BCI style number is issued by Beckmann Converting after review of customer acceptance materials. Production runs are executed to the detailed requirements of individual purchase orders.
Hand samples are made on our ultrasonic bonding production equipment to ensure samples that are as representative of production results as possible.
We generally process hand samples at no charge, assuming the quantity needed is reasonable. We do this because we need to understand what you (the customer) are seeking and to be sure what you want is possible before either side invests a lot of time and money to develop a laminate.
Hand trials that require a larger number of finished samples or require special resources to execute may be charged by the hour.
For a hand trial, we need paper sheet-sized samples approximately 12" wide by 20" long.
Every product requires a customer written specification prior to the Production Validation Trials. The specification indicates product performance criteria, testing protocols, an assessment of the customer's priorities, and potential problems and concerns. The original product specification or a revision number is referenced on all purchase orders and is part of the Order Confirmation process whereby Beckmann Converting officially accepts a purchase order.
If a customer does not have experience creating these types of specifications, Beckmann Converting will provide a suitable format and consultation on details that need to be included.
Yes, we provide testing services to support laminating. Product testing in our quality control laboratory centers on measuring the quality of the bond generated by our laminating processes. Other characteristics that are impacted by the bond quality may also be tested, including dimensions such as slit widths and laminate thickness. Should a customer request testing on other physical aspects of the laminate, Beckmann Converting will make every effort to provide it internally or as an outsourced service to be included as part of the price quotation.
Yes, Beckmann Converting has a Quality Management System that is certified to ISO 9001: 2015. Our certificate is attached as a pdf.
Yes, Beckmann Converting can supply COA documentation as required. The customer provided written product specification should detail what measurements need to be taken and the frequency so that a sampling and testing plan can be crafted.
Example of a COA:
The customer provided written product specification should detail what measurements need to be taken and the frequency.
Example of a COC:
Beckmann Converting will take responsibility for special testing, manufacturing or packaging equipment provided by the customer that is required for successful lamination. Customer owned equipment needs to be labeled clearly as their property. A written Bailment agreement describing the equipment, its value, and the terms for leaving it at Beckmann Converting would need to be provided. For equipment valued at $100,000 or greater, additional documentation may be required as to the value and condition of the equipment.
Any and all customer complaints including those involving non-conforming product is managed through a formal process that is detailed in our ISO Quality Management System. The problem as stated by the customer is recorded, the date the material was laminated, a description of the extent of the problem and, where possible, the actual roll number(s) it was shipped under. Product samples demonstrating the stated problem and additional information should be provided. A formal review and root cause analysis will be conducted. A report and final disposition will be provided to the customer at the earliest possible date.
Laminates manufactured by Beckmann Converting often are leading edge proprietary materials in products selling into highly competitive markets. The sanctity of intellectual property, including trade secrets, is essential. Safeguards are in place and all employees are trained to maintain confidentiality of customer information. Information about a product or customer is only released if written approval is provided by the customer. In most cases a mutual Non Disclosure Agreement (NDA) is executed between our customer and Beckmann Converting so that both parties can be full protected.
Laminating equipment and processes are custom designed and built by Beckmann Converting and are considered proprietary as trade secrets by our company. Restrictions are placed on what may be viewed by customers and others when visiting Beckmann Converting on a case by case basis.
Inventory of both raw materials and finished goods on site greatly facilitates the flow of goods for our customers. Buffer quantities help level peaks in demand and managing any unforeseen problems. Typically production runs are invoiced upon completion or at specified intervals for extended runs.
There are two special considerations for raw material inventories stored on site. (1) Our insurance will cover material in our building covered by a customer order we have on our books. Raw material over this quantity needs to be covered by the customer’s insurance. (2) Material that has been on Beckmann Converting’s premises for over 18 months will be charged a storage fee after notification that this time has expired. Any raw materials or finished product inventories directed by the customer for disposal may require fees to be charged- a quotation for associated costs will be provided to the customer.
YES. We provide this service now to several customers. In fact, we have customers that we provide domestic and international shipping, where Beckmann Converting is the customer’s C-TPAT shipper (United States Customers Trade Partnership against Terrorism) for overseas shipments. In most cases our customers arrange their own transportation of raw materials and finished laminated product.