As head of quality assurance, Frenzel u. a. also the quality of the delivery, the products on delivery as well as the complaint management.
The vosla site measures about four football fields – and in terms of quality control, the whole thing has something of a high-security wing. With the supplier selection and material delivery it starts: There are highest performance requirements and descriptions regarding all starting materials like u. a. Soft glass, quartz glass, toughened glass, tungsten and molybdenum, followed by sometimes meticulous input controls.
Tungsten, for example, must have the correct, exact diameter, be clean and tensile and have no grooves. The team produces an incredible 32,000 lamps per shift. Each resulting lamp passes during its production a course of barely countable controls. In the context of prefabrication, this concerns the production of specific – and secret – gas mixtures of halogen and rare gas for the later filling of the lamps in the different production lines. “Even this mixture is immensely important for product quality,” emphasizes Frenzel.
Even if primitive forces prevail – it is no excuse for an inaccurate measurement
The same applies to the also internal spiral or filament winding and – production. Imaging systems check the tiny coils with relentless precision: even the tiniest deviation – far beyond the norms to be complied with – leads to immediate automated sorting.
This is followed by application to a molybdenum frame, over which the glass body is slipped in the next step. The glass is then heated at the bottom and the wire rack squeezed into the glass. Here, too, detectors and measuring monitors that mercilessly track down every little mistake with microscopically enlarged detail images. Despite piston forming, gas filling and capillary formation, despite the enormous production speed, despite the hissing and chattering, extremely high, then again frosty temperatures: Instead of just random checks, at Vosla every single lamp in every single production step is analyzed and tested in detail.