Quality Assurance of Roll Forming Processes

At OMCO, superior quality is everyone’s responsibility.

Quality products begin with a detailed review of a product print and its associated requirements. Next, robust engineering designs are generated to produce the tooling necessary to manufacture the part to its defined specifications. Those designs are then transformed into reliable and repeatable manufacturing operations and procedures. Finally, our employees’ desire to consistently deliver the best possible part is crucial to achieving our ultimate quality objective … highly satisfied customers.

Our management system has been certified to ISO 9001.

Our quality team is committed to driving our continuous improvement processes in order to achieve the highest level of quality possible. Tools utilized to manage, monitor, and direct our continuous improvement effort include:

  • Statistical Process Control (SPC)
  • Pre-Production Approval Process (PPAP)
  • Failure Mode and Effect Analysis (Processes)
  • Six Sigma
  • Continuously Review and Update Standard Operating Procedures (SOP)
  • On-going Operator Training
  • Visual work instructions
  • Coordinate Measuring Machine (CMM)

Standard Tolerance Guide for Roll Formings

When customer specific requirements are not provided, OMCO adheres to the following Standard Tolerance Guide, relative to both roll formed parts and secondary operations as applicable.

Cross Section Tolerance
+/- .015 on decimal dimensions
+/- .032 on fractions
+/- 1 degree on angular dimensions

Part Length Tolerance
+/- 1/32″ for lengths less than 72″
+/- 1/16″ for lengths from 72″ to 120″
+/- 1/8″ for lengths over 120″

Pre or Post Punch Length Tolerance
+/- .008 per foot of length with non-random end spacing

Camber and Sweep Tolerance
1/8″ Maximum if 10′ length

+/- ½ degree per foot, can be greater in some sections depending on shape and material; depends entirely on part, radii, material, and number of passes

End Flare Tolerance
The amount of end flare is determined by material type, gauge, and sections shape. End flare can sometimes be controlled with the addition of over forming passes if necessary.