Card Quality Management in Card Production Personalization ICMA

Card Quality Management in Card Production & Personalization ICMA Euroforum 2011 Munich, 13 th October Presented by: Thies Janczek

Content u Introduction Quality Management u Card Production Assessment u Card Tests u Quality Strategy October, 13 st 2011 ICMA Euroforum, Munich COCASO 1

Quality Management Introduction u Yesterday l Quality Assurance u l u ISO 9001 first published in 1987 Today l Quality Management u October, 13 st 2011 Inspect Quality into Product Commitment, Communication, Culture ICMA Euroforum, Munich COCASO 2

Quality Management Introduction u What is Quality? l u What is Quality Management? l October, 13 st 2011 „Delighting the customer by fully meeting their needs and expectations“ „A set of coordinated activities to direct and control an organization in order to continually improve the effectiveness and efficiency of its performance. “ ICMA Euroforum, Munich COCASO 3

Quality Management Introduction Classical Quality Assurance Total Quality Management Humans make failures Processes provoke failures Single employees are responsible for failures All employees are responsible for failures Zero failure is not realizable Zero failure is the target Procurement from many supplier Partnering with selected supplier Customer need to accept the quality that is delivered Everything is focused on complete customer satisfaction October, 13 st 2011 ICMA Euroforum, Munich COCASO 4

Quality Management Introduction u Poor practices (examples) l l l l Leaders not giving clear direction Not understanding, or ignoring competitive positioning Each department working only for itself Trying to control people through systems Confusing quality with grade Accepting that a level of defects or errors is inevitable Firefighting, reactive behavior The “It’s not my problem” attitude October, 13 st 2011 ICMA Euroforum, Munich COCASO 5

Quality Management Production Objectives u Culture Change to „Right First Time“ l u Commitment to Continuous Improvement l u Never Stop Improving Total Costs View to be established l October, 13 st 2011 New Products and Components Testing versus Field Return/Claims ICMA Euroforum, Munich COCASO 6

Card Quality Management Card Production Assesment u Process and Product Assessment l l u In-Production Testing l u October, 13 st 2011 Quality Plan / Control Plan Identification of New Products/Materials l u Is every critical Parameter controlled? What are the Variables and Changes? Define Qualification necessities Yield limits / Scrap rates Monitoring ICMA Euroforum, Munich COCASO 7

Card Quality Management Card Tests - Definitions u u u ISO 7810 – ID Cards Physical Characteristics ISO 7811 -x – Magnetic Stripe Recording ISO 7816 -x – Integrated Circuit Cards ISO 14443 -x – Contactless Cards-Proximity ISO 10373 -x – Test Methods Further Specifications/Standards l E. g. ANSI, AFNOR, Tender (Health, ID-cards), Master. Card CQM, Customer Specifications October, 13 st 2011 ICMA Euroforum, Munich COCASO 8

Card Quality Management Product Quality Requirements u u u u Physical Characteristics l Size, Shape, Surface, Chemical, Magnetic, Electrical, Construction Temporal l Mechanical, Electrical, Magnetic, Ageing Functional l Electric, Electromagnetic, Magnetic, Terminal interface Appearance l Layout, Design, Brand, Color Ergonomics l Toxicity, Breaking Behavior Security l UV, Hologram, Signature Panel Miscellaneous l Manufacturing Process Stability October, 13 st 2011 ICMA Euroforum, Munich COCASO 9

Card Quality Management Card Tests - Considerations u Functional l u Durability l u Prefer In-House Testing Qualification/Production l October, 13 st 2011 Adjust for extended Lifetimes (Banking, ID) Internal vs. External l u 100% for Chip Cards Quick and Easy Tests in Production ICMA Euroforum, Munich COCASO 10

Card Quality Management Card Tests – Selection Card size Card Thickness Corners Edges Dynamic Bending test Resistance to Chemicals Card dimensional stability and Relief height of embossing after. Number and location of warpage with temperature and mechanical stress contacts humidity Relief height of embossing after Light Stability to Plasticizer temperature stress High and low temperature Durability Module Adhesion storage Abrasion resistance of Peel strength Temperature stability Personalisation Dynamic Torsion test Adhesion or blocking Bending stiffness Opacity 3 -Wheel test Overall Card Warpage Wrapping test High temperature storage in cantilever position Corner Impact test Surface distortions Impact test Adhesion of Add on's October, 13 st 2011 Tensile stress test to simulate Dimensions of contacts mailing Magnetic stripe tracks position UV-light Surface Profile and Height of contacts Mechanical Strength of contacts Electrical Resistance of contacts Local Pressure on Module w/ counter plate Static Electricity Discharge ICMA Euroforum, Munich X-Rays Static magnetic fields Color fastness Encoding on Magnetic Stripe Relative Height of Contacts COCASO 11

Card Quality Management Strategy / Recommendation u u In-Production Testing Monitor Performance Indicators l l Yield Rate Peel Strength u u l Module Adhesion u u Set Internal Minimum to 60 -70 N Test Matrix (changes vs. tests) l October, 13 st 2011 Set Internal Threshold to 6 N/cm Statistical Analysis as Early Indicator Identification of Changes (Material/Process) ICMA Euroforum, Munich COCASO 12

Card Quality Management in Card Production & Personalization THANK YOU FOR YOUR ATTENTION More Information: COCASO – Thies Janczek – Moewenstrasse 5 a – 24113 Molfsee – Germany Phone: +49 -(0)4347 -703526 – Email : janczek@cocaso. com www. cocaso. com October, 13 st 2011 ICMA Euroforum, Munich COCASO 13

October, 13 st 2011 ICMA Euroforum, Munich COCASO 14