Alternative Product Approval

Alternative products can improve availability, process capability, ergonomics or total cost. They can also change fit, aggressiveness, heat generation, finish, contamination risk, dust, vibration, product life, operator technique or downstream quality. A disciplined approval method separates useful innovation from uncontrolled substitution.

This chapter provides a customer-facing method for comparing an alternative against the current approved basis. It does not assign MKTECH-specific product specifications, operating values, performance results or guarantees. Exact product limits and identification remain controlled by the applicable product information.

Chapter objectives

After this chapter, the reader should be able to:

• recognise when a proposed product is an alternative requiring technical review;
• define the current approved application and product baseline;
• compare product identity, construction, dimensions and grading systems correctly;
• confirm machine, mounting, guard and accessory compatibility;
• review safety, contamination and downstream-process implications;
• prepare a controlled comparison with defined acceptance criteria;
• classify approval decisions and authorised conditions;
• update purchasing, stores, work and inspection controls after approval; and
• monitor early production and control later supplier or process changes.

Treat a product as an alternative when any characteristic relevant to fit, safe use, process behaviour, quality or identification differs from the approved basis. Examples include:

• a different manufacturer or product code;
• a different abrasive family or physical form;
• a change in diameter, thickness, bore, thread, shank, belt size or hole pattern;
• a different grain or grading system;
• a change in backing, bond, density, flexibility, structure or coating pattern;
• a different mounting accessory, backing pad, flange or contact wheel;
• a change in wet/dry use, coolant or process sequence;
• revised safety, storage, marking or shelf-life information; or
• a supplier change that affects product identity or construction.

A packaging change may be purely commercial, but it still needs review if it affects traceability, moisture protection, product condition or store identification. The significance of a change is determined by its practical effect, not by the supplier’s label of “equivalent”, “replacement” or “new generation”.

Routine replenishment purchases an already approved identity under established conditions. Alternative approval determines whether a different identity can enter that controlled route.

Do not permit a buyer, storekeeper or operator to substitute an unreviewed product solely to avoid a stockout. Urgency changes scheduling; it does not remove compatibility and safety questions.

Alternative approval is cross-functional when the change can affect production, safety, quality or stock control.

ISO 45001:2018 provides an occupational health and safety management framework that includes worker participation, hazard identification, risk assessment and operational control. Use the organisation’s current safety-management process for the actual workplace. [S359]

State why the alternative is being considered. Common reasons include availability, discontinuation, lead time, process improvement, reduced rework, ergonomics, technical support, standardisation or total cost.

The proposal should identify:

• current product and approved application;
• proposed product and supplier;
• reason for the change;
• expected benefit stated as an objective, not a guaranteed outcome;
• known technical differences;
• affected machines, parts, work areas and documents;
• proposed comparison and acceptance method; and
• owner and required decision date.

Do not write “same as current” unless each relevant field has been compared. A clearly stated difference is easier to manage than an assumed equivalence.

The baseline is the product, application, machine arrangement, process condition and result against which the alternative will be judged. It should be representative of normal acceptable production rather than an unusually favourable run.

If several approved applications use the current product, do not assume one comparison covers them all. Define the scope of approval by material, machine, operation and outcome.

Obtain the complete supplier-controlled identity before comparison:

• manufacturer and product name/code;
• abrasive family and intended operation;
• physical form and dimensions;
• bore, thread, shank, attachment or hole pattern;
• grain and grading-system designation;
• backing, bond, density, flexibility or structural description where relevant;
• required accessory or mounting component;
• product and packaging marking;
• Technical Data Sheet and applicable safety information;
• storage and shelf-life/use-by information where relevant; and
• change-notification and traceability information.

When an exact product speed, dimension, construction, compatibility limit, storage condition or ordering code is required, Refer to the product label, Technical Data Sheet, or MKTECH representative.

Record “same”, “different”, “not applicable” or “supplier clarification” for each field. Do not leave a blank field to be interpreted as compliance.

P grades for coated abrasives, F grades for bonded abrasives, superabrasive designations and proprietary grades are separate systems. ISO 6344, ISO 8486 and ISO 6106 provide distinct designation contexts. [S346; S347; S348; S349]

Do not approve an alternative because its number resembles the baseline grit. Compare the complete product construction and the result on the defined application. Grain type, backing, bond, structure, flexibility, coating pattern, contact system and process conditions can all change the outcome.

The proposed abrasive must be checked against the actual machine system, not only against a catalogue diameter.

Confirm:

• machine/tool type, model and operating range;
• product form and intended operation;
• outside diameter, thickness/width and bore or attachment;
• spindle, arbor, thread, shank or quick-change system;
• guard type, position and permitted product geometry;
• flange, blotter, nut, pad, contact wheel or accessory arrangement as applicable;
• available power and contact condition;
• wet/dry use and extraction/coolant arrangement; and
• product and machine speed compatibility using their controlled information.

ISO 12100:2010 provides a general machinery risk-assessment and risk-reduction method covering hazard identification, risk estimation, evaluation, documentation and verification. It remains the current published edition while a replacement is under development. [S358]

OSHA 29 CFR 1910.215 illustrates that abrasive-wheel guarding, mounting and flange provisions depend on wheel type and machinery arrangement. It is a United States regulation and is not presented as Malaysian law; use applicable Malaysian requirements, machine instructions and product information for the actual workplace. [S360]

An alternative may fit the machine yet behave differently on the workpiece. Review:

• material grade, hardness and coating;
• thin sections, edges, radii, datums and seal faces;
• starting scale, weld, burr, corrosion or prior finish;
• stock-removal allowance and dimensional sensitivity;
• heat, burn, heat-tint or distortion risk;
• loading, glazing, chatter, gouging or pull-out;
• contamination restrictions for stainless steel, non-ferrous materials or coating preparation;
• finish direction, texture and appearance;
• cleaning requirements and residue; and
• effects on welding, coating, sealing, fatigue-sensitive features or later inspection.

If the alternative changes the required process sequence or accessory, treat that as part of the proposal. Do not approve only the consumable while leaving the necessary process change uncontrolled.

Compare the baseline and alternative for:

FEPA provides separate safety guidance for bonded, coated and superabrasive product families. Use the instructions applicable to the offered product family. [S352]

Use a risk-based classification to set the depth of review without weakening essential checks.

Classification is not approval. It determines the review path; the final decision still depends on compatibility and the defined result.

Compare the baseline and alternative under conditions that represent the application and allow a fair decision.

Define:

• sample identity and traceability;
• workpiece material, geometry and starting condition;
• machine, guard, interface and accessory;
• operator method and sequence;
• wet/dry condition, coolant and extraction;
• required outcome and inspection method;
• observation points such as cut control, loading, heat, finish and product condition;
• stop conditions for unsafe, damaging or clearly unacceptable behaviour;
• sample quantity or comparison duration from the approved quality/risk method; and
• responsibility for observation, measurement and decision.

Do not alter several variables at once unless the proposal is intentionally a complete process-system change and the comparison is designed accordingly.

Acceptance criteria should reflect the functional and production risks of the application.

ISO 2859-1:2026 and ISO 28590:2017 provide frameworks for attribute sampling and selection of sampling systems. Do not assign an AQL, inspection level, sample size or acceptance number without the organisation’s approved sampling method and risk basis. Sampling does not prove every unit conforms. [S356; S357]

Replace “better”, “faster” or “feels good” with defined observations and measurements. Useful records can include:

• component or cut identity;
• baseline and alternative product identity;
• machine and accessory;
• start and finish condition;
• inspection results and defect observations;
• product changes or interruptions;
• operator feedback linked to a defined question;
• rework, rejection or downstream effects; and
• deviations from the planned comparison.

Operator feedback is important, especially for control, access, loading and vibration. Combine it with objective inspection where the decision affects quality or safety.

Price, lead time or availability may influence the business decision after technical classification. They do not convert a technically unacceptable product into an approved alternative.

Record the exact boundary of approval:

• proposed product identity and revision;
• approved workpiece material and condition;
• operation and process stage;
• machine/tool and accessory combination;
• product form, dimensions and mounting;
• wet/dry condition and coolant/extraction arrangement;
• required sequence and operating envelope;
• inspection and acceptance method;
• limitations and prohibited uses;
• effective date, owner and authoriser; and
• relationship to the previous product—additional option, preferred option or replacement.

An approval for weld blending on one machine does not automatically cover cutting-off, another machine, another alloy or another product size.

Update, as applicable:

• approved-product or specification record;
• purchase description and supplier reference;
• receiving inspection and traceability fields;
• store location, label and segregation status;
• issue and return controls;
• machine, accessory and setup information;
• work instruction and operator communication;
• inspection plan and reference samples; and
• superseded descriptions and emergency-buying lists.

ISO 10005:2018 supports the establishment, review, acceptance, application and revision of quality plans. ISO 10007:2017 supports controlled identity, configuration status and change management. These principles help keep the approved alternative aligned across its lifecycle. [S354; S355]

Use an appropriate early-production monitoring period for the application risk and usage pattern. Confirm that the released product continues to produce the approved result under normal production variation.

Monitor, where relevant:

• receiving identity and condition;
• fit and mounting consistency;
• process stability and operator control;
• finish, dimensions and defect trends;
• contamination and downstream effects;
• product consumption, rework and interruption;
• safety observations and exposure controls; and
• supplier, packaging, marking or construction changes.

Define a reversion route before release. If the alternative produces an unsafe condition, machine incompatibility, damage or unacceptable quality, stop use, segregate stock and restore the last authorised method where safe and available.

For exact marking, speed, storage, use or compatibility information, Refer to the product label, Technical Data Sheet, or MKTECH representative.

Before authorisation, confirm that:

• the reason for change and approval owner are clear;
• the current baseline and proposed product identities are complete;
• product family, dimensions, mounting and grading system are compared;
• machine, guard, accessory and speed compatibility are confirmed from controlled information;
• workpiece, finish, contamination and downstream risks are reviewed;
• safety, environmental and operator considerations are addressed;
• the controlled comparison uses representative conditions;
• acceptance criteria and inspection methods are defined;
• observations and deviations are recorded;
• the decision category and scope are explicit;
• purchasing, stores, work and inspection controls are updated;
• early-production monitoring and reversion routes are defined; and
• later supplier or process changes return through change control.

• Never use similarity in colour, size or grit as proof of safe interchangeability.
• Confirm the complete product, machine, guard, mounting and accessory combination.
• Do not exceed the lower permitted speed of the machine/product combination.
• Stop comparison immediately for unsafe behaviour, damaged product, loss of control or incompatible mounting.
• Segregate unapproved and rejected evaluation stock from released production stock.
• Follow the product label, Technical Data Sheet, machine instructions and workplace risk controls.

Chapter 060 begins on the following page of the printed handbook (page 543), outside this chapter extract.