This manual describes for our employees and customers our quality
control system. The system applies both to the items we produce and to the
items we buy from our suppliers.
As dictated by the complexity of product design, manufacturing
techniques used, and customer requirements, more specific written
procedures may be required to implement the policies set in this manual.
No changes may be made to this manual or any supplementary quality
control procedures unless approved by the plant manager or an authorized
representative.
Table of Contents
Description Section
Scope 1.0
Responsibilities 2.0
Purchase Order Control 3.0
Drawing and Specification Change Control 4.0
Receiving Inspection 5.0
Raw Material Control 6.0
In Process Inspection 7.0
Assembly Inspection and Functional Testing 8.0
Final Inspection and Testing 9.0
Faulty (Discrepant) Material Control 10.0
Tool and Gage Control 11.0
Overrun Stock Control 12.0
Packing and Shipping 13.0
Identification 14.0
Appendix A Organization Chart
Appendix B Purchase Order Form
Appendix C Inspection Data Form
(Each company should use its own forms for the Appendices).
Appendix D Identification Tags
Appendix E Travel Card
1.0 Scope
1.1 The quality control system includes: receiving, identifying,
stocking and issuing parts and material; all manufacturing processes;
packing, storing; and shipping.
1.2 The system is designed to ensure customer satisfaction through
quality control management of supplies made and services performed here,
and by our suppliers at their facilities. It is designed to spot
processing problems early so we can correct them before we've produced a
lot of faulty items.
1.3 Written inspection and test procedures will be prepared to
supplement drawings and other specifications, as necessary.
2.0 Responsibilities
2.1 The supervisor of quality assurance reports directly to the plant
manager.
2.2 The quality assurance supervisor's responsibilities include:
2.2.1 Planning how to meet customer's quality requirements
2.2.2 Reviewing customer drawings and specifications.
2.2.3 Determining inspection points.
2.2.4 Writing inspection and test instructions.
2.2.5 Establishing (and making sure employees follow) the most
effective and efficient quality assurance procedures possible.
2.2.6 Keeping adequate quality assurance records.
2.2.7 Reviewing quality assurance records and overseeing follow-up for
correction and prevention of defects.
2.2.8 Assuring that our suppliers' quality control and follow-up are
adequate.
2.2.9 Inspecting all special and standard gages, test equipment, and
tooling used to manufacture products when we acquire them and calibrating
them on a regularly scheduled basis.
2.2.10 Coordinating in-plant correction of items rejected by customers,
explaining to customers what action will be taken, and evaluating the
actions for effectiveness.
2.2.11 Making sure inspectors make unbiased decisions to accept or
reject items.
3.0 Purchase Order Control
3.1 All of our purchase orders to suppliers must be approved by the
plant manager or an authorized representative.
3.2 When the purchase order is released, our buyer will send our
supplier all required drawings, specifications, and other customer
requirements (such as material or process certifications, physical or
chemical analysis, source inspections) with the purchase order.
3.3 If there is a drawing or specification change after our order is
placed with the supplier, our buyer will send the supplier a purchase
order change, including our latest Engineering change and the latest
drawings or other specifications.
3.4 Copies of all purchase orders will be kept on file for our
customers to review.
4.0 Drawing and Specification Change Control
4.1 We manufacture to customer drawings and specifications. Sets of
these are filed in job number folders in Production Control files.
4.2 Production Control is responsible for charging out and keeping
track of drawings and specifications.
4.3 The Sales Department receives Engineering changes from our
customers and is responsible for sending these changes to Production
Control immediately.
4.4 Production Control is responsible for issuing the latest
Engineering changes, drawings, and specifications of departments that need
them and for voiding outdated Engineering changes, drawings, and
specifications.
4.5 A standard procedure will be set up to control changes by effective
date or serial/lot number.
5.0 Receiving Inspection
5.1 All parts and materials will be received and logged in by the
Receiving Department.
5.2 All parts and materials will be sent to Receiving Inspection after
logging in.
5.3 Receiving Inspection will assure that proper certification,
physical and chemical test data, special process certifications, or source
inspection certifications are with the items to be inspected.
5.4 The receiving inspector must document the complete results of all
inspection and tests.
5.5 Inspection will identify accepted lots and send them to stock.
5.6 Rejected lots will be identified and set aside in Receiving
Inspection until the buyer and Production Control decide on disposition.
5.7 The Receiving Department will send a copy of each rejection report
to the Purchasing Department and the supplier.
5.8 The Purchasing Department has the responsibility of assuring that a
pattern of continually receiving faulty items from any supplier doesn't
develop and assuring supplier corrective action.
5.9 The Quality Department will follow-up to see that a supplier who
has sent us items we reject has effectively corrected what it has been
doing wrong.
5.10 Receiving Inspection instructions will be written with
consideration given to the complexity of the parts, material received, and
customer requirements. Follow customer instructions (if any) for
inspection.
5.11 Sample according to customer requirements (if any).
5.12 The Quality Department will review Receiving Inspection records
periodically to see if any suppliers are consistently failing to meet
standards.
5.13 All inspection records will show the number inspected, the number
rejected, and the name of the inspector.
5.14 Inspection records will also show the disposition of
supplier-provided records and data.
6.0 Raw Material Control
6.I Raw materials, bar stock, sheet stock, and castings will be marked
so they can be traced to their certification, and stored in an area apart
from the normal flow of in-process material.
6.2 Copies of all certifications will be filed in the job order number
folder by job order number and available for customer review.
6.3 Only raw material accepted by Receiving Inspection will be released
for production.
6.4 Certified stock will be issued from its storage area only for job
order requirements.
6.5 Verification of suppliers' certifications will be ordered from
independent testing laboratories when deemed necessary by the Quality
Department or to meet our customers' requirements.
6.6 All certifications will be traceable to purchase order, date of
receipt of the material, and the inspector of the material.
In Process Inspection
7.1 The Quality Department will make first piece inspection after set
up is completed and approved by Production.
7.2 No production runs will be made until first piece inspection is
accepted.
7.3 After first piece inspection acceptance, in-process inspections
will be made by the Quality Department at intervals adequate for early
detection of processes producing material that doesn't meet standards.
7.4 The Quality Department will keep records of all first piece and
in-process inspections.
7.5 The inspection records will be stored in the job number folder and
will be available for customer review.
7.6 Tag or otherwise identify rejected items and move them to an area
apart from the normal flow of in-process materials.
7.7 The Quality Department will follow-up to prevent recurrence of
faulty material.
7.8 Inspection records will list: the number of pieces accepted, the
number rejected, kind of defects and basic causes of rejection, date of
inspection, and the inspector's name.
7.9 Attachment shows the locations of fabrication and inspection
stations. For each station, it lists the types of items subject to
inspection, the kind of inspection done, and the applicable drawings and
specifications.
7.10 Special processes will require appropriate inspections and
controls, including qualification and certification of personnel and
equipment.
8.0 Assembly Inspection and Functional Testing
8.1 Production personnel will make assembly inspections and do
functional testing, as required.
8.2 The Quality Department will check functional test under an
established sampling plan.
8.3 The Quality Department will keep the inspection records.
8.4 The inspection records will be kept in the job number folder and
will be available for customer review.
8.5 All faulty (discrepant) assemblies will be marked and set apart so
they won't be accidentally used.
8.6 The Quality Department will initiate corrective and follow-up
action to prevent recurrence of faulty material.
8.7 Inspection records will list: the number accepted, the number
rejected, the date of the inspection, and the inspector's name.
9.0 Final inspection and Testing
9.1 Final inspection and tests will be performed either on 100 percent
or on a sample of the items. The number of items sampled will depend on
the complexity of the items and customer requirements. Inspection will
follow either customer-supplied procedures when available or MIL-STD-105D.
9.2 Each end item will be inspected/tested 100 percent, unless the
customer asks otherwise.
9.3 The Quality Department will keep all final inspection and test
records.
9.4 Inspection and test records will be filed in the job number folder
and will be available for customer review,
9.5 The Quality Department will follow-up to see that processes
producing faulty materials are corrected and to prevent recurrence of
faulty material from those processes.
9.6 All faulty material will be marked and set apart from the normal
flow of finished material.
9.7 Faulty material will not be shipped to the customer without
specific customer instructions to submit such Nonconforming material.
9.8 Rejected material which has been repaired, reworked, or sorted must
be resubmitted to final inspection to make sure it meets requirements.
9.9 Inspection records will list: the number of pieces accepted, the
number rejected, the date of inspection; and the inspector's name.
10.0 Faulty (Discrepant) Material Control
10.1 All faulty (Nonconforming) material, supplies, or parts will be
placed in a "DO NOT USE" area. The items will be clearly marked with job
number, part number, revision letter, lot size, defect, inspector's name,
and any other information necessary.
10.2 The specific reason an item has been rejected will be clearly
written on a rejection tag attached to each part or container.
10.3 No one may remove items from the "DO NOT USE" area until
disposition is determined by a Material Review Board made up of the plant
manager, and representatives of the Production and Quality Departments.
10.4 Nonconforming material will not be shipped unless the customer's
buyer approves it. The shipping documents will be marked with what's wrong
with the items.
10.5 The Quality Department will control all lots submitted for
acceptance inspection. Each lot will be kept as a unit, apart from other
lots, and out of the normal flow of material.
10.6 During the processing of material all production and inspection
operations must be kept in proper order. Each step must be completed
before the next step is begun.
10.7 The Quality Department will set up a system so that the stage of
inspection each item is in, can easily be identified.
10.8 Unidentified material will be taken out of the normal flow of
production until it is inspected to insure that it meets all
specifications.
10.9 Reworked material will be segregated from other material until the
Quality Department determines its status.
11.0 Tool and Gage Control
11.1 All special tools, jigs, fixtures, gages, and measuring equipment
must be properly identified,
11.2 Each new or reworked tool, jig, fixture, gage, and item of
measuring equipment will be inspected before issue for use.
11.3 All gages, measuring and test equipment will be calibrated to
standards.
11.4 A written schedule for calibrating gages, measuring and test
equipment will be set and strictly followed. Frequency of calibration will
be based on type and purpose of the equipment and severity of usage.
11.5 A restricted area for storing and calibrating gages, measuring,
and test equipment will be set up.
11.5.1 A strict system of issue, control, and return will be set and
followed.
11.6 If the customer supplies special gages, they will be checked at
the intervals the customer sets. If the customer supplies no inspection
schedule, the equipment will be checked according to a schedule that takes
into account type, purpose, and severity of use.
11.7 Calibration will follow the written procedures kept in the
calibration area.
11.8 Obsolete or out-of service tools and gages will be tagged.
11.9 Decals or stickers will be put on tools and gages or their
containers to show the last date of calibration and the due date of the
next calibration.
11.10 Personal, as well as company-0wned production and inspection
tools, must be properly and regularly calibrated.
12.0 Overrun Stock Control
12.1 The Quality Department will oversee overrun stock.
12.2 The Quality Department will insure that any overrun parts sent to
stock are properly marked "accepted." The part number, latest drawing
number and specification revision, date of inspection, job number, and
quantity of parts will be shown. The Quality Department will periodically
check to see that the parts are properly packed to prevent deterioration
and damage.
12.3 No overrun parts will be shipped to a customer until they are
reinspected and found in acceptable condition and to meet the latest
drawing and specification revisions.
13.0 Packing and Shipping
13.1 No order will be shipped to a customer until all shipping papers
are stamped or signed and dated by the final inspector.
13.2 No order will be shipped until all required certifications, test
reports, special samples, etc., have been packed with the material in
accordance with the customer's requirements and accepted by the final
inspector.
13.3 All material will be packed to prevent damage deterioration, and
substitution.
13.4 The customer will be identified on the packaging, parts, and as
otherwise necessary to prevent lost and misdirected shipments.
13.5 The order will be packed as directed by the customer, if
applicable.
14.0 Identification
14.1 All materials and articles will be identified by a basic part
number and revision letter.
14.2 Critical materials and articles will also carry a serial or lot
number. If required, a list of materials and articles by identification
numbers will be attached.
