Complete QC Manual Quality Assurance Our inspection system procedures assure conformance to contract requirements. The provisions incorporated hereafter are in accordance with MIL-I-45208A. Unless otherwise requested, the order of precedence for contract requirements shall be: 1) Purchase Order 2) Drawings 3) Supporting Specifications This shall apply to all orders requiring the application of MIL-I-45208A. Organization Chart   Authority of Quality Control Inspection Department has the authority to place stop orders on production where deviations from quality control standards have occurred. At this time quality control director and production control will make necessary corrections. Revisions All requests for revisions to our quality control standards reviewed by Quality Control for applicability and adherence to appropriate specifications. Revisions will be documented, appended and initialed by Quality Control. A complete review of our quality control system will be conducted annually to assure compliance with applicable specifications and so noted under the revision control appendices. Revision Record   Manufacturing Operations The purpose of this document is to identify work in process, sequence of operations, operator, inspection documentation and special instructions. One Manufacturing Operations Sheet is issued for each production lot. The individual operator and/or inspector is responsible for the entries required for each operation. Each operation will be subject to a First Article inspection and in-process inspections as deemed necessary. The product will be subjected to a Final inspection and documented on the Manufacturing Operations Sheet (see Sample Plan for quantity.) The completed Manufacturing Operations Sheet is maintained in the customer file with the drawing, certifications, specifications and other pertinent data. Manufacturing Operations Sheet   Document Change Control Drawings and specifications are filed by customer name. Quality Control shall be responsible for assuring that the correct drawings and specifications of the required revision accompany the released Manufacturing Operations Sheet and are made available for use by production and inspection. Quality Control shall be responsible for making changes received from the customer and assure the obsolete drawings/specifications are removed and clearly identified as obsolete. When a change is put into effect the Manufacturing Operations Sheet must be revised, dated and initialed and the product in process must be reviewed to determine the effectivity of potential rework or separation. Special instructions on the Manufacturing Operations Sheet shall denote proper action. All drawings, specifications, Manufacturing Operations Sheets, certifications and other pertinent data shall be returned to the customer file folder upon completion of the finished product. Corrective Action This procedure details the method of securing corrective action to prevent a repeated discrepancy/rejection. There are two types of action required. IN-HOUSE CORRECTIVE ACTION: Discrepancies caused internally, parts having been rejected by inspection or returned from the customer. VENDOR CORRECTIVE ACTION: Discrepancies of material, parts or processes as received from a vendor. IN HOUSE C.A.R.: When a rejection occurs during the in-house operations or hardware is returned from the customer as rejected, the IN-HOUSE C.A.R. form will be completed and filed in the customer file folder or attached to the Manufacturing Operations Sheet in process. VENDOR C.A.R.: When material, parts or processes are rejected at receiving inspection, a duplicate VENDOR C.A.R. form will be initialed, original to vendor, duplicate to follow-up. Upon receipt of acceptable VENDOR C.A.R., the duplicate will be pulled and filed in the vendor file. In House Corrective Action Request   Vendor Corrective Action Request   DATE: __________ TO:         ATTN:   REF. P.O.#:   The following discrepancies have been documented against the referent purchase order by our Receiving Inspection and require Corrective Action.                 Signed: _________________________ ACTION taken to prevent recurrence: ________________________________________ _______________________________________________________________________ _______________________________________________________________________ BY: __________________________Position:_________________Date: _____________ *Please detail your corrective action and return to our inspection department within 15 days. Material Storage All material shall be clearly identified upon receipt with the following information: Type of material Customer P.O.# All material shall be stored in a controlled manner and in bins or racks to prevent damage. When a partial quantity is released it will be accompanied with a Manufacturing Operations Sheet and the remaining material shall maintain proper identification. Periodic surveillance of the material storage shall be performed by the inspection personnel assigned. Any discrepancy will be reported to the area supervisor for necessary corrections. Non-Conforming Material The inspection department shall be responsible for identifying any and all discrepant material and shall separate discrepancies from the conforming parts. Identification of discrepant material shall be positive and clearly shall indicate the rejection cause. Non-conforming Material shall be segregated in a separate "Hold Area" until disposition by M.R.B. Disposition of non-conforming material shall be made by authorized personnel only. Only inspection personnel may release material after satisfactory corrective action has been taken. Receiving Inspection All sub-contracted parts, material or processes shall be subjected to a receiving inspection. A receiving inspection log shall be maintained to record the activity and actions by receiving inspection. The following steps are to be adhered to in performing receiving inspection. 1) Obtain copy of P.O., drawings and/or specifications. 2) Log date and Purchase Order Number. 3) Inspect material for certifications. 4) Inspect material for quantity and any physical damage. 5) Inspect material for criteria (dimension, processes, etc.) 6) Log accepted or rejected. 7) Identify material (see material storage or issue C.A.R.). 8) Store material, file certifications in customer file.   The quantity of parts to be inspected will be consistent with the sampling instructions of this manual. Receiving Inspection Log   First Article Inspection A first article inspection shall be performed on all quality program production orders. The first article shall be noted on the Manufacturing Operations Sheet. The first article shall be recorded on an inspection form, to be maintained by Quality Control. All records are to be kept on file in the Quality control area. The first article must be acceptable prior to the release for production to be run for that operation. This may consist of one or more characteristics as noted on the Manufacturing Operations Sheet and includes all operations up to the prior inspection. Correction of operations to produce an acceptable first article do not require a formal corrective action. In-Process Inspection If the production run consists of more than 50 parts, an in-process inspection will be performed at a rate designated by Quality Control. The inspection will be based on the complexity and tolerance of the part. This inspection shall be noted on the reverse side of the Manufacturing Operations Sheet. All in-process inspections will be so noted. The information required is as follows: CRITERIA PIECE # ACC/REJ DATE BY The inspected parts will be identified as acceptable or unacceptable so that no co-mingle will occur in the production run. If a reject is found during an in-process inspection, the lot will be 100% inspected for that criteria and the parts rejected will be segregated and identified as non-conforming material. This must be so noted on the reverse side of the Manufacturing Operations Sheet and the foreman notified immediately. Final Inspection A final inspection shall be performed on all completed parts using the sampling plan as reviewed earlier. This sampling plan meets MIL-STD-105. All rejected parts will be segregated and identified for proper action by authorized personnel. A note on the Manufacturing Operations Sheet shall indicate final inspection performed, quantity accepted and shall be dated and initialed by the performing inspector. Final inspection includes verification of all requirements on the Purchase Order, drawings and applicable specifications. Inspection Record Sheet   Inspection Equipment Calibration All inspection measuring devices and control instruments shall be calibrated at regular intervals sufficient to assure the required accuracy at all times. A card file will be maintained by Quality Control to record a calibration record for each device. Each device will be identified with a numbered sticker to relate to the calibration card of the particular instrument/device. Master equipment shall be calibrated by sources capable of traceability to the National Bureau of Standards. The Calibration System shall be in accordance with MIL-C-45662A. Inspection Equipment Calibration Record Cards     Inspection Equipment Calibration Frequency NOTE: These designated frequencies are used as the starting frequency and may be revised as dictated by the frequency of adjustment/repair required. (See individual calibration cards.) In no case will 12 months be exceeded. Micrometers (all types) ----------1 month Dial/Vernier Calipers -----------3 months Thread Plug Gages ---------------3 months or number of passes Thread Ring Gages ---------------3 months or number of passes Dial Indicators ---------------------3 months Plain Plug Gages ------------------6 months Precision Pin Gages --------------6 months Drill Blanks -------------------------6 months Precision Height Gages ----------6 months Electronic Height Gages ---------6 months Gage Blocks -------------------------12 months Surface Plates -----------------------12 months End Standards -----------------------12 months Optical Comparators --------------12 months Protractors ---------------------------12 months Vee Blocks ---------------------------12 months Parallels ------------------------------12 months Angle Plates -------------------------12 months Precision Squares -----------------12 months Sine Bars ----------------------------12 months   Thread Gages   Sampling Plan This sampling plan is applicable to receiving inspection, in-process inspection and final inspection. The chart, as follows, is based upon normal operations assuming the equipment is capable of holding the required tolerances. In the event there are other circumstances such as tight tolerances, difficult material or operations that are historically difficult to produce, the inspector will initiate a tighter inspection plan as required. The customer may establish the sampling plan as per purchase order and specification requirements. If a tightened sample plan is determined necessary, this shall be noted on the reverse side of the Manufacturing Operations Sheet. Sample Plan Table   This page is best viewed with a screen resolution of 800x600 or higher with Netscape 4.0 or Internet Explorer 4.0.