The purpose of this manual is to establish standard procedures and controls to provide the customers of S & F Machine Co., Inc. the assurance that their products will be produced in accordance with quality standards required. We have adjusted the text of the required Military Specifications to suit our small company and yet provide our customers with adequate records of quality inspection designed to assure end product reliability and the traceability required. This manual is based on the requirements as set forth in Military Specification MIL-I-45208A and MIL-STD-45662 with variations to suit our methods of operation. It is our understanding and interpretation that, the basic policy set forth may be adjusted and updated annually, for variations in customer quality requirements.
| DATE ISSUES: | February 19, 1986 Manual I | |
| DATE REVISED: | October 1993 Manual II | |
| APPROVED BY: | Peter Strozza | |
| ISSUED BY: | Peter Strozza | |
| ISSUED TO: | Q.A. Engineer Bruce Steadman | |
| New Hampshire Ball Bearing Co., Inc. |
| DATE REVISED: | November 13, 2001 | |
| ISSUED TO: | Q.A. Administrator, Sandy Ryan | |
| BAE Systems | ||
| 65 Spit Brook Road | ||
| P.O. Box 868 | ||
| Nashua, NH 03061-0868 |
- OBJECTIVE:
Our objective is to assure quality products by using an effective inspection system that has a high reliability rate, which will effect a product cost reduction and maintain our required delivery schedule.- FUNCTION:
To be responsible for maintaining the highest standards of quality for our customers products by a continuing coordinated program of quality assurance to control our manufacturing processes.- DUTIES:
To be responsible for and supervise a complete system of reliability and traceability consisting of incoming inspection, in-process inspection, final inspection, maintenance of inspection and calibration records, tool and gage records and all records necessary to assure that the customers purchase order requirements have been compiled with in their entirety.
In order to assure that the latest purchase order requirements drawing and specifications are available to manufacturing the Quality Control Department will be responsible for checking the purchase order for the quantity ordered, delivery date, drawing revisions, specifications and any special requirements prior to any items being manufactured.
- MATERIAL:
All material shall be processed, controlled, inspected and tested in accordance with the requirements of this standard. The intent of this standard is to specify the requirements which establish the control practices, procedures, and the necessary records that shall be part of the quality control system. Special instructions on the drawings, specifications, engineering standards, purchase order, specifications or blueprint requirement shall have precedence over this manual. We are responsible to implement a quality control system that will meet the requirements of The Military Specification MIL-I-45208 and shall provide a quality organization administered by a qualified and capable person as head of the quality organization to meet the customer's requirements. This person will not be under the control of manufacturing and in the event that this appointment is changed, the customer will be notified.- PROCEDURES:
S & F Machine Co., Inc. has established and maintained system controls covering all phases of the processes used to manufacture and control the product. These systems are detailed in this manual, which cover the areas of initial planning, blueprint and specification control, subcontract control, material handling, inspection function, gage control, shipping, corrective action and records.- INITIAL QUALITY PLANNING:
Upon receipt of a purchase order, the Quality Control Dept. shall check it for the quantity order, delivery date, drawing revisions special requirements and specifications prior to any items being manufactured. The purpose of this review is to assure the product will be manufactured according to the customer's request.- RECORDS:
Records generated by S & F Machine Co., Inc. to verify conformance to the standards of this manual in the areas of inspection, gage control, corrective action, blueprint and specification control, shall be retained by S & F Machine Co., Inc. for a minimum of ten years. After which time the customer shall be given the option in writing to obtain ownership of such records. No records pertaining to any work performed on behalf of the customer shall be disposed of without the written consent of the customer. A record documenting the inspection function shall indicate the characteristic(s) observed, number of observations made, number and types of deficiencies found, final disposition of the material, inspector identification, and the date of the inspection or test.- TRACEABILITY:
S & F Machine Co., Inc. shall maintain a record system, which can demonstrate the control and traceability of material, components and finished products. Such records shall be available to the customer at any time during the contract and shall be retained for a minimum period of ten years after completion of the contract. Serial numbers, when used, will not be duplicated and shall be documented on all shipping paperwork.
- BLUEPRINT AND SPECIFICATION CONTROL:
Obsolete blueprints, specifications and instructions shall be removed from use. For frozen processes, the customer requires that the supplier make no changes to the manufacturing or inspection process that could change the chemical, physical, dimensional, or visual characteristic of the product from the original without first contacting the customer for written approval. S & F Machine Co., Inc. will not deviate from blueprint and customer requirements.- SUBCONTRACT CONTROL
- RESPONSIBILITY:
The responsibility for requesting capability of processing material to our customer specifications prior to placing business with the subcontractor. This includes assuring that the subcontractor has the latest applicable specifications and the equipment available to perform the required process, inspections, tests and is available for our "Customer Quality Assurance" review.- SUBCONTRACT REVIEW:
S & F Machine Co., Inc. shall establish an understanding with each subcontractor that our customer representative may, upon request, contact or visit the subcontractor's facility for the purpose of verifying documentation, work-in process, or end item product.- INSPECTION FUNCTIONS
- OBJECTIVE:
To assure receipt of proper materials to be used in the manufacture of customer's products and to ascertain proper identification of it before such material is assigned to shop production.- PROCEDURE:
- On receipt of material, packing slip must be identified against the proper purchase order.
- Certification must be identified as proper material requested on the purchase order.
- Material must be identified by "stick on " labels (controlled materials) as to the type of material and job numbers used.
- Certifications must be checked against customer blueprint to verify purchase order, proper specification before releasing to production and forwarded to quality control.
- Customer supplied gages are to be forwarded to final inspection to be stored until needed for the specific job.
- Incoming sub-contract work is to be checked off against subject purchase order, visually inspected as to damage as received, recorded and forwarded to quality control.
- Packing slips are to be clipped to subject purchase order and forwarded to office for filing.
- IN PROCESS INSPECTION:
In process inspection will be performed periodically during the manufacturing process, which has been designated by Quality Control so as to detect any discrepancy, which may occur during the manufacturing period. An inspection log shall be maintained during the manufacturing process. Sampling Inspection will be in accordance with MIL-STD-105.
DUTIES INCLUDE:
- Physically performing gage operations on the parts as determined by the Quality Control route card.
- Record number of parts inspected, accepted and rejected.
- Segregate defective parts from accepted parts and place in Quality Control hold area.
- Identify all defective material with tags showing defect and appropriate stick-on label.
- Record all dimensional data on the Quality Control report card in accordance with the requirements of each customer.
- Assure that the proper paper work and certifications are adequate. Proper inspector's stamps and signature are on the final log card.
- GOVERNMENT INSPECTION
When government inspection is required prior to shipment, by the customer, the purchase order sill reflect the following:
"Government Source Inspection - Upon receipt of this order, promptly notify the Government Representative who normally services your facility so that appropriate planning of government inspection can be accomplished."
When the purchase order references government source inspection, the government will have the right to visit/inspect our facility at any time during the term of the contract.
- CUSTOMER'S INSPECTION AS SUPPLIER
Customer may have the right to perform source inspection of materials, supplies, or services manufactured or performed within S & F Machine Co., Inc. facility. Source inspection does not constitute final acceptance of an entire lot, nor does it replace the requirement for inspection for S & F Machine Co., Inc. nor relieve our responsibility to furnish an acceptable product. We also reserve the right to accompany the customer on visits to our supplier facilities.
- PROCEDURES:
- All surplus materials on hand after completion of contract are to be returned to the tool crib for return to stock.
- All materials usable for future commitments shall be identified with material control label and stored with tooling for that customer.
- All materials not usable shall be identified as to type of material by marking or sue of controlled materials label and returned to miscellaneous stock area to be used only as tooling, fixtures and for "in house" projects.
- NONCONFORMING MATERIAL
Quality control will have the overall responsibility for the review, control and disposition of nonconforming material. When material is found discrepant by inspection the defects will be reviewed and if contractually specified, the customer's representative or government inspector will be included in the review. By unanimous decision the material may be accepted as is if the discrepancy is of a minor nature and will not affect the safety, performance or interchangeability or reliability. A unanimous decision may also be made to rework the part to blue print specification or scrapped if not feasible to rework. All nonconforming material will be segregated prior to final inspection.- SCRAP HANDLING
Any material that is determined to be unusable shall be identified and separated to prevent use and returned to the customer.- GAGE CONTROL
Quality Control will assure measurements and standards, including personally owned gages are calibrated at scheduled intervals against certified standards traceable to the National Institute of Standard Technology (NIST) per MIL-STD-45662. When Jigs and fixtures are used for inspection, they will be subjected to the same controls. The detailed procedure defining the S & F Machine Co., Inc. calibration system is in paragraph 16.
Quality Control will also assure the operation of a system that will identify the equipment and indicate its date of recalibration. Records will be maintained of the calibration status and condition of each individual piece of equipment.
- Periodic calibrating of company and personal measuring tools is required.
- Calibration to consist of inspection by use of gage blocks as measuring standards as follows: Micrometers to be checked every .250 of total range for wear of screw and anvils. Also checked for wear by measuring at three points by the use of a ball, gage rod or in the case of .0001 micrometer optical flats. Indicators to be inspected for their full range using a span of gage blocks to check every .010 on a .030 span indicator and every .002 on a .008 span indicator.
- Upon calibrating acceptance of tool accuracy and quality, notation is made on tool card assigned to that particular tool.
- Any tools shown to be worn or outside of limits as specified will be repaired at cost to the company.
When customer gauging is used for Inspection, they will be subjected to the same control as specified for company and personal tools. When customer gauging is no longer required, it shall be promptly returned.
- CORRECTIVE ACTION
S & F Machine Co., Inc. will take corrective action when deficiencies within our system allows nonconformance to occur, and shall be documented by a method with corrections taken. Documentation of corrective action shall be made available to the customer upon request.- NONCONFORMANCE REPORTING
When nonconforming material is reported by customer or encountered by S. & F Machine Co., Inc.,
S & F Machine Co., Inc. shall take immediate action to inspect or test lots or dates of material in our plant for the nonconforming condition (s). S & F Machine Co., Inc. will determine and isolate the cause (s) of the nonconformance (s) and take documented corrective action. When S & F Machine Co., Inc. encounters nonconforming material, which may have been shipped, S & F Machine Co., Inc. will notify the customer's Quality Assurance and Purchasing. Upon receipt of a complaint (such as a corrective action request), S & F Machine Co., Inc. will reply in writing stating the corrective action taken to prevent recurrence.
SHIPPING INSPECTION AND REQUIREMENTS
- The responsibility of the shipping inspector is to ascertain and assure that the completed product is properly packaged to prevent damage and deterioration when stored or in shipment.
- In addition, be responsible for the accuracy of all shipping documents, noting from the customer purchase order the requirements for test reports, certifications, quality control logs and seeing that same are forwarded with each shipment as required. A copy of the shipping document shall be filed in our Quality Control Department as well as the job order folder containing all pertinent information concerning the customer contract.
- SCOPE
This procedure assures the control of measuring, test equipment and standards, as specified in MIL-STD-45662, "Calibration System Requirements."
The detailed procedures are defined in the following paragraphs 16b., 16c. These procedures are maintained in the Inspection Department where the calibration is performed.- CALIBRATION RECORDS
A card is kept on file identifying each gage, by the gage name and description, S & F Machine Co. assigned Identification number, the company or person the gage belongs to, the initials of person that calibrated the gage, date of calibration and due date of calibration.- GAGE LABELING
Each gage will be labeled with the assigned S & F Machine Co., Identification Number and the calibration due date.- CALIBRATION FREQUENCIES
A list of all company and personal gages are on file showing the length of time when each gage is to be calibrated. List shown on Paragraph 16h.- OUT OF TOLERANCE GAGES
When a gage is out of tolerance and cannot be adjusted, it will be sent for repair or scrapped.- PERSONAL GAGES
Personal gages will be identified, calibrated and recorded at the same intervals as the company gage. If gage is broken or beyond calibration, S & F Machine Co., Inc. will have it repaired or replaced.- CUSTOMER GAGES
Customer gages used for production, when received will be inspected for identification, condition, type and size required. Gage shall be put aside in the inspection area for the sole use of inspecting customer parts. When the Production is complete per the purchase order, the gage will be sent back to the customer immediately.- LIST OF GAGES
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