CPMi Quality Control Manual

PMi

ONTROLLED PRECISION MANUFACTURING, INC.

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THE BODY OF THE MANUEL WILL BE LINKED UPON REQUEST WHEN COMPLETED…

However it is currently under construction and revision to SAE AS 9100.

CONTROLLED PRECISION MANUFACTURING, INC

QUALITY CONTROL MANUAL

APPROVED BY

Shirley Hamilton

PRESIDENT

Shirley Hamilton

QUALITY ASSURANCE MANAGER

EFFECTIVE DATE: 1/3/83

REVISION: AG

REVISED DATE: 2/21/02

ASSIGNED TO:

COPY NUMBER:

A Update Q.C. Manual to meet Boeing requirements 2/17/84

B UPDATE REVIEW 3/15/85

C Inclusion of Paragraph 3.6.2.5 Defective Equipment. Change 9/13/85

Paragraph 3.6.2.5 to 3.6.2.6.

D UPDATE REVIEW 3/20/86

E Revised entire Manual 10/10/86

F Change existing 3.6.6 Stamp Control to 3.6.7 and add 3.6.6 4/15/87

Control of Material or Articles With a Limited Storage Life

or Requiring Environmental Control.

G Revised Section 3.6.2 F and Section 3.6.7 E 9/23/87

H UPDATE REVIEW 10/9/87

I UPDATE REVIEW 10/10/88

J Revised Section 3.1.6, added new Section 3.6.7 E and F. 1/3/89

Revised Fig. IX.

K UPDATE REVIEW 10/17/89

L UPDATE REVIEW 10/5/90

M Revised Section 3.6.7 for new stamps 12/4/90

N Revised Section 3.6.3 B Tool Storage Card Fig. XIII 8/8/91

O UPDATE REVIEW 10/9/91

P UPDATE REVIEW 10/8/92

Q Revised Section 2.1 Organization Chart Revised Section 1/6/93

2.2 Q.C. Organization Chart

R UPDATE REVIEW 10/19/93

Revised Section 3.5.3 A added planning required for any

rework. Revised Section 3.5.3 D added planning required

for any repair. Added Section 3.5.5 Noted compliance with

Mil-Std-1520. Revised Section 3.6 Changed name of NIST

Revised Section 3.6.2 B added minimum accuracy, changed

name of NIST. Revised Section 3.6.2 E Schedule of

Calibration from 30 days to 90 days.

S Revised Section 3.6.4 A, B, and C Control of Customer 5/12/94

Production Drawings, Planning, Specifications and other

related documents

T UPDATE REVIEW 10/12/94

U Revised Section 3.4.1 G to include phrase for customer 9/6/95

returned parts. Section 3.4.3 C change to OIS. Add

Section 3.5.6 to include analytical control of rejected

parts. Section 3.5.1 expanded defective parts to include

all rejected items.

V UPDATE REVIEW 10/10/95

W Revised Section 3.5 Material Review and Corrective 3/26/96

Procedures

X UPDATE REVIEW 11/6/96

Revised Section 3.1.6 to test first material purchased

from each vendor. Revised 3.3.6 changes Mil-Q-9858A

to Mil-I-45208A. Split off 3.4.1 D from 3.4. 1C. Added

Section 3.4.1 E. Revised Section 3.4.1 F. Changed 3.4.1

D, E, F and G to F, G, H, and I. Revised 3.4.2 G

reference made to control limits. Revised 3.4.4 B added

temper. Added3.5.2 B d retained scrap impression

stamped, discarded destroyed. Revised 3.6.2 I attach

label where practical.

Y Add Section 1 Boeing D1-9000 requirements. Moved 3/3/97

Section 1.1 to 2.1.1, Section 1.2 to 2.1.2, Section 1.3 to 2.1.3,

2.1 to 2.2, 2.2 to 2.3 and 2.3 to 2.4. Revised Sections 2.3.3

add SPC and 2.3.4 add training log. Add Sections 2.3.6

suitable environment, 3.2.3 FAI in master file, and 3.2.4

FAI updated. Revised Section 3.3.2 add customer list, and

3.3.3 add master spec list. Add Section 3.4.1E traceablity.

Revised 3.4.2A contract review and shop status. Add Section

3.4.2D interchangeable and replaceable and 3.4.2K SPC.

Add Section 3.5.2B CLS and Rejected Parts Tracking.

Revised Sections 3.5.2Cb hold point notice issued and

3.5.2Cc repetitive nonconformance. Added Section 3.5.2Cd

nonconformity notification. Revised Sections 3.5.2Ch corrective

action format, 3.6.2G new gage calibration, 3.6.3B Tool Record

Card changed to Tool Stores List and 3.6.4A add Drawing

Check Out Log. Added Section 3.6.5E finished parts stores log.

Revised Section 3.6.7E lost stamps permanently removed from

service. Add Section 4, which was under separate cover.

Z UPDATE REVIEW 10/31/97

Section 2.2 and 2.3 Personnel Revised. Section 3.6.2E and

Fig X Calibration Schedule changed.

AA UPDATE REVIEW 10/31/98

AB UPDATE REVIEW 10/31/99

AC Revised 3.6.1 and 3.6.2 to meet requirements of ANSI/

NCSL Z540-1 and changed D1-9000 to ISO 9000 2/15/00

AD Incorporated ADDENDUM A & B. Revised ADDENDUM B

to meet requirements of QA111 ADDENDUM J. Added

Exhibit A Current Facilities List 4/15/00

AE UPDATE REVIEW 10/31/00

AF UPDATE REVIEW

Adjust minor discrepancies between Table of Contents and text 10/31/01

AG Revised Schedule of Audits and Logs. Revised 3.6.1 & 3.6.2, changed

calibration interval, added authority to temporarily extend due date.

Added 30 day review to procedure changes 2.1.3 and defined not in

calibration system, reference only 3.6.2 2/21/02

CONTROLLED PRECISION MANUFACTURING QUALITY POLICY

CPMi is committed to a policy of continuous permanent improvement in the quality of our products and processes. To fulfill this commitment sufficient resources will be committed to establish and maintain an effective and economical quality system which will insure the fabrication of quality products beyond the expectations and needs of our customers.

The quality control manager is given the full responsibility to ensure that such quality system is established, implemented and maintained at all level of the organization.

It will be the responsibility of each department manager to insure that each employee within his department is given the tools and time necessary to become proficient in performing their jobs within the established quality system.

It shall be the responsibility of each individual employee to be knowledgeable in the quality system as it pertains to their job and to operate within that system.

Only with the total commitment to quality of each individual as part of a solidified team will we be able to achieve the necessary elements to securing and maintaining complete customer satisfaction.

William H. Hamilton III

President

March 3, 1997

TABLE OF CONTENTS

1. CPMi REQUIREMENTS

1.1 Management Responsibility

1.1.1 Quality policy

1.1.2 Organization

1.1.3 Management Review

Fred 1.2 Quality System

1.2.1 General

1.2.2 Quality System Procedure

1.2.3 Quality Planning

1.3 Contract Review

1.3.1 General

1.3.2 Review

1.3.3 Amendment to a Contract

1.3.4 Records

Fred-Shop Foreman with CPMI since 4/94 1.4 Design Control

1.4.1 Design Authority

1.5 Document and Data Control

1.5.1 General

1.5.2 Document and Data Approval and Issue

1.5.3 Document and Data Changes

1.6 Purchasing

1.6.1 General

1.6.2 Evaluation of Subcontractors

1.6.3 Purchasing Data

1.6.4 Verification of Purchased Product

1.6.5 Requirements of Flowdown

Pat

1.7 Control of Customer-Supplied Product

1.7.1 Notification and Authorization

1.8 Product Identification and Traceabilty

1.9 Process Control

1.9.1 Process Specifications and Requirements

1.9.2 Tooling

1.10 Inspection and Testing

1.10.1 General

1.10.2 Receiving Inspection and Testing

1.10.3 In-Process Inspection and Testing

1.10.4 Final Inspection and Testing

Pat-QC Tech with CPMi since 2/97 1.10.5 Inspection and Test Records

1.10.6 Inspection Options

1.11 Control of Inspection Measuring and Test Equipment

1.11.1 General

1.11.2 Control Procedure

1.12 Inspection and Test Status

1.12.1 Inspection Stamps

Larry 1.13 Control of Nonconforming Product

1.13.1 General

1.13.2 Review and Disposition of Nonconforming Product

1.14 Corrective and Preventive Action

1.14.1 General

1.14.2 Corrective Action

1.14.3 Preventive Action

1.15 Handling Storage, Packaging, Preservation and Delivery

1.15.1 General

1.15.2 Handling

1.15.3 Storage

1.15.4 Packaging

1.15.5 Preservation

1.15.6 Delivery

1.16 Control of Quality Records

1.16.1 Record Retention and Availability

Larry-Hand Finisher/Stock Router

With CPMI since 2/95 1.17 Internal Quality Audits

1.17.1 Annual Audits

1.18 Training

1.18.1 Proficiency Assessment

1.19 Servicing

1.20 Statistical Techniques

1.20.1 Identification of Need

1.20.2 Procedures

1.20.3 Acceptance Sampling

1.20.4 Management Responsibility

1.20.5 Quality System

Don 1.20.6 Corrective and Preventive Action

1.20.7 Internal Quality Audits

1.20.8 Training

1.20.9 Measures of Defect and Waste

1.21 Determine Key Characteristics

1.21.1 Does Customer Provide Key Characteristics?

1.21.2 Collect Data to Determine Key Characteristics

1.21.3 Establish Key Characteristics

1.21.4 Document Key Characteristics and Engineering

Specifications on AQS Control Plan

1.22 Provide Evidence of Variation

1.22.1 Determine Process Steps Where Key Characteristics

are Measured

1.22.2 Select Appropriate Control Charts

1.22.3 Document Process Steps, Control Charts, Sample

Size, and Frequency on AQS Control Plan

1.22.4 Collect Measurements and Maintain Control Charts

Don-Machinist with CPMi since 2/97

1.23 Identify and Control Sources of Variation

1.23.1 Is Key Characteristics in Statistical Control?

1.23.2 Does Key Characteristics Meet Minimum Capability?

1.23.3 Can Special Causes of Variation Be Assigned ?

1.23.4 Remove Special Causes of Variation

1.23.5 Collect New Measurements

1.23.6 Perform Gage Variation Study and Document Results

on AQS Control Plan

1.23.7 Was Corrective Action Take on Measurement

System ?

1.23.8 Identify Potential Sources of Process Variation

1.23.9 Correlate Sources of Process Variations With the

Key Characteristic

1.23.10 Establish Controls for Key Process Parameters

1.23.11 Document Operations, Key Process Parameters,

Process Parameter Settings, and Control Method

on AQS Control Plan

2. COMPANY ORGANIZATION, MANAGEMENT AND

TRAINING PROGRAM

Building

2.1 Introduction

2.1.1 Purpose

2.1.2 Scope

2.1.3 Distribution and Revision

2.2 CPMi Organization Chart

2.3 CPMi Quality Assurance Organization Chart

CPMi location since 1983

2.4 Training of Personnel

3. QUALITY CONTROL FUNCTIONS AND PROCEDURES

3.1 Audit of Quality Control System and Support

3.2 Records-Quality Control Forms and Retention

3.3 Control of Purchased Material and Processes

3.4 Inspection Procedures

John 3.4.1 Receiving Inspection

3.4.2 In Process Inspection/First Article Inspection

3.4.3 Final Inspection

3.4.4 Shipping Inspection

3.5 Material Review Board Procedures, Corrective and Preventative

Action

3.6 Control Procedures

3.6.1 Inspection Department Control of Precision

Measuring Tools

3.6.2 Calibration Procedures

3.6.3 Control of Production Tools

John-Machinist with CPMi since10/98 3.6.4 Control of Customer Production Drawings, Planning

Specifications and Other Related Documents

3.6.5 Control of Production Stores

3.6.6 Control of Material or Articles With a Limited

Storage Life or Requiring Environmental Control

3.6.7 Stamp Control

4. STATISTICAL PROCESS CONTROL

4.1 Policy/Scope

4.1.1 General Policy for Application

4.1.2 Specific Goals

4.1.3 Commitments

Billy Bob 4.2 SPC Structure

4.2.1 Department Ownership

4.2.2 Department Responsibilities

4.3 Training

4.3.1 Provide Training

4.3.2 Qualification

4.3.3 Re-qualification

4.4 Dominant Characteristics

4.5 Statistical Methods

4.5.1 Types of Control Charts

4.5.2 Other Statistical Methods

4.5.3 Criteria for Out of Control

4.6 Process Capability

4.7 Corrective Action Plan

4.7.1 Improve Process

4.7.2 Identify Causes

4.7.3 Corrective Action

Billy Bob with CPMi since 4/99 4.8 Immediate Corrective Action

ADDENDUM A ACCIDENT/ILLNESS PREVENTION PLAN

ADDENDUM B CAD/CAM PROCESS CONTROL PLAN

EXHIBIT A CURRENT FACILITIES LIST

REMEMBER:

When Performance Counts, Only Quality Performs!

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