Products

Aluminum Dip Brazing
Calibration Options
Quality Systems
Specifying Filters
Catalog Request
Custom Design
General Information
Procedures

COLEMAN MICROWAVE COMPANY
P.O. Box 247, 109 Molineu RD
Edinburg, VA 22824
Phone 540-984-8848Fax 540-984-4561
Email coleman@colemanmw.com

INTRODUCTION

It is the policy of Coleman Microwave Company (CMC) to assure that it's customers products and services fulfill all performance requirements and reflect the highest quality standards while maintaining timely deliveries.

Coleman Microwave's Quality System is based upon the concept of every employee's participation in a total quality effort from design to delivery. The critical impact of design and workmanship on the end product performance and reliability has been recognized.

Coleman management is dedicated to the successful manufacture of high quality devices. The policy and procedure set forth in this document will serve to establish those controls and function to achieve the desired results.

Kenneth R. Coleman Sr. President

Dana A. Braithwaite Manager of Operations

1.0 SCOPE

1.1 The quality assurance system encompasses: personnel, purchase and receipt of parts and materials, identification, stocking and issue of parts and materials, the entire process of fabrication and manufacture, packaging, storage, and shipping.

1.2 The system is designed to assure that the supplies and/or services, manufactured or performed at CMC or at supplier facilities are subject to adequate control of quality to ensure customer satisfaction.

1.3 The system is design to provide early detection of discrepancies and positive corrective action.

1.4 Written inspection and test procedures are prepared to supplement applicable drawings and other specifications to the extent necessary.

1.5 The system is designed to provide for quality control audits to provide an assurance that the quality control system is functioning in accordance with this manual.

2.0 RESPONSIBILITY/CONTRACT REVIEW

2.1 The quality assurance function reports directly to the company President.

2.2 The quality assurance function has the following responsibilities:

2.2.1 Interpretation of conformance to customer quality requirements.

2.2.2 Review of customer drawings and specifications.

2.2.3 Determination of necessary inspection points.

2.2.4 Documentation of the necessary inspection instructions including change control.

2.2.5 Planning, developing, initiating, coordinating, implementing, and maintaining the most efficient and effective procedures for optimum quality assurance.

2.2.6 Maintenance of adequate quality assurance records.

2.2.7 Review of quality assurance records to provide for internal corrective action follow-up.

2.2.8 Vendor quality assurance and corrective action follow-up.

2.2.9 Initial and continuing periodic inspection of all standard and special gages, test equipment, and tooling used for manufacturing.

2.2.10 Coordination of internal corrective action on items rejected by the customer, including notification of corrective action taken and evaluation of effectiveness of the action.

2.2.11 Quality control audits, done in accordance with Coleman's Quality Procedure #16.

2.2.12 Assure that the inspection function is capable of rendering an unbiased decision to accept or reject any material inspected.

2.2.13 Each contract and/or customer purchase order, upon receipt is reviewed for pertinent quality requirements. This review includes completion of a Sales Release and Planning Document.

2.2.14 All quality requirements are documented on the Sales Release Planing Document form.

2.2.15 A notebook of the SRPD forms for all active projects is maintained.

2.2.16 A working file is established for each project and contains the applicable drawings, inspection records, inspection and test plans, etc.

3.0 GENERAL POLICIES

3.1 Coleman Microwave Company will notify customers in writing of system changes, and will comply with the customers concerning the changes.

3.2 Coleman Microwave Company does not use inspection equipment that is not specified in Customer/Government contracts

3.3 Coleman Microwave Company permits Customer/Government to evaluate inspection system and supplies, and allows the Customer/Government to make verification and evaluations to determine inspection system effectiveness.

Coleman Microwave Company

Controlled Quality Manual Serial Number Check List

REV LEVEL - DATE

QUALITY ASSURANCE FORMS
TABLE OF CONTENTS

PAGE NO/REV LEVEL

QUALITY PROCEDURES
TABLE OF CONTENTS

PAGE NUMBER/REV LEVEL

QP #01

POLICIES AND PROCEDURES
QUALITY PROCEDURE

SUBJECT: DOCUMENTATION CONTROL & REVIEW

1.0 PURPOSE

This procedure describes the system for quality assurance to review and critique engineering and supplemental documentation for adequacy, completeness, and to monitor in-house and subcontractor operations to see that approved changes are incorporated at the designated point.

2.0 APPLICATION

The procedure applies to all released materials including engineering drawings, specifications, process instructions, production engineering instruction, industrial engineering instructions, design-related work instructions, and engineering changes. CHANGES TO CUSTOMER DRAWINGS ARE EXPRESSLY PROHIBITED.

3.0 PROCEDURE

3.1 Quality engineering of quality assurance has the prime responsibility for documentation review and the drafting department has responsibility for control. In performing this work, quality engineering will participate in design reviews and will be the quality assurance representative on the change.

3.2 Engineering drawings are to be reviewed for adequacy, completeness, and with corrective action taken regarding discrepancies.

3.3 Engineering is to verify that documents received for application are properly released and authorized.

3.4 Audits are to be conducted periodically and on a random basis to see that only current material is being distributed and used, and that obsolete material has been removed.

3.5 Drafting department is responsible for insuring all drawings, part lists, ECN's, etc... are dated and signed.

3.6 As a participant on the Change Control Board, Engineering is to review Engineering Change Notices (ECNs) to determine if they are correct, complete, and in compliance with standards and needs.

3.7 Quality engineering will maintain a drawing revision log, listing all appropriate information as follows: drawing number, ECN number, description, rev level, change date.

3.8 The drafting department will provide quality assurance with a hard copy print out of all drawings in house, if applicable.

3.9 When sending prints and/or films out for reproduction or to subcontractors, the drafting technician will provide purchasing with all requested prints and/or films listed on the approved purchase request order.

3.10 Drafting department will maintain a log of customer prints, listing all appropriate information as follows: drawing number, ECN number, layer number, description, part number, and comments, etc.

4.0 ASSOCIATED DOCUMENTS

QP #02

POLICIES AND PROCEDURES
QUALITY PROCEDURE

SUBJECT: PURCHASE ORDER REVIEW

1.0 PURPOSE

This procedure sets forth a method for reviewing purchase orders, prior to their issuance, to assure that contractual and quality requirements have been properly incorporated.

2.0 APPLICATION

This procedure applies to the procurement of all materials, parts, and assemblies that will be used in actions of both the purchasing department and quality engineering.

3.0 PROCEDURE

3.1 Prior to issuance, the purchasing department is to forward purchase orders to the quality engineering department for review.

3.1.1 Notification that this quality procedure is imposed will be accomplished by test on Coleman Microwave Company sales order form stating "CMC QP #02 is imposed".

3.2 Quality engineering is to review these procurement documents to determine if all contractual and quality requirements have been adequately specified.

3.3 Each purchase order is to be augmented with the appropriate instructions.

3.4 Each purchase order is to specify that company procurement personnel, quality assurance personnel, and engineering personnel will have access to the supplier's or subcontractor's premises.

3.5 ALL QUALITY REQUIREMENTS SHALL BE SPECIFICALLY:

A) Called out on Q.E.R. (QA #003) and be forwarded to purchasing agent for incorporation on/or attached to purchase order prior to purchasing fabricated or modified material.

B) All Q.E.R.'s are to be numbered and entered into the Q.E.R. computer log

(QA #004).

3.6 If there are discrepancies in the purchase order, it is to be returned to the purchasing department accompanied by a description of the problem.

3.7 If the purchase order is determined to be adequate from a quality requirement standpoint, it is to be signed as approved by the quality engineer and returned to the purchasing department.

3.8 The quality assurance department is to maintain records of the review and disposition of procurement documents (QA #004).

3.9 When Government inspection is required Coleman Microwave Co. agrees to add to the purchasing document the following statement: "Government inspection is required prior to shipment from your plant. Upon receipt of this order, promptly notify the Government Representative who normally services your plant so that appropriate planning for Government inspection can be accomplished."

QP #03

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: NON-CONFORMING MATERIAL CONTROL

1.0 PURPOSE

This procedure defines a system that identifies and controls material that does not conform to specification.

2.0 APPLICATION

This procedure applies to all defective material produced by or for this company.

3.0 ASSOCIATED DOCUMENTS

3.1 QUALITY PROCEDURE

All remaining quality procedures.

3.2 FORMS

4.0 PROCEDURE

4.1 Any material rejected by quality control via received inspection, in-process inspection, final inspection, audits, or any other quality activity that may designate non-conforming material reject report (Form No. QA-005). A red tag will be attached to all non-conforming material identifying MRR No., Part No., Serial No., Quantity, Inspection stamp and Date.

4.2 Any material found by other departments that is discrepant will be delivered to quality control. This material must be accompanied by the following information:

1.PART NUMBER; P.O. # AND S.O. #

2.QUANTITY

3.DISCREPANCY

Quality control will generate all material reject reports.

4.3 All non-conforming material will be secured in a locked hold area, when practical, with the MRR and red tag attached.

4.4 All non-conforming material must have a preliminary review by quality engineering and/or manufacturing engineering within two working days. Quality assurance will keep all non-conforming material information in a log book

(QA #006).

4.5 The preliminary review can make the following dispositions without the customers concurrence.

1.NO DEFECT

2.REWORK

3.100% SORTING OF PRODUCT

4.SCRAP

5.RETURN TO VENDOR

6.MRB (REPAIR)

4.6 Materials that cannot be dispositioned by the preliminary review must be held for a material review board (MRB).

4.6.1 Material review board is required when customer approval is required to repair units. NOTE: 1. Definition of "repair" is to form, fit function can not meet print conformance. 2. Definition of "rework" is return to print conformance.

4.7 For material reject reports that have been disposition for corrective action, quality assurance will issue corrective action requests per requirements of procedure no QP 07 (QUALITY PROCEDURE FOR CORRECTIVE ACTIONS).

4.8 Quality assurance will keep all MRR's on file under program or customer name. These reports are the only means for handling non-conforming material. All the history of preliminary review, MRB activities, and final disposition of the product is to be documented on the MRR.

4.9 Material returned from customer must be forwarded to quality control for processing on incoming inspection report form (QA #023).

4.10 All customer returned material shall be inspected per QA-05 (RECEIVING INSPECTION).

4.11 After inspection, the Quality Control function shall determine responsibility for the returned material.

4.12 The Quality Control Department shall insure that prompt corrective action QA #009 is taken to correct assignable conditions which have resulted or which could result in the submission to a customer of supplies which do not conform to: (1) The quality assurance provisions of the item and customer, (2) Inspections and test required by contract, and (3) Other inspections and test required to substantiate product conformance.

4.13 The Quality Control Function shall retain a file of all returned customer material and of all action taken.

QP #04

SUBJECT: RECEIVING INSPECTION

1.0 PURPOSE

This procedure describes the system for inspecting material received from suppliers and subcontractors or customer returns.

2.0 APPLICATION

This procedure applies to the inspection of all material received.

3.0 ASSOCIATED DOCUMENTS

3.1 QUALITY PROCEDURES

QP-02PURCHASE ORDER REVIEW

QP-04NONCONFORMING MATERIAL

QP-05FIRST ARTICLE INSPECTION

QP-07SOURCE INSPECTION

QP-08CORRECTIVE ACTION

QP-16GOVERNMENT/CUSTOMER PROPERTY

3.2 FORMS

QA #005, QA #006, QA #007, QA #012, QA #023

4.0 PROCEDURE

4.1 All materials which are to be inspected upon receipt are to be inspected by receiving inspection in terms of compliance to specified requirements, completeness, transit damage, and proper and complete paper work documentation.

4.2 Parts that have been sent out for special processing are to be inspected, when returned, only for the processing performed.

4.3 Measuring and test equipment devices that have been sent out for calibration and/or repair, when returned, are to be forwarded to the quality control department for processing.

4.4 Materials that have been source inspected, upon receipt, are to examined only for transit damage, and the completeness and correctness of the accompanying paper work and documentation (such as certificates and test reports). Refer to QP 06. A copy of Form No. QA-007) will be included with the shipment.

4.5 All incoming materials are to be processed in the priority sequence of the dates when the materials are required.

4.6 As a prelude to inspecting received materials, obtain specifications, purchase orders, and prints.

4.7 All material lots may be subjected to sampling inspection. The acceptance quality level (AQL) is determined by supplier statistical trend data.

4.8 The materials are to be inspected for conformance to requirements and the results are to be recorded on the P chart data form.

4.9 If the purchase order designates that a first article inspection is required, refer to QP-05.

4.10 Material that has been accepted as a result of receiving inspection will be tagged with a green tag identifying purchase order number, part number, serial number, (if applicable), quantity, and date. Stamp tag with acceptance and dated on the material moved to the stockroom.

4.11 Materials that have been rejected will be tagged with a red tag identifying MRR number, part number, purchase order number, serial number, (if applicable), quantity, inspection rejection stamp and date. A MRR (form No. QA-005) will be generated and the non-conforming material will be processed per QP-04, this material is held in a bonded storage area until disposition can be made.

4.12 If the disposition on the material reject report calls for corrective action for the supplier, refer to QP-08 (Quality Procedure For Corrective Action).

4.13 All inspection records, test data, certificates of compliance, and material certification will be kept on file at receiving inspection.

4.14 Customer/Government material received will be handled in accordance with

QP-16, Government property.

5.0 RAW MATERIAL CONTROL

5.1 Raw material are those received in an unfinished form (i.e. metal, plastic, rubber, castings, paint, chemicals, etc.).

5.2 All raw materials are inspected by the receiving inspection function.

5.3 Accepted materials are identified by inspection utilizing a stamp, tag or color code, then released to the stockroom.

5.4 Non-conforming material is processed in accordance with QP-03 of this manual.

5.5 Corrective action is taken in accordance with QP-07 of this manual.

5.6 Copies of all certifications when required, are filed with the applicable Purchase Order and are available for review upon customer request.

5.7 Verification of suppliers certifications may be accomplished by independent testing laboratories to comply with customer purchase order requirements. Verification is done is accordance with QP-09 of this manual.

5.8 Limited Life Materials are additionally identified with "DO NOT USE AFTER (MM/DD/YY)", information. Materials not totally used prior to the end of their limited use are removed from service.

5.8.1 It shall be the Area Supervisor's responsibility to insure that all materials in their department are current and not out dated. It is also their responsibility to dispose of any out dated materials in their department.

5.9 Certified stock is issued from the raw material storage area to comply with the requirements of the applicable drawing or specification.

5.10 When required by contract, raw material shall be marked so that it is certifiable and traceable to one sales order, purchase order, heat number, etc.

6.0 TRACEABILITY

6.1 The purpose of this procedure is to establish traceability of raw materials when traceability is required by contract specification.

6.2 Any contract requiring traceability will be so noted on the sales release form.

6.3 Purchasing will take note of any sales release that specifies traceability and will submit the purchase orders for this contract to Quality Engineering for compliance to QP-02.

6.3.1 Upon receiving the raw materials in inspection, the inspector will check the sales order to determine if traceability is needed. If traceability is needed the inspector will identify such raw material with the approved tag or lot slip and inspection stamp.

6.3.2 A traceable raw material tag or slip will stay with the raw material unit until either the material is used and a new inspection slip or tag is issued for the resultant part.

QP #05

POLICIES AND PROCEDURES
QUALITY PROCEDURE

SUBJECT: FIRST ARTICLE INSPECTION

1.0 PURPOSE

This procedure defines a method for inspecting the first of a series of articles produced for the purpose of early detection and timely correction of discrepancies.

2.0 APPLICATION

This procedure applies to the first of all new or significantly changed parts and assemblies manufactured for the company by subcontractors, or the first part or assembly manufactured for the company by a new subcontractor or by CMC manufacturing.

3.0 ASSOCIATED DOCUMENTS

FIRST OPERATION, FIRST PIECE

FIRST ARTICLE REPORT PROCURED MATERIAL

3.1 FORMS

CMP #0043, QA #008

4.0 PROCEDURE - SUPPLIER

4.1 The quality engineering department is responsible for citing on a purchase order or contract the requirement for a first article inspection

4.2 First article inspection could be performed in the receiving inspection area or the inspection can be performed by source inspection personnel at the subcontractor's facility if so authorized by the quality assurance and purchasing department per QP-02.

4.3 The first article inspection is to be a complete one, covering all appropriate physical and functional characteristics of the part or assembly, workmanship, and the completeness and correctness of the required documentation. First article material will be tagged with a white tag identifying purchase order no., part no., serial no., inspection acceptance stamp and date. The white tag will remain with first article material.

4.4 The test engineering department is responsible for providing the required test equipment, test equipment operating specifications and test personnel to perform tests required.

4.5 The quality engineering department is responsible for providing the receiving inspection department with the required inspection instructions per QP-17.

4.6 If special analysis or tests are required, receiving inspection is to forward the part or assembly to the appropriate department or function.

4.7 At the completion of their first article inspection, the inspector is to prepare the first article report - procured material. The form is to be filled out as follows:

1. NAME AND ADDRESS OF THE SUBCONTRACTOR

2. DATE OF THE REPORT

3. REPORT NUMBER

4. PART OR ASSEMBLY NUMBER

5. REVISION NUMBER

6. PART OR ASSEMBLY NAME

7. NEXT ASSEMBLY

8. PURCHASE ORDER OR CONTRACT NUMBER

9. CHECK MARK FOR APPROVAL

10. CHECK MARK FOR REJECTION

11. IF REJECTION, DESCRIPTION OF THE DISCREPANCY

12. RECOMMENDED DISPOSITION

13. A CHECK MARK TO INDICATE WHETHER OR NOT A TEST REPORT IS ATTACHED

14. DATED SIGNATURE OF THE INSPECTOR

15. DATED SIGNATURE OF THE PERSON AUTHORIZED TO APPROVE THE REPORT

4.8 COPIES OF THE REPORT ARE TO BE DISTRIBUTED AS FOLLOWS:

1. RECEIVING INSPECTION FILES

2. PURCHASING (FOR FORWARDING TO THE SUBCONTRACTOR).

5.0 PROCEDURE - CMC MANUFACTURING

5.1 CMC manager will be responsible for requesting first article inspection and implementing appropriate step on manufacturing routing, tag, traveler, etc.

5.2 First article inspection is to be a complete one, covering all appropriate physical and functional characteristics of the part of assembly, workmanship, and the completeness and correctness of the required documentation. First article material will be tagged with a white tag identifying purchase order no., part no., serial no., inspection acceptance stamp and date. The white tag will remain with first article material.

5.3 If special analysis or tests are required, quality control inspection is to forward the part or assembly to the appropriate department or function.

5.4 At the completion of the first article inspection, the inspector is to prepare Form #, QA #008. The form is to be filled out a follows:

1. NAME AND ADDRESS OF THE SUBCONTRACTOR

2. DATE OF THE REPORT

3. REPORT NUMBER

4. PART OR ASSEMBLY NUMBER

5. REVISION NUMBER

6. PART OR ASSEMBLY NAME

7. NEXT ASSEMBLY NUMBER

8. PURCHASE ORDER OR CONTRACT NUMBER

9. CHECK MARK FOR APPROVAL

10. CHECK MARK FOR REJECTION

11. IF REJECTION, DESCRIPTION OF THE DISCREPANCY

12. RECOMMENDED DISPOSITION

13. A CHECK MARK TO INDICATE WHETHER OR NOT A TEST REPORT IS ATTACHED

14. DATED SIGNATURE OF THE INSPECTOR

15. DATED SIGNATURE OF THE PERSON AUTHORIZED TO APPROVE THE REPORT

QP #06

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: SOURCE INSPECTION

1.0 PURPOSE

This procedure describes the approach for the source inspection of parts or assemblies produced by suppliers and subcontractors.

2.0 APPLICATION

This procedure applies to all supplies and subcontractors and its application is the responsibility of the Quality Engineering per QP-02.

3.0 ASSOCIATED DOCUMENTS

QP #02, PURCHASE ORDER REVIEW

QP #03, NON-CONFORMING MATERIAL

QP #04, RECEIVING INSPECTION

QP #07, CORRECTIVE ACTION

3.1 FORMS

QA #007

4.0 PROCEDURE

4.1 Source inspection of parts or materials at supplier's or subcontractor's facility will be performed whenever it is specified as a requirement on a contract or purchase order. Quality engineering has the option to waive source inspection and impose receiving inspection.

4.2 The source inspection is made at the point of fabrication prior to shipment to this company using inspection instructions, drawings, and specifications, and includes an examination of the supplier's or subcontractor's records of inspections and tests. The result are recorded on the source inspection report as follows:

1. NAME AND ADDRESS OF THE VENDOR
2. PURCHASE ORDER NUMBER
3. DATE OF THIS REPORT
4. NAME OF THE PROJECT
5. LOT OF SERIAL NUMBERS
6. A LIST OF THE PART NUMBERS INSPECTED
7. QUANTITIES ORDERED FOR EACH PART
8. QUANTITIES INSPECTED
9. SIZE OF THE SAMPLE, IF APPLICABLE
10. QUANTITY ACCEPTED
11. QUANTITY REJECTED
12. ANY REMARKS
13. DESCRIPTION OF THE DRAWINGS AND/OR SPECIFICATIONS INCLUDING THE REVISION NUMBER
14. REASONS FOR REJECTIONS
15. A BRIEF DESCRIPTION OF ANY CORRECTIVE ACTION TAKEN BY THE SUPPLIER
16. SUPPLIER'S DATED SIGNATURE
17. INSPECTOR'S DATED SIGNATURE

4.3 All material lots may be subjected to sampling inspection. The acceptable quality level (AQL) is determined by supplier statistical trend data.

4.4 Material that has been accepted as a result of source inspection will be tagged with a green tag identifying purchase order no., part no., serial no., (if applicable). Quantity, inspection acceptance stamp and date.

4.5 Materials that have been rejected will be tagged with a red tag, identifying MRR generated and the non-conforming material will be processed per QP-03.

4.6 If the disposition on the material reject reports call for corrective action of the supplier, refer to QP-07.

4.7 Materials that have been source inspected, upon receipt at CMC are to examined only for transit damage, and the completeness and correctness of the accompanying paper work and documentation (such as certificates and test reports). A copy of the source inspection report will be included with the shipment.

QP #07

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: CORRECTIVE ACTION

1.0 PURPOSE

2.0 APPLICATION

3.0 ASSOCIATED DOCUMENTS

3.1 FORMS

QA #009, QA #010, QA #022

4.0 PROCEDURES

4.1 In the event of a material discrepancy requiring corrective action, Form # QA #009 is issued to initiate an investigation of the cause of the discrepancy, in order to prevent a recurrence.

4.2 A car can be issued as result of: material review board, inspection/audits, test/failure reports, customer complaints, and field returns.

4.3 The corrective action request form is to be filled out as follows:

1. The number of the (CAR)
2. The name of the person and organization requesting action
3. The date of the request
4. The date when a reply to the request is due
5. The name of the program of project
6. The part name
7. The part number
8. The inspection or failure report number
9. The material review report number, if applicable
10. A description of the condition
11. The apparent cause of the condition, if known

4.4 Information relative to the car is now recorded on Form # QA # 010 as follows:

1. THE CAR NUMBER
2. THE INSPECTION OR FAILURE REPORT NUMBER
3. THE MATERIAL REVIEW REPORT NUMBER, IF APPLICABLE
4. THE NAME OF THE ORGANIZATION RESPONSIBLE FOR THE INVESTIGATION AND CORRECTIVE ACTION
5. THE DATE THE ASSIGNMENT WAS MADE TO THAT ORGANIZATION
6. THE DATE when THE ORGANIZATION RESPONSE IS DUE

4.5 The CAR is forwarded to the assigned organization where an investigation is done to detect the cause of the discrepancy, and action taken to prevent recurrence. This information is recorded on the CAR form as follows:

1. ACTUAL CAUSE OF THE DISCREPANCY
2. ACTION TAKEN TO PREVENT RECURRENCE
3. THE SIGNATURE AND TITLE OF THE PERSON RESPONSIBLE FOR THE CORRECTIVE ACTION AND THE DATE OF THE SIGNATURE

4.6 The completed CAR is returned to quality engineering. The corrective action log is updated.

5.0 PROCEDURE SUPPLIER

5.1 When supplier corrective action is required, a corrective action request is to be filled out either by the quality engineering or the quality control department.

5.2 The CAR form is to be filled out as follows:

1. THE CAR NUMBER
2. THE DATE THE FORM IS BEING PREPARED
3. THE NAME AND ADDRESS OF THE SUPPLIER
4. THE NAME AND ADDRESS OF THE SENDER
5. THE PART NUMBER
6. THE QUANTITY OF PARTS REJECTED
7. THE QUANTITY REJECTED
8. THE NAME OF THE PROGRAM OR PROJECT
9. THE PURCHASE ORDER NUMBER AND SALES ORDER NUMBER
10. A DESCRIPTION OF THE DISCREPANCY
11. A CHECK MARK AS TO THE DISPOSITION TAKEN
12. THE APPROVAL SIGNATURE OF THE APPROPRIATE PURCHASING REPRESENTATIVE
13. THE APPROVAL SIGNATURE OF THE APPROPRIATE QUALITY ASSURANCE REPRESENTATIVE

5.3 The car is to be processed through the quality engineering unit for logging and control process.

5.4 After logging, the CAR is sent to purchasing for forwarding to the supplier.

5.5 The supplier investigates the discrepancy and taken corrective action, to be recorded on the CAR form as follows:

1. DESCRIPTION OF THE CAUSE OF THE DISCREPANCY
2. A DESCRIPTION OF THE CORRECTIVE ACTION TAKEN TO ELIMINATE A RECURRENCE OF THE  DISCREPANCY
3. THE SUPPLIER'S SIGNATURE, TITLE, AND DATE

5.6 The completed CAR is to be returned by the supplier, usually within a 10-day period. If the form has not been received after 30 days, purchasing is to send a reminder to the supplier. if the form has not been received after 45 days, quality assurance may withhold acceptance of all further shipments from the supplier until the requirement is complied with.

5.7 After receipt of the CAR from the supplier, it is reviewed by quality engineering, which can request additional data from the supplier.

5.8 In-house CAR'S issued will be responded to within five (5) working days. Adjustments to allotted response time will be issued by the quality assurance manager only. If the completed CAR has not been received within the allotted time, another CAR will be issued. If there is no response to either CAR it will be escalated to the president of the company.

QP #08

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: VENDOR SURVEY

1.0 PURPOSE

This procedure describes the method for surveying candidate suppliers and subcontractors to gather information relative to their capabilities for confirming to quality requirements.

2.0 APPLICATION

Vendor surveys are used to gather information from potential suppliers and subcontractors who are candidates for all levels of procurement activity. The quality engineering department is responsible for conducting these surveys, for use by the purchasing department to establish and/or maintain the approved vendors list.

3.0 ASSOCIATED DOCUMENTS

3.1 QUALITY PROCEDURES

• QP-04 RECEIVING INSPECTION
• QP-09 VENDOR RATING
• QP-14 STATISTICAL QUALITY CONTROL

3.2 FORMS

QA #011 VENDOR SURVEY AND TABLES I & II (SHORT FORM)

3.3 APPROVED VENDORS LIST

SPC Vendor rating graphs (computer)

4.0 PROCEDURE - ON SITE WITHIN 100 MILES

4.1 Request for quality surveys of candidate suppliers or subcontractors can be generated by program management, purchasing, or quality assurance.

4.2 Authorization to conduct a quality survey of a candidate supplier or subcontractor can be given by either quality assurance or purchasing department management personnel.

4.3 Surveys are to be conducted by the quality engineering department. If a team is to make the survey, the team members are to be selected from the quality engineering organization (team leader), purchasing, program management, and engineering.

4.4 The purchasing department is responsible for making formal survey arrangements with a candidate supplier or subcontractor, including explaining the purpose of the survey, and scheduling a date and time.

4.5 Survey is not to begin at a supplier's or subcontractor's facility without an initial introductory discussion with the appropriate supplier/subcontractor management representative.

4.6 At the conclusion of a survey, the supplier/subcontractor management representative is to be verbally briefed as to the findings. Official survey results will later be transmitted by letter/fax.

4.7 The quality engineering department is to evaluate the survey findings and generate a supplier quality evaluation report. This form is to be used for all surveys of potential suppliers and subcontractors who may be involved in any level of procurement activity.

4.8 If a supplier is found to be acceptable, it is placed on the "Approved Vendors List". Quality engineering's evaluation will determine the category for which the vendor is approved. (See Table I and II).

4.9 Resurveys may be conducted when the following conditions exist:

1. CRITICAL OR NEW PROCESS ARE ADDED TO THE PROCUREMENT
2. SUPPLIER OR SUBCONTRACTOR ACQUIRES A NEW FACILITY OR NEW MANAGEMENT
3. VENDOR SCORE FALLS BELOW 97% ON VENDOR RATING, FOR A PERIOD OF 90 DAYS

5.0 PROCEDURE-OUTSIDE 100 MILES

5.1 QUALITY PROCEDURES SAME AS 3.1 OF THIS PROCEDURE.

5.2 FORMS

Same as 3.2 of this procedure

5.3 APPROVED VENDORS LIST

Same as para: 3.3 of this procedure

5.4 Vendors outside 100 miles, mail or fax form QA #011.

5.5 Quality engineering will review returned forms for completeness and compare to QP #09 and QP #14. When found to be compliant to requirements for commodities and rating levels add to approved list.

TABLE I

SPECIAL PROCESS CODES

CODES

AA PRINTED CIRCUIT BOARDS

BB CASTING

CC BRAZING

DD WELDING

EE METAL FINISHING

FF HEAT TREATING

GG NONDESTRUCTIVE TESTING

HH CONFORMAL COATING

II ELECTRONIC COMPONENTS

JJ ENVIROMENTAL EQUIPMENT

KK ELECTRONIC EQUIPMENT

LL PRIME/PAINT

TABLE II

COMMODITY CODES

CODE COMMODITY

A STANDARD HARDWARE ITEMS (SCREWS, NUTS, BOLTS, ETC.)

B. STANDARD ELECTRONIC COMPONENTS (CAPACITORS, RESISTORS, IC'S ETC.)

C. STANDARD WIRE OR CABLE

D. STANDARD ELECTRONIC EQUIPMENT (POWER SUPPLIES, OSCILLOSCOPES, ETC.)

E. STANDARD ITEMS (MISC.)

F. FABRICATED ITEMS - SHEET METAL

G. FABRICATED ITEMS - MACHINING

H. FABRICATED ITEMS - CASTINGS

I. FABRICATED ITEMS - ELECTRONIC COMPONENTS

J. FABRICATED ITEMS - ELECTRONIC ASSEMBLIES

K. FABRICATED ITEMS - ELECTRONIC EQUIPMENT

L. FABRICATED ITEMS - PRINTED CIRCUIT BOARDS

M. FABRICATED ITEMS - WIRE HARNESSES/CABLES

N. FABRICATED ITEMS - MISCELLANEOUS

O. SERVICES - ELECTRONIC COMPONENTS TESTING

P. SERVICES - ENVIRONMENTAL TESTING

Q. SERVICES - ENGINEERING CONSULTANTS

R. SERVICES - PAINTING

S. SERVICES - METAL FINISHING

T. SERVICES - MARKING/SILK-SCREEN/ENGRAVING

U. SERVICES - MISCELLANEOUS

QP #09

POLICIES AND PROCEDURES

QUALITY PROCEDURES

SUBJECT: VENDOR RATING

1.0 PURPOSE

The procedure defines the method for rating the quality performance of suppliers and subcontractors.

2.0 APPLICATION

This procedure entails the evaluation, rating, and reporting by the source inspection and receiving inspection departments of the quality performance of all suppliers and subcontractors.

3.0 ASSOCIATED DOCUMENTS

3.1 QUALITY PROCEDURE

• QP #04 RECEIVING INSPECTION
• QP #14 STATISTICAL QUALITY CONTROL

3.2 FORMS

• SPC Graphs "P" chart
• SPC Graphs "C" chart
• QA# "P" chart data

3.3 REPORT

4.0 PROCEDURE

4.1 The evaluation and rating of supplier/subcontractor performance in terms of quality are the responsibility of the procurement quality engineering department.

4.2 Evaluations and ratings are to be made on a monthly basis.

4.3 Source material to be used in evaluating and rating supplier/subcontractor performance include, but are not limited to, source inspection reports and receiving inspection records.

4.4 The vendor rating is a simple calculation of percent defective: The total number of accepted parts divided by the total number of parts inspected. This calculation is made over the last five (5) consecutive lots (max.). If five lots are not completed, quality engineering will calculate from the information available.

EXAMPLE: LOT NO. PARTS ACCEPTED PARTS INSPECTED

1. 10 10
2. 14 15
3. 10 10
4. 10 10
5. 14 15

TOTAL: 55 60

55 DIVIDED BY 60 = .966 = 97% VENDOR RATING

4.5 The vendor ratings will be calculated by quality engineering and issued monthly in the approved vendors list.

4.6 Copies of the approved vendors list will be distributed to the quality assurance manager and the purchasing manager also receiving inspection.

4.7 The purchasing manager is responsible for limiting or suspending the use of suppliers or subcontractors who consistently rate below 97% on the rating scales.

4.8 Vendors that fall below 95% will be placed on a suspect list to be evaluated by quality engineering. If their performance does not improve, quality engineering will issue a corrective action request per QP-07. Not improving quality levels within a reasonable time span (30 days).

QP #10

POLICIES AND PROCEDURES

QUALITY PROCEDURES

SUBJECT: CALIBRATION PROCEDURES

1.0 PROCEDURE

This procedure specifies the responsibilities for controlling the accuracy of measuring an test equipment and measurement standards to assure that products delivered to customers conform to specified requirements.

2.0 APPLICATION

This procedure applies to the quality control department and to all departments and individuals who use measuring test equipment. The quality control department has the prime responsibility for operation of the calibration system.

3.0 DEFINITION

3.1 CALIBRATION: comparing measuring and test equipment with measuring standards known accuracy, to detect and adjust deviations from the standards.

3.2 CALIBRATION CONTROL: a documented system for assuring that measuring and test equipment devices and measurement standards are calibrated, and that this is done at intervals that assure accuracy.

3.3 CALIBRATION RECALL: a system for indication in advance for each measuring and test equipment devices and measurement standard the date when it is next due to be calibrated.

3.4 CALIBRATION INTERVAL: the period of time between calibration intervals can vary for devices depending upon their stability, purpose, and degree of usage.

3.5 CERTIFICATION: approval given for the use of newly acquired or reworked, modified measuring and test equipment devices or processes following an examination that has verified that they are compatible with other devices to be processed into the system, and, capable of fulfilling intended functions.

3.6 MEASURING AND TEST EQUIPMENT: all devices used to measure, gauge, test, inspect, or otherwise examine items to determine compliance with specifications.

3.7 MEASUREMENT STANDARD (REFERENCE): an instrument or device of the highest order of accuracy which is used in a calibration system as primary standard of reference, its accuracy traceable to the nation bureau of standard.

3.8 MEASUREMENT STANDARD (TRANSFER): and instrument or device in a calibration system used to transfer measurements from the reference standard to a lower echelon "working" standard or directly to the measuring or test equipment being calibrated to avoid wear or deterioration of the reference standard.

3.9 MEASUREMENT STANDARD (INTERIM): and instrument used as standard until an authorized standard is established.

4.0 ASSOCIATED DOCUMENTS

4.1 PROCEDURES

4.2 FORMS

5.0 PROCEDURE (GENERAL)

5.1 All measuring and test equipment instruments and devices used to determine item's conformance to specifications requirements are to be calibrated. This calibration is to occur at regularly schedule intervals (See Table I) determined on the basis of stability, purpose, and usage or sooner if there is some reason to believe that the instrument or device needs recalibration.

5.2 All measuring and test equipment devices will be calibrated to working measurement standards or transfer measurement standards which are calibrated and certified by the National Institute of Standards and Technology.

5.3 Records are to be maintained that identify each item of measuring and test equipment, each measurement standard, and list and date of each instance of calibration, citing measurements and adjustments. The records are to be able to demonstrate traceability of the calibration work to the National Institute of Standard and Technology.

5.4 Each item of measuring and test equipment and measurement standards is to be marked showing the date of the most recent calibration, the stamp of the technician who performed the calibration, and the date when the next calibration is scheduled. If the item is to small for this type of marking, a color code or smaller identifying mark is to be used which is keyed to independently maintained records that cite the same date.

5.5 Departments using measuring and test equipment are responsible for monitoring calibration due dates and submitting instruments and devices for calibration on schedule.

5.6 Inspectors and test technicians cannot accept measurements values obtained on measuring and test equipment that have exceeded calibration due dates.

5.7 Measuring and test equipment instruments and devices cannot be calibrated with measurement standards that have exceeded calibration due dates.

5.8 Employee-owned measuring equipment (such as micrometers) can be used for product acceptance measurements only if they are calibrated by the company on a regularly scheduled basis.

5.9 The environment where measuring and test equipment instruments and devices are to be both calibrated and used must be controlled to the extent necessary to assure required accuracy, with consideration given to temperature, humidity, vibration, cleanliness, and other controllable factors.

5.10 Purchasing is responsible for coordinating with quality assurance in the selection and acquisition of subcontractors to perform measuring and test equipment calibration and/or repair work.

5.11 All new, reworked, repaired, or modified measuring and test equipment instruments and devices are to be examined, ad when proved acceptable, certified as complying to requirements by the quality control department.

5.12 The quality/control department is responsible for securing calibration instructions for all measuring and test equipment that has been procured.

5.13 The quality control department will maintain a listing of company measuring and test equipment and test equipment that has been certified.

5.14 The quality control department will be responsible for procuring and maintaining all measurements standards required to support product measurement requirements.

5.15 The calibration department will be responsible for developing measurement standards in those instances where measuring and test equipment are calibrated in-house.

6.0 PROCEDURE (CONTROL AND RECALL)

6.1 The quality control department is responsible for the identification, calibration, repair, and calibration record keeping of all measuring and test equipment devices and all measurement standards. The records must offer traceability to the national institute of standards and technology.

6.2 All personnel and departments using measuring test equipment have the responsibility for seeing that an item of equipment is not used when is calibration period has expired. Such items are to be returned to the quality control department for calibration arrangements.

6.3 A calibration/service data record is to be created and maintained for each item of measurement standards, measuring equipment, and test equipment. It is to be filled out as follows:

1. THE ITEM'S NAME AND SERIAL NUMBER
2. THE ITEM'S MANUFACTURER
3. THE MODEL NAME AND/OR NUMBER
4. THE RECALL DATE OR DATES
5. THE CALIBRATION/SERVICE SPECIFICATION NUMBER
6. THE CALIBRATION/SERVICE RECORD (CSDR) NUMBER (TO BE ASSIGNED BY THE PERSON FILLING OUT THIS FORM)
7. THE CALIBRATION JOB INSTRUCTION NUMBER
8. THE DATE THIS RECORD IS FIRST CREATED
9. THE SIGNATURE OF THE PERSON APPROVING THE BASIC RECORD
10. A LISTING OF THE MEASUREMENT STANDARD OR STANDARDS REQUIRING TO CALIBRATE THIS ITEM.

6.4 Actual measurement date is recorded in terms of:

1. THE OPERATION NUMBER
2. THE PARAMETER
3. NOMINAL
4. MEASURED READING OR VALUE
5. CORRECTED READING OR VALUE
6. MINIMUM LIMITS
7. MAXIMUM LIMITS
8. REMARKS

6.5 Calibration and repair status identification is accomplished through the use of decals applied to each item of measurement standards, measuring equipment, and test equipment. These decals are as follows: a calibration due decal, which shows the date when the next calibration stamp of the person who performed the work; a not calibrated decal, which carried the notice that the item of equipment to which this decal is attached is not to be used for official measurement proposes; and out-of-service decal, and with the notice that the equipment to which the decal is attached, must be repaired and/or calibrated before use. It carries the name or stamp of the person who has determined that this condition exists and the date.

6.6 The quality control department has the responsibility for continually examining the calibration intervals assigned to the measurement devices and extending or shortening them as required.

6.7 Calibration of a measurement device can be requested at any time, regardless of the calibration due date for that device, following the occurrence of any event that places the devices accuracy in doubt.

6.7.1 Equipment that has an out of tolerance condition, fails calibration, or whose tamper proof seal is broken, requires quality engineering to assess the appropriate corrective action (QP-07) as follows:

1. Remove failed equipment from process.
2. Identify material, parts, or assemblies tested within calibration cycle of failed equipment.
3. Formal notification to customer any interdepartmental functions of material, parts or assemblies that may require investigative actions.
4. Repair/replacement of failed equipment prior to use in any process upon discovery.
5. Issue formal corrective action per QP #07 of this manual.

6.8 The quality engineering department is to maintain a surveillance function, its purpose to periodically and randomly audit compliance to the calibration control and recall system. Violations are to be reported to the manager of quality assurance.

6.9 Tamper proof seals/labels. Items having dials, levers and or knobs that must remain positioned for purposes of calibration, i.e.: ovens, electronic test equipment, etc., etc., must have a tamper proof seal located so as to prevent any change in calibration parameters.

TABLE I

CALIBRATION INTERVALS

ITEM NUMBER FORMAT INTERVAL MONTHS

MECHANICAL

• Micrometers MCXXX 6
• Vernier Calipers VCXXX 6
• Height Gages HGXXX 6
• Snap Gages SGXXX 6
• Thread Gages TGXXX 6
• Dial Calipers DCXXX 6
• Dial Indicators DIXXX 6
• Flow Meters FMXXX 6
• Barometers BMXXX 6
• Thermometers TMXXX 6
• Hydrometers HMXXX 6
• Pressure Gages PGXXX 6
• Torque Wrenches TWXXX 6
• Crimping Tools CTXXX 6
• Measuring Stands MSXXX 12
• Plug Gages PGXXX 12
• Sine Bars SBXXX 12
• Angle Blocks ABXXX 12
• "V" Blocks VBXXX 12
• Radius Gages RGXXX 12
• Hardness Tester HTXXX 12
• Parallels PLXXX 12
• Surface Plate SPXXX 36
• Gage Blocks GBXXX 36
• Angle Gage Blocks ABXXX 36

ELECTRICAL

• V-O-M meters VMXXX 6
• Network Analyzers NAXXX 12
• Frequency Counters FCXXX 12

QP #11

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: INSPECTOR/OPERATOR TRAINING AND CERTIFICATIONS

1.0 PURPOSE

This procedure establishes the requirements for training, certifying, and recertifying employees involved in performing critical and specialized functions.

2.0 APPLICATION

This procedure applies to employees performing critical and/or specialized functions related to deliverable items. Based on customer imposed specification per contact.

2.1 RECERTIFICATION SHALL BE REQUIRED UNDER THE FOLLOWING CIRCUMSTANCES:

A. PROFICIENCY REQUIREMENTS HEREIN ARE NOT MET.
B. NEW TECHNIQUE HAVE BEEN DEVELOPED WHICH REQUIRE NEW SKILLS.
C. WORK PERIOD INTERRUPTION EXCEED 90 DAYS.
D. THERE IS REASON TO QUESTION PROFICIENCY OR WORKMANSHIP.

3.0 ASSOCIATED DOCUMENTS

3.1 PROCEDURES

3.2 FORMS

4.0 PROCEDURE

4.1 The responsibility for developing training courses and testing criteria, operation of the training session, and conducting certification sessions falls under the jurisdiction of the quality and production departments.

4.2 The quality engineering department is responsible for examining customer-imposed specifications related to inspector/operator certification, and accommodating these requirements.

4.3 Notification of employees of certifications or recertifications sessions will be accomplished throughout the use of an internal memorandum.

4.4 An inspector/operator unable to attend the session as scheduled, is to have their supervisor arrange a new date by contacting the person who prepared the notice.

4.5 The sessions are to be conducted by company engineering personnel and are to cover familiarity with the applicable specifications, procedures and instruction, the performance of tasks related to the job classification, and the techniques for maintaining records and preparing reports.

4.6 The quality assurance department is responsible for maintaining records of the certification/recertification program. The quality certification record form is to be used for this purpose. It is to be filled out as follows:

1. THE EMPLOYEE'S NAME (LAST NAME FIRST).
2. THE EMPLOYEE'S IDENTIFICATION NUMBER.
3. THE DEPARTMENT TO WHICH THE EMPLOYEE IS ASSIGNED.
4. THE EMPLOYEE'S JOB CLASSIFICATION.
5. THE CERTIFIABLE FUNCTION BEING COVERED BY THIS EMPLOYEE'S TRAINING AND CERTIFICATION SESSIONS.
6. THE DATES AND RELATED COMMENTS CONCERNING THE CERTIFICATION EXPIRATION DATES FOR THIS EMPLOYEE.
7. THE DATES AND COMMENTS RELATED TO AUDITS MADE OF THIS EMPLOYEE'S PERFORMANCE.

4.7 Periodically, and at random, the quality assurance personnel are to audit the performance of certified personnel and report the findings on the previously described quality certification record. As a result of this audit, and employee can be required to be retrained and recertified, (regardless of the expiration date on their current certification) if the amount of errors and/or problems with quality warrant such action.

QP #12

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: IN-PROCESS INSPECTION

1.0 PURPOSE

This procedure established the method for monitoring and controlling the quality of parts, components, and subassemblies throughout the various intermediate steps involved in the manufacturing process.

2.0 APPLICATION

This procedure applies to the in-process quality control department of quality assurance, and excludes source and receiving inspection, and final inspection and test.

3.0 ASSOCIATED DOCUMENTS

3.1 QUALITY PROCEDURES

• QP-05 FIRST ARTICLE INSPECTION
• QP-07 CORRECTIVE ACTION
• QP-03 NON-CONFORMING MATERIAL CONTROL
• QP-17 ISSUING QUALITY INSTRUCTIONS
• QP-18 CONTROL OF INSPECTION STAMPS

3.2 FORMS

4.0 PROCEDURE

4.1 Parts, components, and subassemblies, through their intermediate stages of manufacturing, are to be periodically presented for inspection by manufacturing. These inspections are to take place, as called for, on the production router and on the project inspection plan. When there is an occurrence of some nature that indicates that special inspections are appropriate, a quality engineer will issue quality instructions per procedure no. QP-17.

4.2 Inspection methods employed can include inspections by machine operators and witnessed by inspection personnel, the use of automated inspection gauges, moving line, lot sampling, set-up/fixture approval or first piece approval, production line inspection station, roving inspectors.

4.3 Inspections are to be made using applicable inspection instructions, drawings, specifications, and other appropriate reference materials and/o charts (XER,U,C,P Charts).

4.4 The in-process inspector is to secure the required gauges or test instruments required.

4.5 The inspection is to include an examination of the accompanying paper work for completeness and correctness, workmanship, physical and functional characteristics, and when called for the effectiveness of special process such as heat treating or the application of special coating.

4.6 The inspector must verify any special testing or laboratory analysis performed as designated on the production router.

4.7 First piece inspections are to be recorded on the P Chart Data Log. This is to be filled out as follows:

1. THE DATE OF THE INSPECTION
2. THE NAME OF THE PART BEING INSPECTED
3. THE REVISION NUMBER
4. THE PART NAME
5. THE SUBMITING DEPARTMENT
6. THE RESULTS OF INSPECTION (REJECTS, DEFECTS, ETC.)
7. THE INSPECTOR'S STAMP
8. THE MRR NUMBER (IF APPLICABLE)

4.8 Parts or assemblies, when specified, found to be acceptable are to be so marked using an inspection stamp and tagged with a green tag. The production router must also be stamped so material can continue in their normal flow through the manufacturing process.

4.9 A material reject report is to be filled out when parts or assemblies are found to be discrepant. A red tag will be placed on the material identifying mrr no., part no., serial no., date, quantity, inspection reject stamp. The form should be filled out as follows:

1. THE REPORT NUMBER
2. THE PART OR ASSEMBLY NUMBER
3. THE PART OF ASSEMBLY NAME
4. THE DATE OF THE REPORT
5. PROGRAM/PROJECT NUMBER
6. THE LOT NUMBER OR SERIAL NUMBER OR NUMBER RANGE
7. THE QUANTITY SAMPLED
8. THE QUANTITY REJECTED
9. THE DEPARTMENT
10. THE NAME OR STAMP MARK OF THE INSPECTOR
11. THE QUANTITY
12. THE REASON FOR REJECTION
13. REWORK INSTRUCTIONS GENERATED BY MANUFACTURING REPRESENTATIVE

Following a preliminary examination involving product engineering and quality engineering, a disposition will be made per from QP-03. If the disposition requires corrective action, a corrective action request (Form No. QP-009) will be issued per Form No. QP-07.

4.10 On a regular basis, the in-process quality control department is to review all inspection instructions, determine their correctness and effectiveness, and coordinate changes, if required, with the quality engineering department.

5.0 IN PROCESS TEST MONITORING

5.1 When any necessary functional testing is performed, as required, by production personnel the quality control function performs surveillance inspections of the functional tests, assuring verification of units to customer contractual requirements.

5.2 Non-conforming assemblies are processed in accordance with QP-04 of this manual.

5.3 Corrective action is taken in accordance with QP-07 of this manual.

5.4 Test instructions are issued in written form, as applicable, with consideration given to the complexity of the item and the customer requirements. The instruction include criteria for acceptance and rejection. This shall be developed by the test engineering department and approved by the customer when deemed appropriate.

QP #13

POLICIES AND PROCEDURES
QUALITY PROCEDURE

SUBJECT: FINAL INSPECTION

1.0 PURPOSE

This procedure established the methods and responsibility for final inspection, testing and packaging of completed products to assure that they comply with company standards and customer requirements.

2.0 APPLICATION

This procedure applies to the inspection of all deliverable finished goods.

3.0ASSOCIATED DOCUMENTS

3.1 QUALITY PROCEDURES

• QP-05 FIRST ARTICLE INSPECTION
• QP-03 NON-CONFORMING MATERIAL CONTROL
• QP-07 CORRECTIVE ACTION
• QP-17 ISSUING QUALITY INSTRUCTIONS
• QP-18 CONTROL OF INSPECTION STAMPS

3.2 FORMS

4.0 PROCEDURE

4.1 All finished goods are to be presented to final inspection for inspection. These inspection are to take place as called for on the production router and/or the project inspection plan. When there is an occurrence of some nature that indicates special inspections, quality engineering will issue quality instruction per procedure no. QP-17.

4.2 Parts and assemblies will not be accepted for final inspection unless all operations are called out on the production router and are identified as completed.

4.3 Inspections are to be made using applicable inspection instructions, drawings, specifications, and other appropriate reference materials.

4.4 The inspection is to include an examination of accompanying paper work for completeness and correctness, workmanship, physical and functional characteristics, and the proper markings on parts and assemblies.

4.5 The inspector must verify any testing or laboratory analysis performed as designated on the production router.

4.6 Products are to be approved for acceptance testing by final inspection and tested after a determination has been made that the product is complete, that all operations have been completed, and that there are no open items.

4.7 Each acceptance test is to be witnessed by CMC QA and/or the customer's representative.

4.8 Quality engineering is responsible for monitoring the test area to make sure test equipment that has passed its calibration due date is not used.

4.9 Final inspection is responsible for overseeing the proper packaging of finished goods prior to shipment. This includes making sure packaging specifications are being complied with, and making certain that all interior and exterior containers are properly marked.

4.10 Final inspection is responsible for overseeing the proper shipment of goods, including verifying that the shipping, test and customer required documents are correct and properly stamped, and that interstate commerce commission regulations and other applicable requirements are complied with.

4.11 Parts or assemblies, found to be acceptable are to be so marked using and inspection stamp and tagged with a green tag. The production router must also be stamped so material can continue in their normal flow.

4.12 A material reject report is to be filled out when parts or assemblies are found to be discrepant. A red tag will be placed on the material identifying MRR no., part no., serial no., date, quantity, inspection reject stamp. The form should be filled out as follows:

1. THE REPORT NUMBER
2. THE PART OR ASSEMBLY NUMBER
3. THE PART OR ASSEMBLY NAME
4. THE DATE OF THE REPORT
5. PROGRAM/PROJECT NUMBER
6. THE LOT NUMBER OR SERIAL NUMBER OR NUMBER RANGE
7. THE QUANTITY SAMPLED
8. THE QUANTITY REJECTED
9. THE DEPARTMENT
10. THE NAME OR STAMP MARK OF THE INSPECTOR
11. THE QUANTITY
12. THE REASON FOR REJECTION
13. THE REWORK INSTRUCTIONS GENERATED MANUFACTURING REPRESENTATIVE

Following a preliminary examination involving product engineering and quality engineering, a disposition required corrective action, a corrective action request will be issued per form no. QA# 009.

4.13 On a regular basis, the quality control department is to review all inspection instructions, determine their correctness and effectiveness, and coordinate changes, if required, with the quality engineering department.

QP #14

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: STATISTICAL QUALITY CONTROL

1.0 PURPOSE

This procedure sets forth the methodology for establishing data gathering techniques for the systematic and scientific measurement of quality control and manufacturing processes through the use of statistics and statistical analysis.

2.0 APPLICATION

Statistical quality control is focused at obtaining control of manufacturing processes at CMC and CMC's suppliers/vendors.

3.0 GOALS

The overall goal of statistical quality control and statistical process control is to increase the proficiency of performance and thereby reduce the costs.

4.0 ASSOCIATED DOCUMENTS AND HANDBOOKS:

• QP-04 NON-CONFORMING MATERIAL
• QP-05 RECEIVING INSPECTION
• QP-06 FIRST ARTICLE INSPECTION
• QP-07 SOURCE INSPECTION
• QP-10 VENDOR RATING
• QP-13 IN-PROCESS INSPECTORS
• QP-14 FINAL INSPECTION
• QP-16 QUALITY AUDITS
• WESTERN ELECTRIC STATISTICAL QUALITY CONTROL HANDBOOK
• AMERICAN SOCIETY FOR QUALITY CONTROL GLOSSARY AND TABLES FOR STATISTICAL QUALITY CONTROL
• IBM QUALITY INSTITUTE HANDBOOK

5.0 CHARTS AND CHART DEFINITIONS

"P" CHART: UNITS INSPECTED - UNITS REJECTED.

(GO/NO GO): N/P

"C" CHART: DEFECTS FOUND PER REJECTED

"U" CHART AVERAGE DEFECTS PER REJECTED

"X BAR AND R CHART: AVERAGE OF ALL READINGS AND DIFFERENCE between HIGHEST AND LOWEST READING.

PARETO PRINCIPLE: IDENTIFIES SIGNIFICANT FEW FROM INSIGNIFICANT MANY, IN A STAIR-STEP MANNER AND A PARETO CHART.

CMC WORKING CHARTS: CHARTS USED INTERNALLY THAT REFLECT COMPANY WIDE PROGRAMS; REJECT %, DEFECTS ON PROGRAMS AND OPERATOR RESPONSIBILITY.

6.0 PROCEDURE

QP #15

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: QUALITY AUDITS

1.0 PURPOSE

This procedure sets forth the method for periodically and randomly examining products and systems to determine the effectiveness of the overall quality assurance program.

2.0 APPLICATION

This procedure applies to all internal functions

3.0 DEFINITIONS

Quality audit: An official examination of products and systems, taking place on a periodic by random, unannounced basis, to verify the effectiveness of the company's quality program.

4.0 FORMS

5.0 PROCEDURE

5.1 The quality assurance department has the responsibility for planning and conduction quality audits.

5.2 Quality assurance will prepare a audit plan using QA Forms #017. All portions of each form must be filled out completely. Quality assurance will use inter-department procedures and quality procedures to format the audit.

5.3 The audit plan must be reviewed and approved by the quality assurance manager prior to doing the audit.

5.4 Auditor will notify each department manager as to when they will be in their area prior to doing the audit. NOTE: It is the manager descretion to assign someone to walk throughout the audit with the auditor.

5.5 Auditor will be thorough and extensive when performing audits. The detailed description of the audit plan will be researched by each individual item to assure the effectiveness of the audit. Auditor will have access to all material and documentation deemed necessary to perform an accurate and effective audit.

5.6 At the conclusion of the audit the auditor will review all discrepancies, if any, with each department manager.

5.7 If corrective actions are issued follow QA-07.

QA #16

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: GOVERNMENT/CUSTOMER PROPERTY CONTROL

1.0 PURPOSE

This procedure describes the method for providing adequate inspection, storage, and maintenance of property furnished by the government or customer.

2.0 APPLICATION

This procedure applies to all furnished material unless excluded from these requirements by contractual agreement.

3.0 ASSOCIATED DOCUMENTS

4.0 PROCEDURE (GOVERNMENT)

4.1 Upon receipt, receiving inspection is to examine all customer-furnished materials for the following:

• TRANSIT DAMAGE
• COMPLETENESS AND PROPER TYPE
• PROPER IDENTIFICATION

The quantity is also to be verified.

4.2 If appropriate and per contractual agreement, the materials are to be functionally tested to determine satisfactory operation and a GFP# issued and GFP sticker applied.

4.3 If material is defective, procedure QP-04 (non-conforming material control) is in effect.

4.4 Quality engineering is responsible for conducting periodic audits to assure that the materials are being properly stored, adequately protected, subjected to periodic maintenance when required, and that precautions exist to protect them from improper use or disposition.

4.5 Quality engineering is responsible for reporting damage, malfunction, or otherwise unsuitable furnished materials. If the problem is detected after installation, then the report is to contain an indication of the probable cause.

4.6 Quality assurance management is responsible for maintaining complete and accurate records of all furnished materials and making these records available for reviewing by the "government property log book".

5.0 PROCEDURE (CUSTOMER)

5.1 Customer furnished equipment shall be examined upon receipt to detect and identify any existing deterioration, damage, etc.

5.2 Items shall be inspected to ascertain correctness and completeness.

5.3 Any deficiencies shall be documented and the contracting officer and/or appropriate customer personnel shall be notified in writing.

5.4 A control log shall be maintained by the Quality Assurance function of all customer furnished equipment. The log will include item received, date received, description, serial number, contract number and any other applicable data.

5.5 Periodic inventory and inspection shall be made to verify the status of the equipment and assure adequate storage, handling, etc.

5.6 Shipping documents shall indicate the appropriate serial number off the equipment. The control log shall be updated to reflect the shipment and date of the items.

5.7 Customer furnished measuring and test equipment shall be controlled in accordance with QP-11 of this manual (calibration).

5.8 Each item of customer furnished equipment shall be tagged or labeled. The identification marker shall contain indication of CFE and sufficient additional information to allow reference to the control log.

5.9 When customer furnished equipment is shipped/returned the date of shipment shall be entered in the control log to terminate control of the item.

6.0 PROCEDURE (CPFF CONTRACTS, RESIDUAL MATERIALS)

6.1 The quality assurance function shall have the responsibility of surveillance of any residual materials and supplies.

6.2 The quality assurance function will assure that any residual parts presented for stock and/or storage are properly identified as to inspection status, part number, drawing number including revision, and quantity. The parts shall be packaged adequately to prevent deterioration or damage.

6.3 Residual parts which are contractually property of the customer will be properly segregated until customer direction regarding their disposition has been received.

QP #17

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: ISSUANCE OF QUALITY INSTRUCTIONS

1.0 PURPOSE

This procedure provides a system for preparing, issuing, and maintaining instructions for the inspection of specific parts, assemblies, subassemblies and processes.

2.0 APPLICATION

This procedure applies to personnel in the quality assurance department who are responsible for the preparation product quality factors that are not covered in present procedures.

3.0 ASSOCIATED DOCUMENTS

3.1 FORMS

4.0 PROCEDURE

4.1 Quality engineering obtains and reviews the production department's procedures for the part, assembly, subassembly, or processes for which quality instructions are to be prepared.

4.2 Quality engineering develops and issues the project inspection plan for the part, assembly, subassembly, or processes for which quality instructions are to be prepared.

4.3 Quality engineering develops and issues the sampling method for the part, assembly, subassembly, or processes for which quality instructions are being prepared.

4.4 The quality instructions should include the following information:

FORM QA #021

1. THE INSTRUCTION NUMBER
2. THE PAGE NUMBER
3. THE NAME OF THE PROGRAM OR PROJECT
4. THE CONTRACT NUMBER
5. THE NAME OF THE PART OR ASSEMBLY
6. THE NUMBER OF THE PART OF ASSEMBLY
7. THE NAME OF THE PERSON PREPARING THE INSTRUCTION
8. THE INSTRUCTION-PREPARATION COMPLETION DATE
9. THE INSPECTION OR TEST POINT NUMBER (DERIVED FROM QUALITY PLAN)
10. THE DETAILED INSTRUCTION INCLUDING A LISTING OF THE DOCUMENTS THAT ARE ESSENTIAL TO THE PROCESS INCLUDING DRAWINGS, SPECIFICATIONS, AND TEST PROCEDURES AS WELL AS AN IDENTIFICATION OF THE EQUIPMENT REQUIRED AT EACH TEST OR INSPECTION POINT.
11. SAMPLE PLAN PER STATISTICAL TREND DATA (AQL).

4.5 In preparing quality instructions, specify, when needed, proper handling, preservation, storage, packaging, and shipping instructions to protect the product's quality and to prevent damage, deterioration, and degradation.

4.6 The completed instruction is to be reviewed by quality assurance management, signed and dated, then issued for application.

4.7 The quality assurance department has the responsibility for maintaining a comprehensive cross-reference file of all quality instructions.

4.8 This procedure includes Coleman Microwave and supplier/vendor's processes and programs.

QP #18

POLICIES AND PROCEDURES
QUALITY PROCEDURES

SUBJECT: CONTROL OF INSPECTION STAMPS

1.0 PURPOSE

This procedure sets forth the requirements for issuing, using and controlling the quality inspection and identification stamps that are required for quality assurance personnel.

2.0 APPLICATION

This procedure applies to personnel associated with the issuance, use, and/or control of quality inspection.

3.0 FORMS

3.1 QA #018 RECEIPT-QUALITY INSPECTION AND IDENTIFICATION STAMPS

• QA #019 CONTROL LOG-QUALITY INSPECTION AND IDENTIFICATION STAMPS

4.0 PROCEDURE

4.1 Quality inspection and identification stamps will be made of rubber (for use with permanent ink).

4.2 Each stamp will be identified with a unique number, uniquely assigned to a specific individual.

4.3 The types of stamps are illustrated in figure 1, quality inspection and identification stamp. Their uses are as follows:

4.4 Responsibility for issuing and controlling quality inspection and identification stamps is vested by quality assurance management.

4.5 One or more stamps, all with the same identifying number, will be issued to a qualified person using Form No. QA #018 receipt-quality inspection and identification stamps. The receipt contains the following:

1. DATE THE RECEIPT IS RECORDED
2. THE RECORDER'S IDENTIFICATION NUMBER
3. THE RECORDER'S NAME, JOB TITLE, DEPARTMENT
4. AN IMPRESSION OF THE STAMP
5. A DESCRIPTION OF THE STAMP
6. RECIPIENT'S SIGNATURE, ACKNOWLEDGING RECEIPT OF STAMP AND UNDERSTANDING OF COMPANY PROCEDURE RELATED TO USE OF THE STAMP
7. ISSUER'S SIGNATURE

4.6 A separate record of stamps, by stamp number, is to be maintained using form no. QA #019 the control log-quality inspection and identification stamps form displayed in figure 3 for each stamp, the following information is recorded:

4.7 The stamp receipt is the only person permitted to use the assigned stamp and is responsible for keeping it clean and its impressions legible. Worn stamps must be replaced.

4.8 The stamp recipient is responsible for immediately reporting, in writing, the loss of a stamp to quality management.

4.9 Quality assurance management is responsible for the immediate preparation and distribution of a quality bulletin announcing the loss of a stamp and citing the date when its use will not be valid.

4.10 Stamps returned because of transfer or termination shall not be reissued for 6 months. The numbers of stamps that have been lost shall not be reused for 24 months after their reported lost.

• STAMP CONFIGURATION
• SOURCE, IN-PROCESS, FINAL INSPECTION STAMP
• QUALITY CONTROL, RECEIVING INSPECTION
• TEST ACCEPTANCE STAMP
• DISCREPANT MATERIAL STAMP
• EQUIPMENT CALIBRATION STAMP
• QUALITY ENGINEERING STAMP