AIRCRAFT SYSTEMS & MANUFACTURING, INC. Quality System Manual

Transcription

1 AIRCRAFT SYSTEMS & MANUFACTURING, INC. 104 Golden Oaks Drive, Georgetown, TX Quality System Manual Revision D 11 Mar 2016 This manual establishes and describes the Quality Control/Assurance system used by Aircraft Systems & Manufacturing, Inc. in support of Production Approval PQ0601SW Required Physical Manual Distribution 1 of 5 Original-Document Control (Vault) 2 of 5 FAA 3 of 5 President 4 of 5 Director Quality 5 of 5 Production Manager Approved by FAA

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3 Title: Introduction Issue Date: 27 Jun 2013 Page: i Revision: A TABLE OF CONTENTS SECTION DESCRIPTION PAGE - TABLE OF CONTENTS i - INTRODUCTION iii - MANUAL CONTROL & REVISIONS iv - RECORD OF REVISIONS v - LIST OF EFFECTIVE PAGES vi I HOUSING AND FACILITIES II COMPANY ORGANIZATION III OPERATIONS & PROCEDURES 3.1 Design Data Control Document Control Supplier Control Manufacturing Process Control Inspection and Testing Inspection, Measuring and Test Equipment Control Inspection and Test Status Nonconforming Product and Article Control Corrective and Preventive Actions Handling and Storage Control of Quality Records Internal Audits In-Service Feedback Quality Escapes Other Quality Procedures 22

4 Title: Introduction Issue Date: 27 Jun 2013 Page: ii Revision: A Table of Contents (cont d) IV QUALITY CONTROL FORMS 4.1 QC Forms Index Equipment Calibration Record Vendor Survey Forms Vendor Qualification Tracking PO Receipt Sales Order Work Order Purchase Order MRB Record Stamp Log Stamp Impressions Sample Harness Inspection Checklist Kit Final QC Checklist Manual Review Record 41 APPENDICES Appendix A MOU between ASW-190 and ASM 42

5 Title: Introduction Issue Date: 21 Apr 2014 Page: iii Revision: B INTRODUCTION This Quality Control Manual (QC Manual) is prepared in accordance with the current Federal Aviation Regulations, 14 CFR Part for PMA Production Approval Holders (PAH), and the policies of Aircraft Systems & Manufacturing, Inc., also known as ASM. This manual complies with 14 CFR and explains the structure, operations and administrative requirements of ASM s PAH in detail. It gives examples of quality forms used and their method of execution. Manufacturing of products by ASM s PAH will be performed in accordance with current Federal Aviation Regulations (FARs), approved manufacturer's data, drawings, specifications, ASM s Quality System Manual and bulletins, and other technical data approved by the administrator for the particular product or part. In all circumstances, parts will be manufactured that conform to approved data, are airworthy and safe for installation and use. ASM s Manufacturing Operations and Quality Control are conducted in a separate building a short distance from the company headquarters. The HQ building houses Administration, Engineering, Document Control, Archives and Purchasing. Information and requirements flow in both directions digitally, telephonically and in person, as required. Documents required for the operation of ASM s PAH will be kept in the technical library and maintained in a current status at all times by Document Control. Management, production and inspectors in the PAH will have a current copy of this manual in their respective work areas. All personnel will be provided training by the Director of Quality on the directly applicable portions of this manual and must thoroughly understand its contents. A record of this training will be kept in individual personnel files. This manual is approved by the FAA, and compliance with all procedures herein is mandatory. The aviation industry is wide ranging, complex and dynamic. It is not possible to cover every possible situation within either the regulations or a manual. Deviations from the manual must be authorized in writing by ASM and the FAA. THIS REVISION OF ASM S QS MANUAL SUPERCEDES AND REPLACES ALL PREVIOUS REVISIONS.

6 Title: Introduction Issue Date: 21 Apr 2014 Page: iv Revision: B MANUAL CONTROL & REVISIONS PROCEDURES 1.Each manual will have a control number and an assignment entry on the manual cover page. A master list containing the manual number, location and revision status will be maintained by document control. 1.1 The approved original paper manual with physical signatures will be stored in ASM s vault in the fireproof safe. 2.The manual will be provided in paper form (copy) to all applicable work areas. A current on-line (electronic) edition, will be maintained on ASM s internal secure web-site for reference by all authorized users. 3.The Director Quality will have those revisions he finds necessary produced in a final form and transmitted by electronic means ( ) to the FAA Manufacturing Inspection District Office (MIDO) in San Antonio, TX for review and approval, prior to implementation. 4.All proposed changes to the manual will be coordinated with and approved by the FAA prior to implementation. The Director Quality will be the focal point of applicable FAA communications. Generally, approved changes are effective immediately unless otherwise specified. 5.The QC manual is organized for revisioning purposes by a List of Effective Pages. Upon approval by the FAA, sufficient copies will be made and distributed to provide revision pages for each physical manual holder. 6.Upon receipt of a revision, each manual holder will be responsible for inserting the revised pages into its manual, record the revision on the manual s record of revision page. 7.The Director Quality will audit manuals annually for accurate revisioning, and continued applicability, and will annotate the inspections on the Manual Review Record (see Section IV)

7 Title: Introduction Issue Date: 11 Mar 2016 Page: v Revision: D RECORD OF REVISIONS Retain this record in the manual. Upon receipt of revisions, insert revised pages in the manual, remove superseded pages, and enter the revision number, revision date, insertion date and initials of person incorporating the revision, in the appropriate block on the Record of Revisions. Revision No. Initial Release Revision Date 04/16/2011 A 27 Jun 2013 Insertion Date By: Audit By: B 21 Apr 2014 C 23 Oct 2015 D 11 Mar 2016

8 Title: Introduction Issue Date: 11 Mar 2016 Page: vi Revision: D LIST OF EFFECTIVE PAGES SECTION - - TABLE OF CONTENTS & FRONT MATTER PAGE Cover i ii iii iv v vi REVISION D A A B C D B DATE 03/11/ /27/ /27/ /21/ /23/ /11/ /21/2014 SECTION I - HOUSING AND FACILITIES PAGE 1 REVISION IR DATE 03/11/2016 SECTION II - COMPANY ORGANIZATION PAGE REVISION DATE SECTION III OPERATIONS AND PROCEDURES PAGE A 7 REVISION A A A B B A A B DATE 06/27/ /27/ /27/ /11/ /11/ /27/ /11/ /11/2016 PAGE REVISION A A A A A A A A DATE 06/27/ /27/ /27/ /27/ /27/ /27/ /27/ /27/2013 PAGE REVISION A A A A A A A A DATE 06/27/ /27/ /27/ /27/ /27/ /27/ /27/ /27/2013 SECTION IV QUALITY CONTROL FORMS PAGE REVISION A A A A A DATE 06/27/ /27/ /27/ /27/ /27/2013 PAGE REVISION A A A A A A A A DATE 06/27/ /27/ /27/ /27/ /27/ /27/ /27/ /27/2013 PAGE REVISION A A A A A A A DATE 06/27/ /27/ /27/ /27/ /27/ /27/ /27/2013

9 Section I: Housing and Facilities

10 Title: Housing & Facilities Issue Date: 11 Mar 2016 Page: 1 Revision: IR 1.1 LOCATION Corporate Headquarters Aircraft Systems & Manufacturing, Inc., a Texas corporation, is located at: Aircraft Systems & Manufacturing, Inc. 104 Golden Oaks Drive Georgetown, Texas, USA (office) askasm@asminc.net ( ) Functions integrated at the headquarters building include corporate offices, administration, engineering and design, document control, purchasing and quality management. All mail service for the company is directed to this location Manufacturing Manufacturing is a satellite facility in close proximity of the headquarters, located at: 105 Halmar Cove St 170 Georgetown, Texas, USA (office) Functions integrated at the manufacturing facility include receiving and incoming inspection, stores, assembly and fabrication, test and inspection, and shipping. Quality records are stored digitally on distributed servers. This address is used for shipping and deliveries only, no mail service.

11 Section II: Company Organization

12 Section III: Operations & Procedures

13 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 1 Revision: A 3.1 DESIGN DATA CONTROL Design Data Design data is generated and/or aggregated by ASM s Engineering staff. Finished data is managed by Document Control, see paragraph 3.2. The data packages are coordinated with, reviewed by and ultimately approved by the FAA, in accordance with current rules, policies and procedures. Any data element, whether a report, list, diagram, etc., is generically referred to as a drawing. Each data package is unique in format and content, however the following data elements, relevant to manufacturing and quality, are common and consistent within each data package: Top Drawing List or TDL (also referred to as Master drawing list). List of all drawings, documents and data pertinent to the project May include other subordinate lists, such as a Fabricated Parts List, Kit Contents List, etc. Each project varies depending on the complexity of the project. Certain documents may be embedded within others, or may not be applicable, or may be titled differently or formatted differently than past projects. This is determined by engineering, as required. Drawings/data are listed by drawing number, drawing title, revision level and date of revision. FAA approval of the Top Drawing List confers approval of all subordinate drawings listed thereon. Coordination of data submittal to the FAA and approvals thereof is per Memorandum of Understanding (MOU) between ASM and ASW-190, dated April 7, Fabricated Parts List or FPL List of all drawings relevant to manufacturing of parts (as opposed to buy parts such as standard and/or TSOA parts. Includes all fabrication drawings for parts and assemblies, special process drawings, and specification control drawings for parts manufactured to a certain design which are not considered standard or TSOA parts. Drawings/data are listed by drawing number, drawing title, revision level and date of revision.

14 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 2 Revision: A Kit Contents List or KCL List of sub-kits/sub-assemblies which, when aggregated, form a complete STC PMA installation kit by part number. Generally, but not always, ASM applies for PMA of the complete STC installation kit part number, rather than individual or sub-component parts. Revision status of the kit part number is defined by the revision status of the TDL Revision Control All drawings listed under the Top Drawing List, and the TDL itself, are controlled by revision and date. There are uncountable reasons to revise data. This procedure does not define the necessity for revisions, only the processes necessary to control revisions Generally, any change in any subordinate drawing in a data package causes that changed drawing to be revised, and any other affected drawings to be revised concurrently. At a minimum, the Top Drawing List must be revised to account for any change in revision status of a subordinate drawing An Engineering Change Order (ECO) is the normal vehicle for defining changes to a drawing. The ECO form is generated from a sequential list and log maintained by Engineering, so that each ECO is unique for each drawing, and accompanies the drawing for its life cycle. In rare circumstances the required change is easily described on the drawing s revision table, obviating the need for an ECO Revision bars, revision clouds, or change flags are the preferred method of indicating a change in the body of a drawing and constitute a good practice, however, are not required.

15 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 3 Revision: A Approval All drawings must be approved before manufacturing may commence Engineering Approval or Release. This usage of the term approved in engineering drawing title blocks DOES NOT imply FAA approval of the drawing. This usage indicates that the drawing is completely finished through ASM s design, drafting, checking and configuration management, and is in a state where it can be reviewed and evaluated by FAA personnel for compliance with regulations. Engineering Approval or Release is indicated on drawings by the engineer s or other company authority s initials or signatures and dates in appropriate blocks on the body of the drawing and ECO, if applicable. Engineering Approved or Released drawings may be used for planning, purchasing, R&D and prototyping purposes only. FAA APPROVED or FAA DER APPROVED. Indicates that the drawing(s) have been reviewed and evaluated by appropriate FAA personnel, the design/drawings comply with applicable regulations, and may proceed to manufacturing. FAA Approval may be in the form of an FAA Form from a qualified FAA DER, or in the form of an FAA stamp on the drawing with the FAA project engineer s initials. Revised data is submitted periodically to the applicable ACO on a schedule and in a form determined by the ACO, or per MOU dated Apr 7, Revisions of Instructions for Continued Airworthiness (ICA) are coordinated with the ACO and applicable AEG.

16 Title: Operations & Procedures Issue Date: 11 Mar 2016 Page: 4 Revision: B Distribution Design data is distributed to authorized users according to need. Method of distribution is also according to need FAA personnel are authorized unlimited access to all design data at any time. They have access to all paper and electronic records on demand Manufacturing personnel are provided approved design data as necessary to accomplish specific tasks in hardcopy or electronic format Customers (end users), when licensed, are authorized all pertinent design, installation, operational, and maintenance data. Proprietary data may be released to customers on a case-by-case basis. Data may be provided in hardcopy or electronic format Certain data may be used for educational or marketing purposes. Data used for these applications is not considered FAA Approved, regardless of original approval status Revised data is made available to authorized users as required. Document control is responsible for providing current, approved design data to suppliers (fabricators) and ASM s manufacturing personnel for building and inspection of parts. 3.2 DOCUMENT CONTROL Doc Control manages storage, distribution and change process of all data. Data may be in paper (hardcopy) or electronic format or both Design Documents and Data Design data is maintained in secure storage systems, both physical for hardcopy and in distributed databases for electronic data. Data includes engineering drawings, diagrams, reports, test results and supporting data, among others. Hardcopy is under lock and key or restricted access. Electronic storage is password protected with multiple backups All current engineering data is stored in hardcopy format in the vault. Hardcopy revisions of data (historical data) prior to 1 Jan, 2011 are stored in ASM s archives and scanned to digital format as time allows Data revisions post 1 Jan, 2011 are stored in distributed databases in native format or scanned to common format. Hardcopy prints are provided to all authorized users on demand.

17 Title: Operations & Procedures Issue Date: 11 Mar 2016 Page: 5 Revision: B All design data is retained indefinitely Quality System Documents and Data Quality system documents and data include this QC manual, forms, checklists, reports, purchase orders, work orders, material certs and other records applicable to the manufacturing (including acquisition of raw materials), inspecting, testing and delivery of parts produced under the PAH s authority The QC Manual is FAA approved by revision level. Proposed changes must be reviewed and approved by the FAA prior to implementation. The introductory paragraphs of this manual describe revision and control procedures for the QC Manual Purchasing, traceability and material certification documents are scanned and filed in a searchable database as they are received, and printed out as required. The database is username and password protected Work orders, inspection checklists, Acceptance Test Procedures (ATP) reports, copies of airworthiness certificates, certificates of compliance (C of C s) and shipping documents accompany each lot (typically a discrete installation kit) as it progresses through the line. During final inspection, all data is reviewed, collated and packaged for filing. Each QC data package is dated and filed by project number in office type file cabinets until scanned for digital archives. 3.3 SUPPLIER CONTROL Purchasing Department ASM s Purchasing Department is responsible for all aspects of purchasing (with the exception of invoicing and payment), receiving, stocking, kitting and exercising surveillance and qualification of suppliers of materials Fabricators ASM contracts with specialist fabricators to manufacture sheet metal and machined parts. Those parts are manufactured to ASM supplied engineering drawings. Fabricators, due to the specialized nature and inherent complexity of metalworking, require a high level of oversight. To the greatest extent practical, fabricators must be qualified by on-site inspection, and must provide references and samples of materials before a qualification determination is made.

18 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 6 Revision: A Stocking Distributors Distributors of standard and common aviation parts provide centralized distribution of parts from many different manufacturers, or may combine manufacturing and distribution of certain parts OEMs OEMs manufacture discrete units, such as LRUs, antennae, indicators, etc, usually under TSOA or PMA Vendor Surveys All vendors are required to be initially qualified and to maintain qualification. All vendors are subject to on-site surveillance by ASM quality personnel, either for initial qualification or for maintenance of qualification Candidate suppliers must normally fill out and return a general ASM vendor survey. Many large national vendors refuse on the grounds of too many customers with too many surveys. Alternative qualification may be supported by review of certifications, (ISO, ASI, etc), evaluation of the vendors quality manual, distributor s franchise, criticality of the parts, and vendor status with other OEMs. If alternately qualified, copies of documents evaluated are maintained with the vendor s file To the greatest extent possible, ASM quality personnel should conduct an onsite physical survey of the vendor s plant to verify qualifications. Generally, if located within the state, all vendors should be site surveyed prior to or within a year of qualification A vendor s sub-tier suppliers must also be qualified. The level of sub-tier inspection and surveillance required is based on the criticality of the operation. Finishing operations (paint, non-critical plating, etc), may be evaluated by samples and surveilled during routine receiving inspections. Sub-tier suppliers who provide tempering, heat treatment, welding, critical plating or exotic processes must be qualified to the same extent and by the same methods as a fabricator OEM vendors of TSOA / PMA parts are assumed pre-qualified by virtue of existing FAA approvals, however parts and services provided receive the same level of inspection/qualification to ensure that OEM parts conform to their approved design and are in a condition for safe operation.

19 Title: Operations & Procedures Issue Date: 11 Mar 2016 Page: 6A Revision: A Foreign vendors (non-us, overseas) require special qualifications efforts ASM will only qualify foreign vendors of non-safety, non-critical parts, and only when such parts are not manufactured or distributed by qualified U. S. vendors Vendors in Canada and the European Union who are subject to EASA rules, will be qualified in the same manner as US based vendors. On-site evaluation, while desirable, may not be possible due to funding constraints. This will not be a disqualifying factor, so long as all other requirements are met Other foreign vendors (OFV) of non-safety, non-critical parts, must not have US State Department and/or Commerce Department restrictions/sanctions OFV must submit an ASM Vendor Audit, in English, see OFV must submit a company quality manual, in English OFV must submit copies of traceable, international certifications such as ISO9001 and/or AS9100, if available. Such certifications are not required, however, they provide strong evidence of a stable, reliable company with an established quality system OFV must submit design documents for parts, in English, so that ASM can verify conformity of parts. Acceptance Test Procedures for some assemblies may be required, and special equipment, if required, must be provided by the OFV If all requirements are met, then ASM will schedule an on-site vendor audit to validate the OFV quality system. Audit criteria will include being provided visible, credible evidence of compliance with items listed on the ASM Vendor Audit Form If all requirements are met, then ASM will qualify the OFV as a provider of parts. The OFV will be subject to re-audit, with reasonable notice, at any time if there are significant instances of non-conformities All OFV parts must be accompanied by Certificates of Compliance. In addition, Acceptance Test Reports for some assemblies may be required OFV can be disqualified at any time, for any reason.

20 Title: Operations & Procedures Issue Date: 11 Mar 2016 Page: 7 Revision: B Maintenance of Qualification Generally, if the supplier remains qualified with ASM for a significant period of time, adequate surveillance is assured through normal and routine receiving inspections. At QC personnel s discretion, or if there is indication of cause, the vendor may be required to re-qualify. All vendors are continuously rated by QC personnel based on discrepancies found during receiving inspection, responsiveness to inquiries, and on time delivery. A simple percentage ratio of acceptable parts delivered to rejections is recorded for each delivery. A 10% rejection rate or higher may be cause for requalification, suspension or termination of qualifications. Due to criticality or cost, a much lower rejection rate may also be cause for further actions. Each situation must be examined on its own merits. It is possible for a vendor to have a 100% quality rating but become disqualified for other reasons Reporting of Vendor Supplied Non-Conformities All vendors must report to the PAH any product or article released that is subsequently found not to conform to PAH requirements Vendor Disqualification A vendor may be disqualified at any time, for any reason, or for no reason. 3.4 MANUFACTURING PROCESS CONTROL Manufacturing Processes ASM s standard manufacturing processes fall within OEM s (Boeing, McDonnell-Douglas, Airbus, etc) Standard Wiring Practices guidance, AC43-13, or best commercial practices. Uncommon, special or exotic manufacturing processes are either referenced in approved manufacturing drawings by Mil-Spec number (chromium conversion, anodizing and priming metal surfaces), or are defined by ASM Specifications and approved by the FAA Mil-Spec processes, such as conversion coatings, anodizing and priming are accomplished by qualified fabrication vendors, and attested to by C of C s accompanying the delivered part ASM Specifications are a refinement or clarification of standard practices adapted to ASM s specific requirements. ASM specifications necessary for a specific product are listed in Top Drawing List, Fabricated Parts Listing of the data package, and are reviewed and approved by the FAA. Changes to manufacturing processes are treated as changes of design data In addition to the drawings provided to manufacturing technicians, work orders also list the ASM Specifications to be used for those products.

21 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 8 Revision: A Proposed changes are forwarded to ASM Engineering for evaluation as a change to design data and are processed in the same way ASM does not authorize unapproved, preliminary, experimental or investigatory changes on production articles in-process Deliverable Software ASM does not design, alter, modify or install deliverable software Non Deliverable Design Software ASM uses commercial Computer Aided Design (CAD) software, authoring software, and database programs for design and administrative purposes only, to produce paper or paper equivalent drawings. In the event of prolonged power outages, ASM Engineering will revert to prior generation revision design tools (stubby pencil, #2, and yellow paper). No versioning or revision control of design tools is required. 3.5 INSPECTION AND TESTING Deliverable Products Inspection Procedures ASM s deliverable products are primarily PMA installation kits for avionics upgrades, or sub-components of those installation kits. Typical kits consist of preassembled wiring harnesses, nuts, screws and fastening hardware for electrical components, circuit breakers and brackets Most of the sub-component parts of an ASM PMA installation kit go directly from incoming receiving inspection to stores without further assembly/modification. See Receiving Inspection, para following Wire harness or component manufacturing requires in-process inspection steps as listed on the work orders. Parts and assemblies are inspected as required, and if satisfactory, the inspection step on the work order is signed off (or stamped) by the inspector If the part or assembly does not pass inspection, it is reworked on the bench to correct any defects and retested or reinspected Following final assembly, completed harnesses/components are forwarded to QC along with associated work orders. QC verifies that in-process inspections have been recorded on the work order, then provides a General Visual Inspection (GVI) of the completed part to the approved manufacturing drawing.

22 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 9 Revision: A Following the GVI, QC performs 100% electrical continuity test of all terminated wiring, diode and resistor testing (if applicable), using approved diagrams and test procedures (if applicable) QC records the results of all testing and inspections on a QC checklist, recording the rev level of all applicable drawings, serial number if applicable, pass/fail annotation on all GVI details, and description of any GVI or electrical discrepancies. If any discrepancies are detected, the part is returned to the shop floor for rework Parts that test 100% are routed to stores, along with the appropriate work orders, check lists and test results as applicable Parts from stores are aggregated and organized as sub-kits with work orders for each. When completed, QC inspects the completed kit using approved drawings and the kit final checklist Following final QC, the completed kit is packaged and routed to stores Receiving Inspection Procedures Purchase Orders are used to acquire all raw materials used in production of approved parts. Purchase Orders are generated by the purchasing department. Material requirements referenced on drawings and/or engineering specifications, special tests or requirements will be furnished to the Purchasing Department by Engineering for inclusion on the Purchase Order. Suppliers from whom materials and supplies are purchased will be furnished with any applicable engineering drawings, engineering specifications or special information in addition to the Purchase Orders, as required. Certification of material and/or processes must be supplied by the vendors Receiving inspectors will ensure that material orders to be inspected have: a shipping list reflecting quantities shipped and engineering references by revision level (if required), and, Certificate(s) of Conformance signed and dated by the original manufacturer and any distributors.

23 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 10 Revision: A Note: Note: MilSpec and standard parts are generally ordered by part number alone. If not specified in approved drawings, revision level of MilSpec and standard parts is not applicable. Fabricated parts are defined by drawing number and revision level. Conformance to revision is required Receiving inspectors will inspect 100% of fabricated parts to approved design / fabrication drawings. Verify each dimension shown on the drawing, as modified by notes and tolerances, and, Conduct electrical operations tests as applicable for electrical parts. Lamp assemblies and certain switches may be tested on the bench with simple apparatus. LRU s and antennae are normally beyond ASM s means of electrical/functional testing. Note: Inspectors must verify calibration of applicable measuring tools prior to inspection MilSpec or standard parts in lots will be sample inspected by 10 items or 10%, whichever is smaller, for nominal size, thread gauge, length, color, general appearance, etc., as required. Check for nominal characteristics to the greatest extent possible using available measuring instruments. If a sample lot passes inspection, and there are no other indications of nonconformance, then all items in that lot pass. If any of the sample items fail, then 100% of the remaining items must be inspected, or the entire lot must be rejected Unless otherwise specified by approved design drawings, neither non destructive inspection (NDI) nor sophisticated qualitative/quantitative testing is required.

24 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 11 Revision: A Prepare labels, tags, bags, as required with part number, P.O. number, rev level (if required), lot number (if required) and route conforming parts to stores Certain existing parts in stores may have been accepted under previous revisions/versions of QC inspection manuals and may have different tags. Older standard parts may continue to be used until exhausted without further showing. Older non-standard parts may continue to be used, but should be evaluated for applicability prior to use Sign off or stamp acceptance of parts on Received Goods by Purchase Order form. Scan all accompanying documents (packing slip, certs, etc) and electronically file in QC database. Forward paper copies to accounting. 3.6 INSPECTION, MEASURING AND TEST EQUIPMENT CONTROL Calibrated equipment ASM uses a variety of precision tools for fabrication and inspection, some of which are calibrated periodically, some of which cannot be calibrated, and some of which must be calibrated per use with other calibrated tools All precision tools or equipment which must be calibrated is controlled with a Calibrated Tools Master or log, which records the part number, serial number, calibration date, and period of required calibration Equipment requiring calibration must be calibrated using methods and standards acceptable to the FAA, such as, National Institute of Standards and Technology (NIST). Equipment calibrated must have a calibration certificate on file which identifies the equipment by part number and serial number, date of cal, and specify the periodicity of cal All calibrable tools must be in cal to be used for testing or production of parts. Tools need not be in cal if not in use, however once identified, must be red tagged and stored in quarantine. Out of cal tools cannot be used again until properly calibrated and certified. Calibrable tools/equipment must have a sticker or tag affixed which shows the cal date, re-cal date, part number & serial number of the tool Certain tools, such as some wire crimpers, may be calibrated in house by using manufacturer s instructions and certified, calibrated tooling to accomplish the calibration. A current ASM Calibration certificate must be on file for those tools, and a cal sticker or tag affixed.

25 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 12 Revision: A Certain tools, such as adjustable power supplies, must be calibrated per use using calibrated test equipment. Those tools must have a sticker or tag affixed showing Calibrate Before Using or similar Certain tools, such as scales, may be calibrable, but are used for reference only. Such tools must have a label or sticker affixed showing Reference Only or similar, and cannot be used for manufacturing or inspection until calibrated and certified Calibrated equipment control Calibrated tools used for manufacturing may go out of cal or become damaged between periodic calibrations. To reduce impact, severity, and improve traceability, the use of calibrated tools will be monitored as follows: All calibrable tools used in the course of an assembly must be inspected prior to use. If possible, calibrable tools are quick checked with go-no go gauges prior to use, daily. Out of cal or damaged tools must be red tagged and quarantined immediately Calibrated tools used to manufacture parts must be recorded by serial number on the work order used to produce those parts Where applicable for Acceptance Test Reports, calibrated tools used to inspect products must be recorded by serial number on the report Unless otherwise specified by approved drawings, it is not necessary to record the tooling used to test or inspect incoming raw materials (receiving inspection). 3.7 INSPECTION AND TEST STATUS Inspection and test records are generated for receiving, in-process, Acceptance Test and final inspections as specified in Section 3.5 above. 3.8 NONCONFORMING PRODUCT AND ARTICLE CONTROL All articles and products manufactured by ASM under the PAH authority must conform to approved data and be in a condition for safe operation. At any stage of manufacture, nonconforming parts may be identified. In all cases of nonconformity, review, evaluation and disposition must be accomplished and results recorded Material Review Board ASM has a standing Material Review Board (MRB) to review, evaluate and disposition nonconforming materials and processes. The board consists of a

26 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 13 Revision: A minimum of three qualified individuals; a design engineer, a manufacturing specialist and a QC representative. Additional members may be empanelled as required A qualified PAH engineer is required to evaluate all data pertinent to the nonconforming part. If the part is to be used without alteration or modified to be used, then drawings and or data must be prepared detailing the nonconformity, use, or alteration It is ASM policy that all design data (minor change) must be approved by a DER. Major changes will be coordinated with the FAA A design engineer is required to evaluate, analyze and prepare supplemental drawings and or data to use or modify the part for use A QC representative is required to insure that parts intended for use or modification are in fact used or modified in accordance with approved data Qualified manufacturing technicians and or logistics personnel may advise the board as required Procedures Any inspector, technician, engineer or interested other may stop the production line at any time to resolve a nonconforming part question Return to Vendor Any receiving inspector may identify nonconforming incoming parts during the receiving inspection. Nonconforming raw parts identified at this stage may be Returned to Vendor (RTV) with no MRB action required. Parts are RTV d with a note describing the non-conformity. The vendor must then correct the part or provide the correct part Rarely, parts may arrive which are useable or can be made useable with little effort, despite the nonconformity. This may be the case with cosmetic blemishes, non-critical tolerance errors, or finishes. If the part(s) are RTV d then no further action is required Use as Is (raw parts) If there is consideration of use or alteration of the part to be made useable, then the MRB must convene Engineering must determine what impact, if any, is presented by the nonconformity. He must evaluate based on structural considerations,

27 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 14 Revision: A mechanical fit and function, reliability and operational effect. At all times, safety must be the primary concern Engineering may reject the part and direct RTV, in which case, no further MRB action is necessary Engineering may determine that there is no impact caused by use of the part as is. For use as is the engineer must present a numbered report describing the part, the non-conformity, and substantiate the degree of impact of the nonconformity, if any. Sketches, drawings and any other pertinent data are included with the report Rework (raw parts) Engineering may determine that reworking the part may bring it back into conformity or into a useable state. The engineer must consider all of the other potential impact with use as is, plus the capability and economic impact of reworking the part, at all times keeping safety as the paramount requirement. If Engineering determines that rework is acceptable, then the engineer must present a numbered report describing the part, the non-conformity, details of rework to be accomplished and substantiation of degree of impact. Sketches, drawings and any other pertinent data are included with the report The report is numbered with the corresponding ASM project number and becomes a part of the current design data. Reports are maintained, distributed and archived as engineering documents, ie, indefinitely Disposition Engineering will submit the report(s) to a qualified DER (see para ), for review, evaluation of compliance with applicable regulations and approval of the data. If the data is approved, as evidenced by an FAA Form approving the data, then the part can be used for manufacturing or reworked to return it to a conforming state. Reworked parts must be re-inspected to the approved data before re-entering the production line If the data is not approved, then the part is RTV d or scrapped In-process nonconformities. In process non-conformities are not evaluated by MRB, they are returned by QC to production for rework to a conforming state without further action. If unable to be reworked to a conforming state, then the assembly must be scrapped Nonconforming parts discovered during receiving inspection, in stores or prior to entering the production line must be segregated at all times until disposition

28 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 15 Revision: A is made. Nonconforming assemblies discovered in-process remain on the line until they conform or until scrapped. If there is some delay in determination, all nonconforming parts are segregated and quarantined until disposition is determined Scrap If the disposition is scrap, then the nonconforming part is immediately removed from production, stores, or the line and destroyed; OR red tagged, quarantined and held for destruction. In rare cases the part or assembly may be retained for training use, in which case it is red tagged For Training Use Only, and marked with X s in prominent display. Parts used for training are stored in quarantine Destruction There are many acceptable methods of destroying parts to be scrapped, including simple disposal in a properly regulated landfill. Destruction may be assured, if required, by application of one or whacks with a hammer (ball peen, carpenter s or sledge). If no suitable hammer is available, a balanced hard soled shoe may prove effective. 3.9 CORRECTIVE AND PREVENTIVE ACTIONS Most, if not all, nonconformities or noncompliances are caused by human error. Procedures for hiring qualified personnel, maintaining proficiency, providing adequate environmental, health, morale and welfare conditions are beyond the scope of this manual. Procedures for detecting and correcting nonconformities and noncompliances are addressed in Sections 3.8, Nonconforming Product and Article Control and 3.5, Inspection and Testing, above. Those procedures are effective to control occasional, minor nonconformities and noncompliances. No further action, other than spot correction and continued surveillance, is required In rare circumstances, continuous, uncorrected and inappropriate behavior results in nonconformities and or noncompliances. Remedies must be worked out with Human Resources personnel to ensure appropriate and legal behavior modification strategies are attempted. Such remedies may include remedial training, reassignment or termination. More commonly, suppliers sometimes provide parts which do not conform or comply. Spot corrective action procedures are provided in Section 3.3 above, Supplier Control, and 3.8, Nonconforming Product and Article Control, above. In the event that procedural remedies are not effective, then the supplier must be disqualified for cause.

29 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 16 Revision: A Procedures The President of ASM will be briefed on significant nonconformities as they occur. Issues relating to safety or which have significant business impact (financial, time, personnel, relationships), will be addressed as follows: The President will direct any qualified member of ASM s staff to perform an analysis of the significant nonconformity The staff member will prepare a report, in a form and presentation directed by the President, specific details of which may include: The detailed nature of the nonconformity, including who, what, where, when, why, and how. The extent of the nonconformities impact. A recommendation from the staff of any corrective actions. An evaluation of the effectiveness of the corrective actions. Proposals for long term monitoring and trend data collection. Periodic follow up reviews of data The President will evaluate the report and determine appropriate corrective action. HR issues will be resolved through appropriate labor relations and/or legal means. Those reports will be filed and maintained by HR in accordance with applicable federal and state laws Reports of noncomformities resulting from supplier error, engineering, technical, or training issues will be maintained as QC documents for not less than 5 years HANDLING AND STORAGE ASM maintains a store of raw materials, completed subassemblies and finished parts. All parts must be segregated, organized, secured and issued to maintain the integrity and preservation of the parts Procedures All materials enter the stores system through a single point of entry (Receiving) and are issued from a single point (Stores) according to strict procedures.

30 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 17 Revision: A ASM stores is located under cover, in a temperature controlled, dry and well lighted environment Conforming parts which have passed incoming (receiving) inspection, are identified by part number, p/o number, location code and lot code (if applicable), and tagged or packaged in clear poly bags with tag affixed Parts are routed to designated storage areas and shelved or binned as appropriate Items having a shelf life are prominently tagged with the expiration date, are routed to the shelf life storage area, and binned in order that oldest materials are used first Shelf life items in stores are inspected monthly for expiration. Expired items are scrapped and inventory records adjusted Stores inventory control is maintained by periodic cycle count and annual inventory count. A periodic listing of bin samples (cycle) is generated by database software and physically counted by stores personnel. This statistical sampling method maintains a high degree of inventory integrity without requiring complete inventory counts Materials are issued by kitting order associated with work orders. As work orders are generated by the database, kitting orders and pick lists are concurrently generated. Kitting orders define sub-assemblies. Pick lists are presented to stores personnel for issue of parts necessary to build subassemblies Entry to stores is limited to authorized personnel Nonconforming parts, training parts and out of cal tools are stored in a locked, marked quarantine vault with access limited to authorized personnel only CONTROL OF QUALITY RECORDS Quality records consist of this manual, inspection forms, checklists, work records, quality reports and purchasing, shipping & receiving records. All quality records are retained for a minimum of 5 years from the date of approval, acceptance or generation as appropriate. ASM does not manufacture critical components as defined by Part 45.15(c) Procedures

31 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 18 Revision: A Purchasing and receiving records are collected after acceptance of the parts and stored in archival storage on ASM s second floor Work orders, inspection checklists, completed forms, test reports, and shipping records are collected and attached to the parts if in stores. After shipment, all records are combined with the shipping record and stored in archival storage in the shipping department The original of this manual and any generated QC reports, correspondence, etc., are stored in the records vault Purchasing and receiving records are stored indefinitely, as raw parts may remain in stores for periods exceeding the minimum record retention rules The original manual and subsequent revisions are retained indefinitely. QC reports and correspondence (exceeding 5 years old) are reviewed annually for determination of retention or destruction Shipping records are purged annually (exceeding 5 years old) and destroyed INTERNAL AUDITS Internal audits are used to ensure compliance with regulations and to provide ASM management with a snapshot in time of the organization s quality health, efficiency, and compliance. Audits may be specific and localized to evaluate a particular situation, or may be applied across the organization Procedures An annual, organizational audit is required each calendar year The President may direct an additional full or limited audit at any time Auditors will use the Standardized Audit Criteria from current FAA Order , applicable system elements, for the annual audit Copies of system elements will be used by auditors as checklists. Notes will be entered in available space, with additional sheets added as required. Nonapplicable system elements will be N/A d. Copies of substantiating documents will be made and attached as required The President will define criteria for on-demand audits Auditors will be appointed by the President from qualified personnel.

32 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 19 Revision: A From the checklists and substantiating documents, the auditor(s) will present a controlled (dated) narrative summary report to the President, management and appropriate personnel. Checklists and substantiating documents will be attached to the report as appendices. Audit records and reports will be retained as quality records The President will use the audit reports to direct and manage corrective actions and system improvements as an ongoing quality system improvement tool IN-SERVICE FEEDBACK ASM has a long history and tradition of providing superior customer service and support. This is accomplished ensuring that all possible lines of communication are kept open between end users, mechanics, pilots, QC and ASM personnel Procedures ASM s website, provides full contact information, mailing address, listings and phone numbers of ASM points of contact (POCs) All ASM installation kits are shipped with an appropriate approved data package. The last page of all doc packages is the customer feedback questionnaire & survey All customer feedback is evaluated by the President, QC and Engineering. For suggestions, proposals for improvements and complaints, the President directs actions as required Malfunctions and/or defects will be reported to the FAA within 72 hours using FAA Form , Malfunction Defect Report Unsafe features, unairworthy conditions, and unsafe characteristics reported, that result in or could result in occurrences listed in FAR Part 21.3(c), will be reported to the FAA within 24 hours as detailed in the regulation ASM will provide all documents, personnel, and assistance required to assist with any investigation and resolution of unsafe or unairworthy factors ASM will evaluate all feedback for determinations of design changes and changes to Instructions for Continued Airworthiness.

33 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 20 Revision: A Minor changes will be coordinated with the FAA in accordance with MOU dated April 7, Major changes will be coordinated with the FAA and processed as directed by FAA personnel QUALITY ESCAPES The quality system exists to prevent nonconforming material from escaping, that is, from leaving the factory and being installed in aircraft. However, it is possible for an escape to occur. If and when an escape occurs, the following procedures must be implemented to control, recall or correct any nonconforming condition: Procedures Upon discovery, consult with Engineering and appropriately qualified DERs to determine if there is an unsafe condition IF AN UNSAFE CONDITION EXISTS, notify the FAA per paragraph above. ASM will provide all documents, personnel, and assistance required to assist with any investigation and resolution of unsafe or unairworthy factors. In addition, if not otherwise directed by the FAA: Immediately recover and quarantine all identified nonconforming parts remaining in the factory in-process or in stores, including all applicable work orders, inspection results, manufacturer s certs and other documentation applicable. Make available to investigators. From the project control records in Doc Control, prepare a list of all owner/operators/customers for the applicable project, including serial numbers of affected aircraft and registrations. Provide that list to the FAA and to the contacted owner/operator/customers. Notify all owner/operators of the condition by the most expeditious means possible, normally by telephone contact. Provide the name and contact of ASM s technical representative. Provide a list of names and contact information of those contacted, and a list of those unable to contact, to the FAA. Notification of an unsafe condition will result in What must I do? questions from operators. ASM is unable to advise or speculate on

34 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 21 Revision: A operational matters such as maintenance, repair, operational limitations, dispatch and grounding of aircraft. Refer all such questions to the FAA. Follow up as directed by FAA personnel If an unsafe condition does NOT exist, then Engineering and appropriately qualified DERS must determine the impact of the nonconforming condition and respond appropriately If the condition MAY result in a malfunction, then do the following: Notify the FAA and advise of the condition. Make all design data and records available to the FAA, and comply with any direction provided. If not otherwise directed by the FAA: Immediately recover and quarantine all identified nonconforming parts remaining in the factory, in-process or in stores, including all applicable work orders, inspection results, manufacturer s certs, work orders and other documentation applicable. Make available to investigators. Concurrently notify all owner/operators of the condition by the most expeditious means possible, normally by telephone contact. Follow up as directed by the FAA If the CONDITION IS SAFE and NOT subject to malfunction, then proceed as follows: If the condition is a result of drawing or documentation errors, then correct the documentation by means of the normal revisioning process, FAA approval, and distribution of the revised documents, as per paragraph 3.1 above. If nonconforming parts are not installed in aircraft, then recall shipped nonconforming parts and replace with conforming parts. Coordinate with owner/operator s QC staff. If nonconforming parts are installed in aircraft, advise the owner/operator of the condition by means of a Service Information Letter (SIL), and provide conforming parts for replacement at the next maintenance interval. Coordinate with the owner/operator s QC staff.

35 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 22 Revision: A Advise the FAA and provide copies of the SIL. Perform all additional actions directed by the FAA. Immediately recover and quarantine all identified nonconforming parts remaining in the factory, in-process or in stores. Destroy or quarantine as required. MRB action may be implemented. File a copy of the SIL(s) with the ASM project design data files. Insure that nonconforming parts are recalled, returned, and destroyed Review procedures and practices to determine the cause of the nonconformity, the escape, and implement corrective actions to prevent recurrence. Report as required, see paragraph SILs are design data and are retained indefinitely OTHER QUALITY PROCEDURES Paragraphs 3.1 through 3.14 above address specific elements of Part (a) thru (n). The following procedures are local and specific to ASM s quality system Stamp Use and Control ASM s QC personnel use stamps to indicate approval and/or acceptance of various steps, materials, documentation, etc Qualified QC personnel are issued controlled stamps by the Director Quality Stamps are retained and controlled by the individual, and used within the individual s qualifications Un-issued stamps are quarantined under lock and key Lost stamps are struck from the control roster and retired for minimum 6 months. Transitioning personnel will surrender their stamp upon discontinuation of their authority to inspect. Lost and/or transitioned stamps will be quarantined for a minimum of 6 months before re-issue to qualified personnel Initials and date in ink may be used by all qualified QC personnel in all circumstances where a stamp could be used.

36 Title: Operations & Procedures Issue Date: 27 Jun 2013 Page: 23 Revision: A Kitting and Shipping Kitting for manufacturing consists of pulling parts from stores according to a kit or pick list, generated concurrently with work orders. Pick lists are working papers that are destroyed after use Kitting for shipment involves organizing, inspecting and packaging parts for shipment. Kitting for shipment is accomplished by work order, with appropriate work steps and in-process inspections annotated thereon. Certification, after final inspection, is indicated by Certificate of Compliance. A domestic Airworthiness Certificate, FAA Form , is prepared if requested and indicated on the applicable sales order. Items to be exported must be presented to the FAA or designees, as appropriate. Packaging is by best commercial method, unless otherwise specified in the sales order.

37 IV. QUALITY CONTROL FORMS

38 Title: Quality Control Forms Issue Date: 27 Jun 2013 Page: 24 Revision: A 4.1 QC FORMS INDEX Forms used in the ASM, Inc. Quality Control program are developed and revised as needed. The format of forms may change due to software or configuration differences Equipment Calibration Record Vendor Survey Form Vendor Qualification Tracking PO Receipt Sales Order Work Order Purchase Order MRB Record Stamp Log Stamp Impressions Sample Harness Inspection Checklist Kit Final QC Checklist Manual Audit Log

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