Vosky Precision Machining Corp. 70-B Air Park Drive, Ronkonkoma, NY 11779 Tel: (631) 737-3200 Fax: (631) 737-3240 Quality Control Manual ISSUED: January 21, 2005 Revision. G (12/3/2003)
Vosky Precision Machining Corp. 70-B Air Park Drive, Ronkonkoma, NY 11779 Tel: (631) 737-3200 Fax: (631) 737-3240 Date: This Manual has been reviewed and inspected by the following personnel and has been found to be in compliance with current procedures performed at Vosky Precision Machining Corp. This Manual is subject to Customer approval. Any procedures not within customer parameters shall be overridden by Customer requirements, pending review by Vosky Management. M. Voskinarian - PRESIDENT J. Flock - GENERAL MANAGER 2
Quality Control Manual Revision Record Revision Level Author Approved Date Section Affected and Reason for Revision A B C D E F G H J.F. Warning: No part of this document shall be reproduced in any form without the written consent of Vosky Precision Machining Corp. All inquiries regarding this manual shall be directed to the General Manager, who is responsible for its administration. 3
TABLE OF CONTENTS Sect. Description Page COVER 1 APPROVAL SHEET 2 QUALITY CONTROL MANUAL REVISION RECORD 3 TABLE OF CONTENTS 4 COMPANY PROFILE AND MISSION STATEMENT 7 QUALITY POLICY STATEMENT 8 QUALITY MANUAL AND DOCUMENTATION CONTROL 9 1 SCOPE 10 2 RESPONSIBILITY FOR QUALITY SYSTEM 10 2.1 - ORGANIZATION 10 2.2 - RESOURCES 10 2.3 - MANAGEMENT REPRESENTATIVE 11 2.4 - MANAGEMENT REVIEW 11 3 QUALITY MANAGEMENT SYSTEM 12 3.1 GENERAL 12 3.2 PROCEDURES 12 3.3 QUALITY PLANNING 12 4 CONTRACT REVIEW 13 4.1 GENERAL 13 4.2 REVIEW 13 4.3 RESPONSIBILITES 13 4.4 REPEAT OR MULTLINE ORDERS 15 4.5 AMENDMENTS TO CONTRACTS 15 4.6 RECORDS 15 5 DESIGN CONTROL 15 6 DOCUMENT AND DATA CONTROL 15 6.1 GENERAL 15 6.2 DOCUMENT AND DATA APPROVAL AND ISSUE 17 6.3 DOCUMENT AND DATA CHANGES 17 4
TABLE OF CONTENTS 7 PURCHASING 17 7.1 GENERAL 17 7.2 EVALUATION OF SUPPLIERS 17 7.3 PURCASHING DATA 18 7.4 VERIFICATION OF PURCHASED PRODUCT 18 7.5 VERIFICATION AT SUPPLIER S PREMISES 18 8 CONTROL OF CUSTOMER SUPPLIED PRODUCT 18 8.1 GENERAL 18 8.2 DAMAGED CUSTOMER FURNISHED MATERIAL 19 9 PRODUCT IDENTIFICATION AND TRACEABILITY 19 9.1 GENERAL 19 9.2 IDENTIFICATION 19 9.3 TRACEABILITY 19 10 PROCESS CONTROLS 20 10.1 GENERAL 20 10.2 MANUFACTURED PRODUCT 20 11 INSPECTION AND TESTING 21 11.1 GENERAL 21 11.2 RECEIVING INSPECTION AND TESTING 21 11.3 IN-PROCESS INSPECTION AND TESTING 22 11.4 FINAL INSPECTION 22 11.5 INSPECTION AND TESTING RECORDS 22 12 CONTROL OF MEASURING AND TESTING EQUIPMENT 23 12.1 GENERAL 23 12.2 CONTROL PROCEDURE 23 12.3 ADEQUACY OF MEASURING STANDARDS 24 12.4 ENVIRONMENTAL CONTROLS 24 12.5 INTERVALS OF CALIBRATION 25 12.6 CALIBRATION PROCEDURES 25 12.7 ADEQUACY OF CALIBRATION SYSTEM 26 12.8 CALIBRATION SOURCES 26 12.9 RECORDS 27 12.10 CALIBRATION STATUS 27 12.11 CONTROL OF SUB-CONTRACTOR CALIBRATION 28 12.12 STORAGE AND HANDLING 28 5
TABLE OF CONTENTS 13 INSPECTION AND TEST STATUS 28 13.1 GENERAL 28 13.2 USE OF INSPECTION STAMPS 29 13.3 INSPECTION STAMP ISSUE AND CONTROL 29 14 CONTROL OF NONCONFORMING PRODUCT 29 14.1 GENERAL 29 14.2 REVIEW AND DISPOSITION OF NONCONFORMING PRODUCT 29 15 CORRECTIVE AND PREVENTIVE ACTION 30 15.1 GENERAL 30 15.2 CORRECTIVE ACTION 30 15.3 PREVENTIVE ACTION 31 16 HANDLING, STORAGE, PACKAGING, PRESERVATION AND DELIVERY 32 16.1 GENERAL 32 16.2 HANDLING 32 16.3 STORAGE 32 16.4 PACKAGING 32 16.5 PRESERVATION 32 16.6 DELIVERY 32 17 CONTROL OF QUALITY CONTROL RECORDS 33 17.1 GENERAL 33 17.2 RECORD STORAGE 33 18 INTERNAL QUALITY AUDITS 33 19 TRAINING 33 20 SERVICING 34 21 STATISTICAL TECHNIQUES 34 APPENDIX A MANUFACTURING PLAN 35 INSPECTION REPORT 37 DISCREPANT MATERIAL REPORT 38 INSTRUMENT CALIBRATION RECORD 39 ORGANIZATIONAL CHART 40 6
Vosky Precision Machining Corp. COMPANY PROFILE AND MISSION STATEMENT VOSKY PRECISION MACHINING is a full service machine shop, providing top quality parts and service to our customers for over twenty years. Our company provides a wide range of services to our customers in the commercial, military, aerospace, architectural and industrial fields that require the best in quality and delivery on a consistent basis. Vosky Precision uses the latest in computer-controlled, state of the art precision lathe and milling machines, set up and operated by some of the finest, most versatile and well-trained technicians in the business. Along with a top-notch Quality Control Department and CAD-CAM programming system, all our resources work together to make Vosky Precision one of the most capable small machine shops in the region. Vosky Precision is a family owned business, established in 1980, and currently employs 22-30 people in our 12,000 square foot, temperature controlled shop. As a family-owned enterprise, we have held onto some of the business principles that seem to have been forgotten these days. We offer a more personal, service oriented touch when dealing with our customers, thus we have acquired a reputation for customer service and quality. Our dedication to quality and service has been the principle that has guided us through our evolution from a one-man shop to today s thriving, growing business. The premises that we occupy is a 24,000 square foot building, owned by our company. Within two years, we shall be expanding our operations to encompass all of this space, in order to increase our capabilities. Vosky Precision Machining Corp. has implemented the AS9100 Quality Standard. We use internal audits to provide feedback to management as to the effectiveness of the Quality Management System and to continually make improvements in our system. We are in the process of obtaining AS- 9100 Quality System Certification and will be certified by the end of calendar year 2004. Our Mission: To provide all of our customers, from the biggest to the smallest, with the best quality, the best service, and on-time delivery, every time, every day, and to do it all at a competitive price. In addition, we will strive to continually improve the quality of our workforce, delivery times, processes and customer service. 7
Vosky Precision Machining Corp. QUALITY POLICY STATEMENT VOSKY PRECISION MACHINING specializes in providing full service machine shop services in accordance with military, prime contractor, aerospace and commercial specifications, standards and requirements.vosky Precision s objective is to provide complete, start to finish services to ensure complete control and adherence to requirements. We will provide our customers with optimum quality, reliable performance, on time delivery and fair pricing. Our goal is to meet all of these requirements, continually improving on all aspects of our job, by focusing resources on identifying, preventing and eliminating any deficiencies. To achieve these objectives, our company is focused on implementing and maintaining our Quality Control Management System, which is based on the AS-9100 Quality System. The successful implementation and operation of this system depends on the cooperation and involvement of all personnel at every level. Our continued success and growth is only insured by the dedication of our staff to customer satisfaction. Adherence to the manual and system contained herein is the best way that we can achieve this satisfaction. We will work with our Suppliers to develop relationships with them that will expand our quality and delivery capabilities. 8
Vosky Precision Machining Corp. QUALITY MANUAL AND DOCUMENTATION CONTROL The General Manager is responsible for the administration, control, review and distribution of the Quality Control Manual and for the procedures contained within. Revisions are identified by consecutive letters A, B, C,, AA, AB, etc. The revision level is to be indicated on each page. The front page of the manual is the cover page, followed by the approval page. Next is the revision page, which shall list the issue revision, author and approval of each revision, the date of revision, and reason for such. Only those revisions approved in writing by either the President or General Manager shall be considered official. Controlled copies of the Quality Control Manual will be maintained in the General Manager s office, the Quality Control Department, and the online computer version. A copy of this manual will be made available to the customer s representative upon request, but shall not be considered a controlled copy. This manual is not to be released to the general public. 9
1.0 SCOPE 1.1 This manual establishes the requirements of VOSKY PRECISION MACHINING CORP., inspection and process control systems. These requirements pertain to the inspections and tests as well as the documentation necessary to substantiate product conformance as required by contract. This manual has been prepared in accordance with and outlines the quality control system maintained by VOSKY PRECISION MACHINING CORP. The requirements of this manual pertain to and cover all parts and materials supplied by VOSKY PRECISION MACHINING CORP., whether machined in house or purchased from a vendor, or a combination of the two. The aim of this manual and the quality system is to ensure that products produced by VOSKY PRECISION MACHINING CORP. are of the desired quality and that all customer and specification requirements are met. The quality system is based on the applicable requirements of the MIL-I-45208A Inspection System and the ANSI/NCSL Z540-1-1994 Calibration Standard and the ISO-9002 Quality System. Unless otherwise specified, all standards referred to are the latest revisions. 2.0 MANAGEMENT RESPONSIBILITY FOR QUALITY SYSTEM 2.1 ORGANIZATION 2.1.1 RESPONSIBILITY AND AUTHORITY The organization chart shown on page 36 shows the interrelation of positions within the company, and the paths of responsibility and authority in relation to quality. The responsibility, authority and interrelationship of every person who does work relating to product quality is defined in Job Descriptions and Requirements, on file in the Personnel Department. All personnel may, in their absence, delegate their responsibilities and authority to others as specified in their job description. All personnel have the authority to stop work being performed that is non-conforming. This policy gives our personnel the freedom and authority to: A) Initiate action to prevent the occurrence of any nonconformities relating to the product, process, or quality system B) Identify and record any product, process or quality system problems C) Initiate, recommend, or provide solutions through proper channels D) Verify and evaluate the implementation of solutions E) Control further manufacture, processing, delivery or installation of nonconforming products until the deficiency or unsatisfactory condition has been corrected 2.2 RESOURCES 2.2.1 VOSKY PRECISION MACHINING CORP. management has identified resource requirements for management of, manufacture of, and verification of all work done by the company. Adequate resources and trained personnel are provided. 2.2.2 Company management believes in self-inspection of work by operators as well as quality control department inspection, therefore, all personnel are trained to carry out all inspection 10
techniques required (when possible) Approved sub-contractors and their resources may be used for specialized verification tests when necessary. 2.2.3 Internal Quality Audits are performed by representatives appointed by the company president or general manager. These representatives are to be independent of the department or function being audited. 2.2.4 Adequacy of resources and personnel are formally reviewed each year as part of management review. 2.3 MANAGEMENT REPRESENTATIVE 2.3.1 The General Manager of VOSKY PRECISION MACHINING CORP. has appointed the Quality Control Manager as the company s Management Representative. The Quality Control manager is responsible for and has the authority to: A) Insure that the requirements specified in this manual are implemented and maintained B) Report on the performance of the quality system to management. A minimum of one annual review shall be performed and submitted to management identifying areas for improvement to be acted upon during management review. C) Co-ordinate with various departments or vendors on matters affecting quality or related to the company s quality system 2.3.2 The Quality Control Manager reports directly to the General Manager, or in his absence, to the President of the company. 2.3.3 The Quality Control Manager has full authority to stop, reject, and resolve any work or services not conforming to either contract requirements or the Quality System requirements. 2.4 MANAGEMENT REVIEW 2.4.1 The management of VOSKY PRECISION shall meet at least once per year to ensure that the Quality Management System continues to be suitable and effective in satisfying stated company policy and objectives, as well as customer expectations and needs and the requirements of the MIL-I-45208A Inspection System and the ANSI/NCSL Z540-1-1994 Calibration Standard and the ISO-9002 Quality System. 2.4.2 The review shall be carried out in a meeting chaired by the President or General Manager, and attended by the Quality Control Manager, Shop Leadmen, Sales Manager, and anyone else deemed necessary by the Management Representative. 2.4.3 Management shall use all available information, such as internal and external quality audits, customer complaints and/or comments, discrepancy reports, corrective and preventive actions, employee reviews and so on, to improve the system 11
2.4.4 The results of these reviews are to be documented and maintained by the Quality Control Manager. The Quality Control Manager will also work in concert with personnel concerned during the implementation of any actions taken as a result of these reviews. 2.4.5 Any action taken as a result of these reviews which requires modification of this manual must be documented in this manual within ten days of implementation. 3.0 QUALITY MANAGEMENT SYSTEM 3.1 GENERAL 3.1.1 This Quality Control Manual documents VOSKY PRECISION MACHINING CORP. policies regarding the handling, inspection, management and routing of jobs according to ISO9002 standards. It shall be the responsibility of the VOSKY Quality Control Department to maintain this system and all associated data. The quality control system shall include data from the following, but not limited to: Certifications Incoming inspection. (Receiving inspection) First article inspection reports. Final inspection reports. Discrepant material reports Manufacturing plans 3.2 PROCEDURES 3.2.1 Detailed procedures for support and maintenance of the Vosky Precision Quality Control System are contained within this manual. Second Tier documents are used as tools through which methods of operation are implemented. These describe, in detail, methods by which a particular activity is performed. Vosky Management and/or Quality Control prepares documented procedures and work instructions consistent with the requirements of this manual and ISO9002. 3.3 QUALITY PLANNING 3.3.1 In order to meet the quality requirements for products, Vosky performs quality planning activities. These activities are documented in this manual in a format suitable for Vosky s method of operations and include the following: A) Preparation and review of documents such as drawings, parts lists, standards and purchase orders B) Identification and acquisition of personnel and equipment necessary to manufacture products to desired specifications. C) Generating of Manufacturing Plans containing detailed, sequential instructions necessary to manufacture the part in question. D) The design, manufacture and use of tooling necessary to either manufacture or inspect parts. 12
E) Identification of key characteristics and appropriate verification methods F) Preparation of Inspection and First Article Reports G) Clarification of any questions regarding contracts or standards of acceptability 13
4.0 CONTRACT REVIEW 4.1 GENERAL To insure the quality, accuracy and timely completion of our contracts, VOSKY PRECISION MACHINING has developed procedures documented in this manual for the review of contractual requirements for all orders, including amendments. 4.2 REVIEW All quotations, purchase orders, and contract acknowledgements shall be reviewed by management prior to submission to a customer or vendor. The review is to insure that: A) The contract is accurate and to determine if all contract requirements are adequately defined and understood. B) An order is received in writing before work is started manufacturing. C) The company has the resources and capability to meet contract requirements. 4.3 RESPONSIBILITIES 4.3.1 MANAGEMENT RESPONSIBILITIES IN CONTRACT REVIEW VOSKY PRECISION MACHINING CORP. will be responsible for meeting all terms and deliveries required on a Purchase Order, or of notifying the customer if this is not possible for one reason or another. Upon receipt of a customer purchase order management shall review customer s Purchase Order accuracy of all terms and conditions. Management will, at this time, assign a Control Number, usually the Part Number, by which that contract shall be known at VOSKY. VOSKY management shall assign this number and assemble and maintain a file complete with all drawings, revisions, part lists, specifications, and requirements. This is the master file which will also contain all certifications acquired during the course of the contract s life. Management shall then generate a VOSKY MANUFACTURING PLAN, which shall list consecutively all steps necessary to make a contract-compliant part. This manufacturing plan must be checked against the part Blueprint, Parts List, and any applicable Control Drawings, rather than any internal documents, prior to approval. This manufacturing plan should include all information required to manufacture the component in question, including but not limited to information about material required, heat treating, sketches for preliminary machining operations, sizes required for plating, coating or grinding allowances, any dedicated fixturing or inspection equipment, and a sequential listing of all outside processing. The Manufacturing Plan shall also contain reference points requiring inspections and tests, along with space to note the date a particular operation was finished, the quantity/length/weight of an item, and room for an inspection stamp to verify that an operation has been accomplished to specifications. A master copy of the Manufacturing Plan will accompany each run of a particular part from start to finish. This is the Plan that will have all pertinent dates and inspection stamps in regards to each operation. A copy of this plan will be placed in the master file for reference purposes. 14
Management shall also make a determination, with reference to contract requirements, of manufacturing the constituent components or purchasing them from external sources, (make or buy). Purchased components shall be purchased using VOSKY Purchase Orders, detailing exactly what is required (including sketches if necessary), including but not limited to processes and raw materials, certificates of compliance and/or additional tests. All such details shall be referenced to the assigned VOSKY Control Number. 4.3.2 QUALITY CONTROL RESPONSIBILITIES IN CONTRACT REVIEW A copy of the contract along with all pertinent drawings, revisions, specifications and requirements shall be forwarded to the Quality Control Department. Quality Control shall set up and maintain a control file under the designated control number. Quality Control shall compare all pertinent copies of Purchase Orders and Manufacturing Plans for accuracy as related to revisions, drawings, specifications and requirements of the contract before release for general use. All inaccuracies shall be corrected immediately and any questions regarding any aspect of the contract should be relayed to the customer at this time. Once the Manufacturing Plan has been reviewed and OK ed, the plan can be put into use and material procured at this point. Quality Control shall, at this time, before any machining takes place, generate an INSPECTION REPORT for each component of a customer s purchase order. The inspection report should be a form listing, in numeric order, all measurable characteristics of a part, as well as all part list notes, ADCN or Engineering Order notes, special sizes noted on customer s P.O., and any other information that needs to be inspected in order to make an acceptable product. Alongside each characteristic or note should be a space for recording the measured characteristic or note observed. Each of these items shall be circled and numbered on a Master Inspection Print that will be maintained in the Quality Control Department s file system. The numbers on the master print shall correspond to the matching numbers on the Inspection Report. ALL ITEMS on a print must be documented. If an item appears multiple times in a print, or is noted as typical x number of times, then each instance should be listed alphabetically, such as #1a, #1b, #1c and so on. The applicable numbers on a report shall be filled in as they are preformed according to the Manufacturing Plan. The first time that a component is being manufactured by VOSKY, a first article report report must be made as well as a general one. The first article report will conform to AS9102, a three part form illustrated in the appendix. 4.3.3 CUSTOMER RESPONSIBILITIES RELATED TO CONTRACTS The customer is responsible for spelling out in a Purchase Order, all related part and blueprint numbers and revisions, part list revision levels, pricing, quantities, and delivery dates required of Vosky Precision Machining for each item in a contract. This purchase order should also include any special instructions or sizes to be maintained by Vosky during the manufacture of said components. The customer is also responsible for flowing down to Vosky, in a timely manner, any information that affects the manufacture of a part in any way. If a customer requirement changes in the middle of manufacturing and modification of the component in question is not possible at this point, then the customer is responsible for purchasing work done to that point and Vosky shall re-manufacture the part to the new specifications. 15
4.4 REPEAT OR MULTIPLE LINE ORDERS Items that are repeats of old orders or that, due to time or scheduling considerations, must be run multiple times in order to complete a contract, may use copies of existing Manufacturing Plans and Inspection Reports for the same items, AS LONG AS NO REVISIONS HAVE BEEN MADE. If any changes have been made to a part or the manufacturing sequence or method, either because of manufacturing considerations or Customer revisions, a revised Manufacturing Plan and/or inspection report must be made, with changes in each noted on the particular form. 4.5 AMENDMENTS TO CONTRACTS Immediately upon receipt, of any Customer contract changes, a copy shall be compared to the original order on file, and immediate action taken to assure the use of the appropriate information used for fabrication and inspection. Should the work have progressed to a point where the changes are impossible or inappropriate. All work will stop. The appropriate customer purchasing agent shall be promptly notified. 4.5.1 Any amendment to any contract, coming in to VOSKY or out-going, shall be reviewed in the same manner as the original. All changes must be clearly noted in the amendment. 4.5.2 Information about amendments and details are promptly communicated to the affected departments. 4.5.3 Any impact of an amendment that affects price, delivery capabilities, or Vosky s ability to manufacture affected component must be communicated to the customer by management before any additional work proceeds on the order in question. 4.6 RECORDS Records of contract reviews are documented and maintained. Each contract is stamped and initialed. The original is kept in the master file in the main office. 5.0 DESIGN CONTROL Since VOSKY offers only informal design consultation to its customers, and does only internal design of fixtures and tooling, this element is not applicable to VOSKY. 6.0 DOCUMENT AND DATA CONTROL 6.1 GENERAL VOSKY s inspection system shall provide for procedures which will assure that the latest applicable drawings, specifications and instructions required by the contract, as well as authorized changes thereto, are used for fabrication, inspection and testing. A complete copy of the contract or customer order along with a copy of applicable drawings, specifications, and instructions shall be on file in the VOSKY Quality Control Department in its appropriate VOSKY Job Number file. Manufacturing Plans, when initiated, shall be compared to the appropriate Job Number file to confirm the correct usage, of the latest drawing revisions, specifications or instructions. When, First article and Final 16
inspection tests are performed, confirmation of correct drawing revisions, specifications or instructions shall be performed as a regular part of the inspection system. 6.1.1 VOSKY PRECISION MACHINING CORP. has established and documented in this manual procedures to describe the methods for controlling all documents and data necessary for maintaining the quality system and ensuring product acceptability. 6.1.2 Documents that are controlled and their method of control include: A) Inspection and Testing Reports These documents are maintained by the Quality Control department, with each report filed according to part number. Files shall be maintained for a minimum of ten years. B) Manufacturing Plans Manufacturing Plan Number assignment shall be traceable to each Customer contract number. A copy of Manufacturing Plan is to be filed in the Quality Control Department for use in In Process Inspection, Final Inspection, and/or Incoming Inspection. Provision of space shall be provided on the Work Order for Inspection acceptance or rejection at each manufacturing method or process point. C) Purchase Order Number assignment shall be traceable to VOSKY Manufacturing Plan, which in turn shall be traceable to each Customer contract. Purchase Orders shall provide choice option of the need for Certification of Compliance, (CoC), certifying that the material ordered conforms to the specifications. Copy of Purchase Order to be filed in Quality Control Department for use in Incoming Inspection to assure purchased material meets specification. Copy of Certificate of Compliance referencing specific purchase order (number) to be filed in Master File for each part. In addition, when a Purchase Order is generated for outside processing, Purchase Order requirements shall be reviewed for accuracy by the Quality Control department before the parts go out for processing. D) Certifications of Compliance (Source/supplier) on file in VOSKY Job Number file (front office), traceability provided by Purchase Order, Work order, item identification, Job Number, contract or customer order number. Additional copy on file in Quality Control Dept. in respective Job Number file. E) First Article Inspection Report. Filed in the Quality Control Department; traceability provided by either Purchase Order or Manufacturing Plan, item identification, Job Number, then contract or customer order number. See Appendix A for: VOSKY INSPECTION REPORT F) Final Inspection Report. Filed in the Quality Control Department; traceability provided by Work Order, item identification, and Job Number. See Appendix A for: VOSKY INSPECTION REPORT G) Discrepant Material Report. Filed in the Quality Control Department; traceability provided by Purchase Order, Manufacturing Plan, item identification, and Job Number. 17
See Appendix A for: VOSKY DISCREPANT MATERIAL REPORT 18
6.2 DOCUMENT AND DATA APPROVAL AND ISSUE 6.2.1 Prior to issue, all documents are reviewed for accuracy and adequacy and approved by authorized personnel. 6.2.2 To prevent the use of invalid and/or obsolete documents, a Document Control Index is maintained to identify the current revision level of Quality System documents. This index is maintained by the Quality Control Department and is available for reference to all personnel. 6.2.3 Invalid and/or obsolete documents are promptly removed from all points of issue or use to prevent their unintended use. Any documents retained for legal and/or knowledge preservation are to be appropriately identified and kept secure. 6.3 DOCUMENT AND DATA CHANGES 6.3.1 Changes to documents are reviewed and approved in the same manner as the original issues, by the same personnel responsible for the original, or their designee. 7.0 PURCHASING 7.1 GENERAL VOSKY PRECISION MACHINING CORP. assumes responsibility for the quality of all materials, services, and processing purchased from subcontractors. Vosky has implemented and maintains procedures documented in this manual to select reliable suppliers. 7.2 EVALUATION OF SUPPLIERS 7.2.1 A listing is maintained in the main office of all suppliers who provide products, services, processing, or support to Vosky. 7.2.2 The evaluation and selection process shall determine a supplier s ability to meet Vosky s quality requirements. The selection process shall include: A) Evaluation and approval by Management of vendor surveys to determine the adequacy of said vendor s Quality Control System. B) On-site visits by Vosky Management or Quality Personnel may be necessary to determine a vendor s ability to fulfill contract requirements. C) Consideration of already issued Customer approvals shall be a factor in evaluation of a supplier. A Boeing approved chrome plating house, for instance, shall be approved by Vosky for chrome plating upon receipt of a completed Quality survey. 7.2.3 Customer approved supplier listings are consulted when dictated by contract or purchase order. 19
7.2.4 Completed Quality Surveys shall be maintained by the Vosky Quality Control Department and reviewed on an annual basis. 7.3 PURCHASING DATA 7.3.1 VOSKY PRECISION MACHINING uses PURCHASE ORDERS to communicate all requirements pertaining to material, technical data, quality and inspection, manufacturing and shipping, as well as revision levels. 7.3.2 Purchase Orders, attachments, and amendments are reviewed by either Management or the Quality Control Department for accuracy and to ensure that all requirements are communicated to the supplier. 7.4 VERIFICATION OF PURCHASED PRODUCT When a purchased part comes in to Vosky, the Quality Control department shall prepare all necessary equipment to measure all characteristics being done at this point. Quality control shall inspect the part and note the dimensions in the proper spot on the Inspection Report. If a part is found to be non-compliant, a DISCREPANT MATERIAL REPORT shall be generated and submitted to the vendor. This is the same report as generated for in-house evaluation and follows the same procedures. 7.5 VERIFICATION AT SUPPLIER S PREMISES Purchase Orders for parts requiring on-site inspection at a vendor s facility shall contain a right of entry clause, allowing Vosky management or its customer s representatives to enter a vendor s facility for the purpose of either inspecting that facility to determine a vendor s ability to meet purchase order requirements or to inspect products at the vendors facility. Purchase orders shall also provide a selective choice option should Customer inspection be required for material, prior to shipment from a subcontractor's or vendor's plant with the following wording: "Customer inspection is required prior to shipment from your plant. Upon receipt of this order, promptly notify the Customer representative who normally services your plant so that appropriate planning for inspection can be accomplished." See Appendix A for a copy of VOSKY PURCHASE ORDER 8.0 CONTROL OF CUSTOMER SUPPLIED PRODUCT 8.1 GENERAL Vosky has established and maintains procedures for the examination and control of all incoming product, whether material is furnished by the Customer, or purchased by VOSKY, VOSKY procedures shall be as follows; Examination upon receipt, consistent with practicability, to detect if damage in transit occurred. Inspection for completeness and proper type. 20
Periodic inspection and precautions to assure adequate storage conditions and to guard against damage from handling and deterioration during storage. Functional testing, either prior to or after installation, or both, as required by contract to determine satisfactory operation. Identification and protection from improper use or disposition Verification of quantity. 8.2 DAMAGED CUSTOMER FURNISHED MATERIAL VOSKY shall report to the Customer representative any Customer furnished material found damaged, malfunctioning or otherwise unsuitable for use. In the event of damage or malfunction during installation, the contractor shall determine and record probable cause and necessity for withholding material from use. Verification by Vosky does not absolve Customer of the responsibility to provide acceptable product. 9.0 PRODUCT IDENTIFICATION AND TRACEABILITY 9.1 GENERAL VOSKY PRECISION MACHINING CORP. has established and maintains procedures documented in this manual for the identification and traceability of each part during all stages of manufacture, storage and shipping. 9.2 IDENTIFICATION 9.2.1 WORK IN PROCESS Work in process is accompanied by a VOSKY MANUFACTURING PLAN, which is traceable to the Customer contract or purchase order. The manufacturing plan provides the drawing number and revision levels to which parts are being manufactured. All certifications and test results are stored in the main part file and recorded on VOSKY s Certificate of Compliance. 9.2.2 FINISHED PARTS Finished parts are identified by part marking according to drawing specifications. (i.e.: Bag and Tag, Electrochemical etch, engrave, etc ) in addition to package marking which provides traceability to its origin. 9.3 TRACEABILITY 9.3.1 Traceability methods are used only if required by standards or customer contract. 9.3.2 The extent of traceability shall be agreed upon by Vosky s representative and the customer and documented before starting work. 9.3.3 All serialized parts are controlled by noting serial numbers on Vosky s Manufacturing Plan and on all certifications issued by vendors. 21
10.0 PROCESS CONTROLS 10.1 GENERAL VOSKY PRECISION MACHINING CORP. has implemented and documents in this manual the means by which all operations performed at Vosky are controlled. Special process control procedures, such as Statistical Process Control, shall be an integral part of the VOSKY inspection system when such inspections are a part of the specification or the contract or customer order. All processes required by contract or customer order shall be included in the VOSKY Manufacturing Plan so that they are included within the normal inspection systems. Those parts or processes required from a subcontractor or vendor shall be cited on a VOSKY Purchase Order so that they may be included within VOSKY s normal Incoming inspection systems. 10.2 MANUFACTURING PROCESSES 10.2.1 Management describes, in a Vosky Manufacturing Plan, the sequence of all operations necessary to make a conforming part. 10.2.2 Manufacturing shall coordinate with Management and Quality Control to provide fixtures, gauges, and specific process control information. 10.2.3 Manufacturing is responsible for machine setup and part conformity to specifications. 10.2.4 Quality Control is responsible to inspect the first piece of any manufacturing operation and to provide the manufacturing department with all necessary equipment to maintain part conformity. In addition, Quality Control will conduct and document by means of an inspection stamp in the appropriate place on the Manufacturing Plan, in-process inspections of ongoing operations. 10.2.5 Upon completion of each operation, the Operator/Technician responsible notifies the Quality Control Department, which will verify and document by means of an inspection stamp in the appropriate spot on the Manufacturing Plan, that the operation has been completed to specification. 10.2.6 Manufacturing processes are monitored by various means including Coordinate Measuring Machine readings, Statistical Process Control, mechanical and visual evaluation, auditing, and lot sampling. 22
11.0 INSPECTION AND TESTING 11.1 GENERAL 11.1.1 Vosky has established procedures for the inspection and testing of products to ensure that they meet requirements. These procedures are documented on Manufacturing Plans and Inspection Reports for each applicable part or detail. AS9102 First Article Reports document methods by which these tests are performed. 11.1.2 VOSKY shall maintain adequate records of all inspections and tests. The records shall indicate the nature and number of observations made, the number and type of deficiencies found, the quantities approved and/or rejected, the nature of corrective action taken, if necessary, and the disposition of nonconforming parts, as appropriate. These records shall remain on file for a period of not less than ten years. 11.1.3 Inspections and tests are performed using standard inspection methods and calibrated instruments capable of the necessary accuracy. 11.1.4 Authorized Inspector Stamps document the acceptance of parts. 11.1.5 Nonconforming parts are tagged and segregated from acceptable parts. 11.2 RECEIVING INSPECTION AND TESTING 11.2.1 All incoming products are inspected or otherwise verified as conforming to specifications before being released for use or for further work. 11.2.2 To ensure that incoming raw material conforms to specifications, Vosky requires all purchased materials to be accompanied by written and signed certification from the supplier and chemical analysis ascertaining that the material supplied is in accordance with the required specifications. These certifications must be reviewed by Management or Quality Control and review is documented by use of an approved Inspection Stamp at the bottom of said certification. 11.2.3 Parts purchased from a vendor in a machined state will be treated as if machined at Vosky and inspected as detailed in sections 7.4 and 10.2.4 to 10.2.6. Manufacturing plans and Inspection reports shall be generated for these parts as if they are being manufactured in house. Note that any parts manufactured by vendors that are on probation due to past rejects or deficiencies in their Quality System shall be inspected 100% for all characteristics. Parts purchased from a vendor in good standing may be inspected using lot sampling methods, except for Key Characteristics, which must be inspected 100%. 11.2.4 Products that are needed urgently may be used prior to passing Incoming Inspection with the approval of the General Manager, Quality Control Manager or one of their designees. This is a temporary action used only to expedite delivery and does not absolve Vosky of the responsibility to ensure part quality. The customer must be notified of this and parts must be tagged to reflect this status until received and approved by the customer. 23
11.3 IN-PROCESS INSPECTION AND TESTING 11.3.1 In-process inspections and tests are performed at appropriate intervals during the manufacturing process and as specified in the Manufacturing Plan and Inspection Reports. Manufacturing Plans have places for inspection stamps to document when in-process inspections have been performed by the Quality Control Department. 11.3.2 Product conformance to specifications is established by a combination of Quality Control oversight and constant monitoring by manufacturing personnel. As noted in section 2.2.2, Vosky Management believes in operators monitoring their own work. This enables us to detect a discrepancy immediately and to minimize scrap parts. 11.3.3 No product is released for use or further processing until all of the required inspection procedures have been performed and documented, except under the conditions outlined in section 11.2.4, under incoming inspection. All clauses remain in effect when a part is manufactured in house. 11.4 FINAL INSPECTION 11.4.1 No product is released to the customer until all manufacturing, inspection, and testing procedures have been performed as per the Manufacturing Plan. All tests must be documented by means of a Quality approval stamp at their appropriate place in the Manufacturing Plan. 11.4.2 The Manufacturing Plan, First Article Report and Inspection Reports will be used in conjunction with each other to ensure that all quality requirements and tests have been satisfactorily completed. 11.4.3 The Quality Control Department is responsible for ensuring that all Quality requirements of a contract are fulfilled prior to shipment of a product to a customer. These requirements include, but are not limited to: A) Dimensional conformity B) A review and verification of required documentation C) Verification of marking, storage, packaging, and shipping requirements. 11.5 INSPECTION AND TEST RECORDS 11.5.1 All inspection and test records for all products are maintained for a minimum of ten years by the Quality Control Department (40 years for flight safety parts and critical parts). 11.5.2 These records show clearly whether the product has passed or failed the tests according to defined criteria. 11.5.3 These records, by means of Inspection Stamps, identify the personnel responsible for product acceptance and release. 24
12.0 CONTROL OF MEASURING AND TEST EQUIPMENT 12.1 GENERAL 12.1.1 VOSKY PRECISION MACHINING CORP. has established and documents in this manual detailed instructions for the use, calibration, maintenance, shipping and storage of all measuring and test equipment used to ensure product acceptability. This system is in accordance with the ANSI/NCSL-Z-540-1-1994 calibration standard. 12.1.2 VOSKY shall provide and maintain gages and other measuring and testing devices necessary to assure that supplies conform to the technical requirements. In order to assure continued accuracy, these devices shall be calibrated at established intervals against certified standards, which have known valid relationships to national standards. If production tooling such as jigs, fixtures, templates, and patterns are used as a media of inspection, such devices shall be proved for accuracy at established intervals. Calibration of inspection equipment shall be in accordance with ANSI/NCSL-Z-540-1-1994. 12.1.3 When required, VOSKY s measuring and test equipment shall be made available for use by the Customer's representative to determine conformance of product with contract requirements. In addition, if conditions warrant, Vosky personnel shall be made available for operation of such devices and for verification of their accuracy and condition. In the event of a conflict of equipment use, VOSKY Quality Control Department shall generate a plan or schedule that provides opportunity for customer use and VOSKY use, without inhibiting the flow of production or processing of Customer contracts. 12.1.4 Inspection, measuring and test equipment shall be used in a manner that ensures measurement uncertainty is known and is consistent with the required measurement capability. 12.2 CONTROL PROCEDURE 12.2.1 Suitable measuring and test equipment capable of necessary accuracy and precision are selected after identifying the measurements to be made and the accuracy requirements. 12.2.2 VOSKY shall provide and maintain all necessary measuring and testing tools and equipment required to assure compliance with technical Quality Control requirements. The VOSKY Quality Control Department shall be responsible for actual quality assurance through the following: Calibration. Adequacy of measuring standards. Environmental controls. Intervals of calibration. Calibration procedures. Out-of-tolerance conditions. Adequacy of calibration system. Calibration source. Records. Calibration status. Control of Subcontractor's calibration Storage and handling. Amendments and revisions 25
Should an out-of-tolerance condition be discovered during calibration, and the tool or instrument is currently being used on an in process work order, immediate corrective action must be taken. The procedures outlined in the tool s calibration sheet shall be followed. See Appendix A for a copy of VOSKY CALIBRATION SHEET 12.3 ADEQUACY OF MEASURING STANDARDS. At frequent prescribed intervals, the VOSKY Quality Control Department shall sub-contract the measurement and test of the following described equipment to a measuring laboratory with accuracy standards traceable to the National Institute of Standards and Technology herein known as NIST. (Formerly National Bureau of Standards; NBS), who will perform for VOSKY the calibration, documentation and certification of the following standards tools and/or devices: Restricted use measuring blocks (commonly known as Jo- Blocks) Master ring gages Coordinate measuring machine Granite surface plate Restricted use Jo-Block sets and Master Sunnen ring gages shall be set aside for the exclusive use of the Quality Control Department as master calibration reference. Working Set Jo-Blocks shall be used for day to day confirmation and calibration of all other company owned measuring equipment and employee owned measuring equipment. Wherever practicable, VOSKY Quality Control shall calibrate all working tools, instruments and measuring devices to a minimum of a 4 to 1 ratio to reflect a minimum acceptable area of un-certainty of 25%. Ex. If a specified tolerance is.0002"., the device used must be calibrated to.00005" at minimum 12.4 ENVIRONMENTAL CONTROLS The VOSKY inspection work area shall be at ambient room temperature and humidity. The area shall be kept neat, clean and free of chips and dust. 24
12.5 INTERVALS OF CALIBRATION 12.5.1 The VOSKY Quality Control Department shall be responsible for the maintenance and calibration intervals of the following types of measuring equipment, tools, instruments and devices at the following intervals: Every 6 Months: Working Jo-Blocks Sunnen Gage master setting micrometer Sunnen Gage master setting rings Dial indicator micrometers Outside micrometers* Inside micrometers* Electronic outside micrometers* Vernier dial calipers* Vernier electronic calipers* Height gage* Dial indicators All other measuring instruments, tools and devices, Company and employee owned are to be considered only as reference instruments and should be used only upon approval from the Quality Control Department * To be checked (calibrated) before each use 12.5.2 VOSKY Quality Control shall establish and maintain records for calibration of all measuring instruments, tools and devices, company owned and employee owned, and shall determine the schedule of calibration. Users and owners (employee owned) of measuring tools and instruments, shall be notified one week prior to the actual calibration interval. Measuring tools and instruments must be submitted to Quality Control on their due date. If not, Quality Control must impound them. All measuring tools, instruments and devices shall contain unique marks or pressure sensitive labels indicating calibration status. At the time of calibration interval or at any time prior, should the tool or instrument prove to be incapable of calibration, it shall be so marked or labeled, and shall not be used for measurement at all. 12.6 CALIBRATION PROCEDURES 12.6.1 VOSKY Quality Control shall establish and maintain a calibration procedure file for each and every type of measuring tool, instrument or device in use at VOSKY. At minimum, the file should contain the following: Manufacturer's procedures, if available. The required parameters, range, and accuracy of the measurement standard. The acceptable tolerance of each instrument characteristic being calibrated. Calibration procedures providing instructions to enable calibration by VOSKY Quality Control personnel, to adequately calibrate each instrument characteristic or measurement parameter of concern and the equipment that should be used. State the collective accuracy ratio (minimum) between the uncertainty of the calibration equipment and the tolerance of the characteristic being calibrated. 25
Instruction for the placement of the proper calibration status seal, labels or wax. 12.6.2 OUT-OF-TOLERANCE CONDITIONS Should anyone within the VOSKY quality system, discover that any measuring tool, instrument, device or equipment is calibrated as an out of tolerance condition, immediate action must be taken. The VOSKY Quality Control Department and the current user of the tool or instrument must be notified immediately. If the tool or instrument is currently in use on an in-process work order, and the out-of-tolerance condition is significant, immediate corrective action must be taken. A significant out-of-tolerance condition is one that has less than a 4 to 1 calibration to tolerance ratio, as related to the minimum uncertainty area indicated in Section 12.3. 12.7 ADEQUACY OF THE CALIBRATION SYSTEM The VOSKY Quality Control Department shall periodically, but randomly audit, the quality of the VOSKY calibration system, including all related calibration records, in order to assure the integrity of the VOSKY calibration system and it's components as described in section 12.2. The results and data of these audits shall be recorded in a VOSKY Calibration System Audit Report on file in the Quality Control Department. 12.8 CALIBRATION SOURCES Measuring tools, instruments, equipment and devices shall be calibrated by the VOSKY Quality Control Department or an external qualified calibration facility using measuring standards whose calibration is traceable. All measurement standards used in the VOSKY calibration system shall be supported by certificates, reports or data sheets attesting to the description or identification of the item: The calibration source Date of calibration Calibration assigned value Statement of uncertainty and environmental or other conditions under which the calibration results were obtained All certificates and reports shall be on file in the VOSKY Quality Control Department, and shall contain the following information: Identification or serial number of the measurement standard or measuring tool, instrument or equipment to which the report or certificate pertains. Identification of the calibration source and report number. Date of calibration. Calibration assigned value(s) with statement of uncertainties. A statement attesting to the fact that the measurement standards used in obtaining the results are traceable, if the calibrating laboratory is other than the NIST or DoD laboratory. 26