Company: Process Title Process Check Report Ref. No: Raytheon Process Auditor(s): Date Of Process Audit: AEROSPACE FASTENER MANUFACTURERS Summary: Conclusion: Distribution: Auditor: Approved By: Approved For Distribution: RCJI/QA/SC135(M).XLS Issue 3 1
Invoked Documents Listing 1. Process Specifications Reference No. BS 2M54 BAEP9226 BAEP2502 BAEP4544 Title Temperature Control In The Heat Treatment Of Metals Hardness Testing - Metallic Materials Magnetic Particle Flaw Detection of Materials Etch Inspection of Machined Components Manufactured From Steel 2 2 2 3 Issue 2. Quality Assurance Instructions To Suppliers Reference No. Title Issue 3. Other Technical Documents Invoked Reference No. Title Issue RA QS/QAP/DHS/01/00 Quality Assurance Plan For The Manufacture Of Alloy Steel DHS Bolts Heat Treated To The Properties Of BS S98. 1 4. General RCJI/QA/SC135(M).XLS Issue 3 2
Details Of Check Will a unique batch number be allocated to each issue of parts to production Are there procedures for establishing techniques for all manufacturing processes. Are 12 off blanks produced under full running conditions and the last 2 submitted for dimensional and metallurgical approval before commencement of a production run. Is a batch record card established which will reference the material cast number or material batch, material certificate of conformity number, any order details, part number and associated manufacturing specifications. Will the unique batch number ensure traceability of the parts through the fulfilment of the order. Is process control inspection maintained to ensure conformity of the forgings to the specification requirements. Is the frequency of sampling demonstrated to be adequate to maintain the quality of production and the acceptance or otherwise recorded and referenced against the batch number. Result / Remarks Cold Forging Action Required RCJI/QA/SC135(M).XLS Issue 3 3
In the event of any sample failing a quality control check will production of the batch cease until new samples are submitted which demonstrate corrective action has been taken. Will changes in the batch of material or major changes in tooling involve a new setting of the machine or necessitate a separate batch reference number being raised before production of parts is continued. Is a last-off sample submitted for dimensional and metallurgical clearance before the production batch of forgings are released for further processing. Are the first 2 blanks submitted, patrol and last-off dimensional and metallurgical inspection carried out to check for the presence of cracks/laps and overheating Hot Forging Is process control inspection maintained to ensure conformity of the forgings to the specification requirements. Is the frequency of sampling demonstrated to be adequate for the process. Is acceptance or rejection by the patrol inspection recorded against the batch reference number. RCJI/QA/SC135(M).XLS Issue 3 4
Will the control of the forging temperature, grain flow, grain size and general metallurgical structure of the forgings be supervised by a qualified metallurgist, to ensure conformance to specification requirements. Do changes in the batch of material or major changes in tooling or heating necessitate a separate batch reference number being raised before production is continued. Will failure of a operator/inspection inspection involve action as for cold forging. Will heat treatment be carried out in accordance with the drawing or procurement specification requirements. If so then complete the RCJI/QA/SC121 questionnaire As a minimum are 2 fasteners from each cast per diameter per heat treatment load checked for carb/decarbby etching in a suiable conc of HNO3 in alcohol and examined at x100 mag. For tensile fasteners is it stipulated that no carb/decarb is allowed For shear fasteners is it stipulated that the max allowable decarb is.003" and that no carb/decarb is allowed RCJI/QA/SC135(M).XLS Issue 3 5
Is a sample of the wire / bar taken from the same lot of fastener material and tested for physical properties To which method are the fasteners verified i) Metallographically examined by a qualified metallurgist or ii) Microhardness tested on the section atarting at the surface then towards the core Is hardness testing of bolt blanks / test wire, undertaken. If so complete RCJI/QA/SC132 questionnaire. In addition are 5 random fasteners taken per heat treatment lot and hardness tested Of the 5 fasteners taken are the following tests carried out i) Surface hardness on the head after removal of 0".001of metal ii) The same fasteners are sectioned longitudinally and the core hardness measured iii) Has the surface hardness not exceeded the core hardness by 20 points (Knoop or Vickers) Do the hardness values fall between the limits of 360-410Hv RCJI/QA/SC135(M).XLS Issue 3 6
Is an in-process quality control system maintained e.g, operator control or patrol inspection. Are rejected parts segregated from the system and identified accordingly. Are checks for grinding abuse carried out by suitably qualified personnel. If any of the fasteners have failed to meet this criteria has either one of the following occurred i) 2 further samples from the same batch tested with both samples meeting the above requirements or ii) Fasteners re-heat treated iaw para 4.1.4 of Quality plan and rehardness tested Secondary Machining Operations Will machining of forged blanks be controlled to ensure adequate removal of heat treatment scale, oxidation or otherwise contaminated layers, from the surface, as determined by the individual product procurement specification. Are grinding operations supervised particularly when the materials may be subject to grinding abuse. If so complete RCJI/QA/SC158 questionnaire. RCJI/QA/SC135(M).XLS Issue 3 7
Is it demonstrated that the frequency of testing is adequate and that the grinding parameters such as wheel speed, wheel dressing intervals, feed rates, coolant supply are satisfactorily controlled. Is Fillet rolling of the underhead radius inspected at sufficient intervals to demonstrate conformance to specification, both dimensionally and metallurgically. Will a production run commence only when first-off samples have been cleared dimensionally for conformance to specification of thread effective and major diameters using calibrated gauges and projector check where considered necessary. Thread Rolling In addition, are 3 samples submitted for metallurgical examination for evidence of thread rolling defects : e.g Laps in the thread roots, flank or crest, byetching in Nital and examined at x10 mag or immersed in 50% aqueous solution of HCl at 80-90OC for 3 minutes then examined at x10 mag Are the fasteners subject to operator / inspection sampling during a production run. RCJI/QA/SC135(M).XLS Issue 3 8
Will the frequency of checks depend on the batch size and method of thread rolling e.g., Hand fed circular die or automatic feed flat die. Does the manufacturer demonstrate that it is adequate for controlling the quality of parts produced by each method. Are last-off samples taken and cleared before a production batch is release for further processing. In the event of rejection of a patrol sample, will the production run cease until new samples are submitted which demonstrate corrective action has been taken to bring the thread back within specification. Will the production quantity represented by a defective sample be rejected for sorting, rectification or scrap. Does the manufacturer maintain records of the operator / inspection patrol inspection traceable to each batch number. Where the operation is performed in-house, will suitably qualified Laboratory personnel control of plating solutions and reference tests for adhesion, porosity, coating thickness, hydrogen embrittlement. Metal Finishing RCJI/QA/SC135(M).XLS Issue 3 9
Is pre-plate and post-plate inspection of the threaded portions of fasteners carried out using gauges in a known state of calibration. Is the calibration of gauges to a defined standard. Are records of all such inspection maintained for each batch of fasteners. Does the manufacturer ensure that all individual finished parts where required by specification drawing or order are marked with his unique code letter(s) enabling traceability of original supply of all such parts to be maintained throughout their life. Is incoming material tested in accordance with in-house procedures Is a first-off sample submitted for dimensional approval before commencement of a production run. Is a batch record or inspection card raised which will detail the material cast number, certificate of conformity number, any order details, part number and manufacturing operations as required. Manufacturer's Identity Items Machined from Bar RCJI/QA/SC135(M).XLS Issue 3 10
Do changes in the batch of material necessitate a separate batch reference number being raised before production continues. Are the parts Non-Destructively tested. If so then complete the RCJI/QA/SC103 questionnaire Is operator / inspection patrol inspection maintained to ensure conformity of the parts to specification requirements. Is the frequency of sampling demonstrated to be adequate to maintain the quality of production and the results recorded and referenced against the batch number. In the event of any sample failing a quality control check, will production of the batch cease until new samples are submitted which demonstrate corrective action has been taken. In addition, will the production quantity which the failed sample represents be rejected for sorting. RCJI/QA/SC135(M).XLS Issue 3 11
Raw Material- Qualification Where the manufacturer does not have his own approved laboratory facilities, will the additional testing required to clear such material be carried out by a Laboratory or Test- House facility approved by an organisation acceptable to Raytheon. Will the Certificate of Conformity be obtained and placed on record for audit purposes. Is the purchase of material from overseas within the agreed Raytheon Quality Plan and the organisation is listed within the RAC QVL Overseas sources Does the fastener manufacturer raise a Material Order and Inspection Schedule for all materials purchased overseas. If so, will this detail the specification requirements and onreceipt inspection to be carried out by the fastener manufacturer to assure the quality of the material. Where the fastener manufacturer does not have his own approved laboratory facility, will the required tests be carried out by a facility which will supply a Test Report for the record, and holds an approval that is acceptable to Raytheon. RCJI/QA/SC135(M).XLS Issue 3 12
In addition to the controls above, is the name of the original manufacturer of the material ascertained and recorded on delivery documentation. Will the overseas source supply a Raytheon certificate to the UK source including control documents such as Test Reports. Will the Test Report be used to compare with the results obtained from the on-receipt inspection. Is sub-contract machining placed on Raytheon approved subcontract firms. Machining Is it an exception for a nonregistered company to be used, if so, does the manufacturer's quality organisation ensure that the sub-contractor has an adequate system of gauging and inspection. Does the manufacturer carry out on-receipt inspection to ensure conformance to specification. Will sub-contractors be subject to regular audit to ensure batch control, calibration frequencies etc. Is the source listed in the RAC QVL Plating/Surface Treatment RCJI/QA/SC135(M).XLS Issue 3 13
In the latter case, is evidence of plating inspection obtained, such inspection having been carried out by suitably qualified personnel. Does the manufacturer demonstrate that batch identity and pre and post-plate inspection records are maintained. Are any exceptions to this approved by the customer Quality Asurance Authority prior to placement of the order. Is batch testing by statistical quality control sampling employed. Laboratory Testing Do such tests include metallurgical examination, by etching. Where the manufacturer does not have the approved facilities to perform these final tests, is a random sample, as indicated by the sampling plan for the batch size involved, forwarded to an organisation holding approvals acceptable to Raytheon for testing and certification. Is a Test report detailing the part number, batch number, sample size, quantity and test results of the finished fasteners retained by the manufacturer. RCJI/QA/SC135(M).XLS Issue 3 14
Control of Traceability Do manufacturers undertake to ensure that traceability of finshed products be maintained from the Raw Material stage through the manufacturing cycle up to and including the point of despatch to the customers. Is it recognised that although many Main Contractors use a common bin system upon receipt of finished parts, do manufacturers make every effort to facilitate identification of their own parts. Are items that are received partfinished and subsequently completed by the supplier uniquely identified. Will an Approved Certificate, uniquely numbered, and signed by the manufacturer or stockists quality assurance representative, accompany each delivery of thread fasteners. Certificate of Conformity Will this documents include sufficient information to fully identify the parts supplied and to enable traceability to be followed through the supplier's quality control and inspection record system. RCJI/QA/SC135(M).XLS Issue 3 15
Do these include the following:- Adequate identification of all incoming raw material and relevant supplies, including maintenance of the original batch identification. Satisfactory material identification whilst in bonded store and during its subsequent processing. Test Report Does the manufacturer retain on record related to each production batch number, a Test Report recording the actual physical and/or chemical test results obtained from the statistical quality control sample representative of the batch. If all or part of such testing is subcontracted, is a valid Test report obtained for the record. Quality Control and Inspection Record Is a system of records maintained by the Quality / Inspection / Laboratory functions of the Accredited Manufacturer. Are retention of these records in accordance with the guidelines of Raytheon RAIFSAS/QA/SC1 Evidence of interstage inspection and testing together with the identity of the Quality / Inspection / Laboratory representative responsible for such testing. RCJI/QA/SC135(M).XLS Issue 3 16
Evidence of final inspection and acceptance / rejection together with the identity of the quality representative responsible for final release of the parts. Are adequate facilities available so that items are sufficiently segregated. Stockists Will containers be clearly identified with the reference number(s) to the items they contain. Are items packed and stocked so that the chance of damage or deterioration is reduced to a minimum. Is documentation available for items put into stock. Is stock rotation practices. Are all goods released on an approved Certificate of Conformity, giving the information as required by RAIFSAS/QA/SC1. Despatching RCJI/QA/SC135(M).XLS Issue 3 17