KNC DOC NO. QC-1000, Rev. D RELEASE DATE: February 21, 2013 KING NUTRONICS CORPORATION QUALITY CONTROL PROGRAM MANUAL

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1 KNC DOC NO. QC-1000, Rev. D RELEASE DATE: February 21, 2013 KING NUTRONICS CORPORATION QUALITY CONTROL PROGRAM MANUAL

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5 KNC PUB NO. QC-1000, Rev. D KING NUTRONICS CORPORATION QUALITY CONTROL PROGRAM MANUAL RECORD OF REVISIONS SECTION NO. REVISION LETTER EFFECTIVE DATE DESCRIPTION OF CHANGE QC-1000 A 10/26/11 Initial release of QC-1000 QC Program Manual B 12/15/11 Responsibility for maintaining Approved Vendor List, Form QA- 370, assigned to Quality Control Manager B 12/15/11 Detailed procedures for surveying and approving service providers and vendors for M&TE and Calibration Standards are crossreferenced in Sections and C 12/16/11 Added section accepting manufacturer's certificate of calibration or traceability for new M&TE C 12/16/11 Added section accepting manufacturer's certificate of calibration or traceability for new Calibration Standards D 2/21/13 Defined J-STD-001E, ANSI/ESD and ISO to annual review requirements. Added necessary review items to Form QA- 105, Rev. C. 17 D 2/21/13 Retitled Subcontractor and Vendor Control. 18 D 2/21/13 Added J-STD-001E requirements for soldering vendors. i

6 KNC PUB NO. QC-1000, Rev. D KING NUTRONICS CORPORATION QUALITY CONTROL PROGRAM MANUAL RECORD OF REVISIONS SECTION NO. REVISION LETTER EFFECTIVE DATE DESCRIPTION OF CHANGE ii

7 KNC PUB NO. QC-1000, Rev. D KING NUTRONICS CORPORATION QUALITY CONTROL PROGRAM MANUAL RECORD OF REVISIONS SECTION NO. REVISION LETTER EFFECTIVE DATE DESCRIPTION OF CHANGE iii

8 KNC PUB NO. QC-1000, Rev. D KING NUTRONICS CORPORATION QUALITY CONTROL PROGRAM MANUAL RECORD OF REVISIONS SECTION NO. REVISION LETTER EFFECTIVE DATE DESCRIPTION OF CHANGE iv

9 KNC PUB NO. QC-1000, Rev. D FOREWORD This King Nutronics Corporation Quality Control Program Manual, Document No. QC-1000, and its successive revisions, is intended to establish a comprehensive set of Quality Control policies and procedures. These policies and procedures shall define the management and operation of an inspection system and other preventive and corrective actions taken to ensure the quality and reliability of products and services delivered by the Company to its Customers. The sections in this manual define the elements of each Quality Control policy and procedure and the organizational responsibilities and requirements of Company personnel. Examples of various internal process documents and forms are provided in the Appendices for clarity and completeness. The King Nutronics Corporation Quality Control Program complies with the requirements of MIL-STD-45662A, ANSI/NCSL Z-540, and ISO 17025: Other Industry Standards and Quality Standards are incorporated as cited in the following sections. The QC-1000 Quality Program Manual shall be revised as the Company adopts additional Quality Standards to ensure conformance to those Standards and accreditation guidelines. v

10 KNC PUB NO. QC-1000, Rev. D Fig. 1. Quality Control Program QCS-1000 Organizational Chart vi

11 KNC PUB NO. QC-1000, Rev. D TABLE OF CONTENTS Section Page 1 QUALITY CONTROL PROGRAM POLICIES, RESPONSIBILITIES, AND FUNCTIONS Quality Control Program Policies and Procedures Quality Control Program Annual Review Quality Control Program Internal Audits Quality Control Program Elements Responsibilities Engineering Personnel Quality Control Manager Production Manager Receiving Inspection In-Process Inspection Calibration & Final Inspection Document Control Officer Sales and Marketing Personnel Calibration Lab Manager MANUFACTURING, INSPECTION, AND ACCEPTANCE TEST INSTRUCTIONS Responsibilities Purchasing Production Manager Engineering Personnel Quality Control Manager Requirements Receiving Inspection Instructions In-Process Inspection Instructions Acceptance Test Procedures QUALITY ASSURANCE (QA) INSPECTION PROGRAM Responsibilities Receiving Inspection In-Process Inspection Calibration & Final Inspection Production Manager Requirements Receiving Inspection In-Process Inspection Calibration & Final Inspection INSPECTION PROCESS CONTROL Responsibilities Shipping & Receiving Clerk Receiving Inspection In-Process Inspection Calibration & Final Inspection Quality Control Manager Alternate Quality Control Manager Requirements Shipping & Receiving Clerk Receiving Inspection In-Process Inspection vii

12 KNC PUB NO. QC-1000, Rev. D Section Page Final Inspection INSPECTION STATUS INDICATORS Responsibilities Requirements Description of Inspection Stamps Assembler Identification Stamps NON-CONFORMING MATERIAL CONTROL AND DISPOSITION Responsibilities Receiving Inspection In-Process Inspection Calibration and Final Inspection Material Review Board (MRB) Requirements Identification of Non-Conforming Materials Reporting of Non-Conforming Materials Root Cause Analysis for Non-Conforming Materials Non-Conforming Materials Disposition Actions Customer Review Procedures for Non-Conforming Materials MATERIAL REVIEW BOARD (MRB) Responsibilities Material Review Board (MRB) Membership Requirements INTERNALLY- AND EXTERNALLY-GENERATED CORRECTIVE ACTIONS Responsibilities Material Review Board (MRB) Quality Control Manager Receiving Inspection Production Manager In-Process Inspection; Calibration and Final Inspection Requirements CUSTOMER COMPLAINT RESOLUTION Responsibilities Complaint Resolution Process CONTROL AND CALIBRATION OF M&TE AND CALIBRATION STANDARDS Responsibilities Quality Control Manager Purchasing Requirements Identification and Registration Control of Measuring and Test Equipment (M&TE) Control of Company Calibration Lab Measurement Standards Out-of-Tolerance Criteria for M&TE and Calibration Standards Customer-Furnished M&TE Operation of Company Calibration Laboratories Exceptions and Departures from Documented Policies and Procedures Government Use of Company M&TE and Calibration Standards viii

13 KNC PUB NO. QC-1000, Rev. D Section Page Personally-Owned M&TE DOCUMENT CONTROL Responsibilities Company President Document Control Officer Quality Control Manager and Engineering Personnel Company President and Production Manager (Contracts Administration) Requirements Engineering Drawing Revisions Engineering Drawing Distribution Engineering Drawing Control Government Approval Records Retention Document Control Officer Production Manager Quality Control Manager GOVERNMENT PROPERTY CONTROL Responsibilities Receiving Inspection Quality Control Manager Production Manager Requirements RAW MATERIALS CONTROL Responsibilities Purchasing Shipping & Receiving Clerk Receiving Inspection Production Manager Requirements Raw Materials Documentation Raw Materials Acceptance Raw Materials Storage STOCK AND SUPPLY CONTROL Responsibilities Shipping & Receiving Clerk Receiving Inspection Production Manager Requirements Documentation of Incoming Stock Items and Supplies Processing of Incoming Stock Items and Supplies Identification and Marking of Stock Items and Supplies Warehouse Acceptance Storage of Stock Items and Supplies Records Retention ix

14 KNC PUB NO. QC-1000, Rev. D Section Page 15 PACKAGING AND SHIPPING CONTROL Responsibilities Production Manager In-Process Inspection Shipping & Receiving Clerk Requirements Invoice Requirements Final Inspection Requirements Shipping Requirements PURCHASE ORDER CONTROL Responsibilities Requirements SUBCONTRACTOR AND VENDOR CONTROL Responsibilities Quality Control Manager Purchasing Receiving Inspection and In-Process Inspection Requirements Subcontractor and Vendor Qualification Engineering Documentation SUBCONTRACTOR AND VENDOR QUALIFICATION PROCEDURES Responsibilities Quality Control Manager Purchasing Requirements Work Performed By Subcontractors and Vendors Calibration Laboratory and M&TE Service Providers QUALITY CONTROL MANUAL QC-1000 REVISION CONTROL Responsibilities Company President Quality Control Manager Requirements TRAINING OF CALIBRATION LABORATORY PERSONNEL Responsibilities Requirements Calibration Laboratory Personnel Training Activity Training Examination Annual Training Review x

15 KNC PUB NO. QC-1000, Rev. D Section Page 21 CALIBRATION LABORATORY ENVIRONMENTAL CONTROL Responsibilities Quality Control Manager Requirements Pressure and Torque Calibration Lab Requirements Thermo Unit Calibration Lab Requirements Environmental Monitoring and Documentation, Pressure and Torque Lab Environmental Monitoring and Documentation, Thermo Unit Lab Drum Recorder Calibration and Maintenance Backup Drum Recorder Data Logger Calibration and Maintenance Environmental Monitoring During Standardization and Calibration Activity Environmental Monitoring During Use of Reference Gage Blocks OXYGEN-CLEAN POLICIES AND PROCEDURES Responsibilities Sales and Marketing Personnel Purchasing Production Manager Mechanical Assembly Personnel In-Process Inspection Oxygen-Clean Vendor Qualification xi

16 KNC PUB NO. QC-1000, Rev. D THIS PAGE IS INTENTIONALLY BLANK xii

17 KNC PUB NO. QC-1000, Rev. D 1 QUALITY CONTROL PROGRAM POLICIES, RESPONSIBILITIES, AND FUNCTIONS 1.1 QUALITY CONTROL PROGRAM POLICIES AND PROCEDURES 1) All Quality Control Program policies and procedures formulated by the Company President or Quality Control Manager shall be approved by both prior to implementation. All current Quality Control Program policies and procedures shall be documented in the latest revision of the Quality Control Manual, Doc. No. QC ) All revisions to existing Quality Control Program policies and procedures shall be approved by both the Company President and Quality Control Manager prior to implementation. All revisions shall be documented in the Quality Control Manual. 3) All requests for waivers or deviations from existing Quality Control Program policies and procedures are subject to review and approval by the Quality Control Manager. 4) The Quality Control Manager shall ensure workmanship, service, and consistency in detail design characteristics as expressed in the Engineering drawings and product specifications, and enforce the Quality Control Program policies and procedures as established by Senior Management. 5) The Quality Control Manager shall be concerned with all functions that directly or indirectly affect product quality and the reliability of Company services. 6) Quality Control Inspectors, i.e., Quality Assurance (QA) personnel, shall not be indifferent in their responsibility for determining the acceptance or rejection of finished goods and replacement parts delivered to the Customer. QA shall coordinate with Engineering personnel and the Production Manager to verify the accuracy of Engineering drawings and product specifications so that design data and calculations can be proved or disproved. 7) The Production Manager shall ensure that workmanship standards and Quality Control Program policies and procedures are complied with throughout the manufacturing process as defined in this manual. 8) The Quality Control Manager shall ensure that the Quality Control Program is in compliance with Quality Control Standards and Industry Standards documents as defined by the Company President, third-party accreditation organizations, and customer contract and purchase order requirements QUALITY CONTROL PROGRAM ANNUAL REVIEW. The Quality Control Manager shall, on a yearly basis, review the suitability and effectiveness of the Quality Control Program, and its compliance with Quality Control Standards and Industry Standards requirements, the requirements of third-party accreditation organizations, and customer and purchase order requirements. The review shall be conducted in the first quarter of each Calendar Year. The following Quality Control Standards and Industry Standards documents shall be used as the basis for Quality Control policies and procedures incorporated in the QC-1000 quality program: MIL-I-45208A and superseding documents ANSI/NCSL Z540-1 and ANSI/NCSL Z540.2 ISO 17025: 2005 IPC J-STD-001E: 2010 ANSI/ESD 20.20:

18 KNC PUB NO. QC-1000, Rev. D Additional quality control and industry standards documents may be included in the document review for incorporation into the QC-1000 quality policy and procedures to maintain conformance to customer contract and purchase order requirements. The results of the annual Quality Control Program review shall be documented by the Quality Control Manager on the Quality Control Program Review Form, Doc. No. QA-105, and forwarded to the Company President. The Company President and Senior Management shall evaluate the continuing suitability and effectiveness of the Quality Control Program, and recommend any necessary changes or improvements in the form of Corrective Action Requests (CARs). Section 8 of this manual defines the policies and procedures for internally-generated corrective actions. The Quality Control Manager is responsible for documenting and resolving the Corrective Actions for all discrepancies noted during the annual review. A copy of the annual review report and all related data shall be retained permanently by the Quality Control Manager as described in Section 11 of this manual, Document Control. Appendix A contains an example of the Quality Control Program Review Report Form, QA QUALITY CONTROL PROGRAM INTERNAL AUDITS. The Quality Control Manager shall, on a yearly basis, conduct an internal audit of Company activities to verify that operations continue to comply with the requirements of the Quality Control Program, and Quality Standards and Industry Standards documents defined in Section The internal audit shall address all elements of the Quality Control Program, including testing and calibration lab activities. Personnel conducting internal audits shall be trained and qualified for such tasks. When audit findings cast doubt on the effectiveness of operations or on the correctness or validity of testing and calibration results, timely corrective action shall be taken. Customers shall be notified in writing if investigations show that laboratory results may have been affected. Internal audit activities, audit findings, and resultant corrective actions shall be documented. Follow-up audits of previous findings shall be conducted and documented to verify the implementation and effectiveness of corrective actions taken. Audit findings may also be used as the basis of the Quality Control Program Annual Review described previously in Section Appendix A contains an example of the Internal Quality Audit Form, QC

19 KNC PUB NO. QC-1000, Rev. D 1.2 QUALITY CONTROL PROGRAM ELEMENTS The Quality Control Program consists of the functional elements detailed in the following manual sections: 1) Quality Control Program Policies, Responsibilities, and Functions 2) Manufacturing, Inspection, and Acceptance Test Instructions 3) Quality Assurance (QA) Inspection Program 4) Inspection Process Control 5) Inspection Status Indicators 6) Non-Conforming Material Control and Disposition 7) Material Review Board (MRB) 8) Internally- and Externally-Generated Corrective Actions 9) Customer Complaint Resolution 10) Measuring and Test Equipment Control and Calibration 11) Document Control 12) Government Property Control 13) Raw Materials Control 14) Stock and Supply Control 15) Packaging and Shipping Controls 16) Purchase Order Control 17) Subcontractor and Vendor Control 18) Subcontractor and Vendor Qualification 19) Quality Control Manual QC-1000 Revision Control 20) Training of Calibration Laboratory Personnel 21) Calibration Laboratory Environmental Control 22) Oxygen-Clean Policies and Procedures 3

20 KNC PUB NO. QC-1000, Rev. D 1.3 RESPONSIBILITIES ENGINEERING PERSONNEL. Engineering personnel are responsible for the following functions and duties: 1) Change and control of Engineering drawings and product specifications. 2) Participating in Material Review Board (MRB) actions as a permanent member. 3) Preparing work instructions and acceptance test procedures (ATPs) for use by the Production Manager and Quality Assurance (QA) personnel QUALITY CONTROL MANAGER. The Quality Control (QC) manager is responsible for the following functions and duties: 1) Reviewing, implementing and enforcing Quality Control Program policies and procedures as defined in QC ) Evaluating subcontractor, vendor, and in-plant product quality. 3) Maintain inspection and test records. 4) Overseeing Quality Assurance (QA) activities, i.e., Receiving Inspection, In-Process Inspection, and Calibration & Final Inspection. 5) Steering the Corrective Action process for internally- and externally- detected Non-Conformances. 6) Preparing reports on Non-Conformance Corrective Actions for Senior Management. 7) Participating in Material Review Board (MRB) as a permanent member. 8) Investigating customer complaints, discrepancies, and other Non-Conformances in returned products. 9) Maintaining control and issuance of Quality Assurance inspection stamps. 10) Coordinate maintenance and schedule re-certification of test and measurement equipment and calibration standards used in determining or establishing the acceptability of materials and finished goods and replacement parts delivered to the Customer. 11) Overseeing the training of Company personnel on Quality-related subjects and maintaining records of training activities. 4

21 KNC PUB NO. QC-1000, Rev. D PRODUCTION MANAGER. The Production Manager oversees aspects of the manufacturing process, i.e., the Machine Shop, Electronics Assembly and Mechanical Assembly, and Purchasing. The Production Manager is also responsible for ensuring that manufacturing travelers, i.e., shop orders and production checklists, contain instructions and procedures required for in-process and final inspection of machined parts, electronic assemblies, etc., fabricated within the company s facilities, and by outside subcontractors and vendors, per the approved Engineering drawings. Additionally, the Production Manager shall maintain complete records of shipped goods, including calibration data, acceptance test reports, and production checklists, as applicable. Such records shall be retained by the Production Manager for a period of five years per the procedures in Section 11 of this manual, Document Control RECEIVING INSPECTION. Under the scope of QA, Receiving Inspection determines the suitability of received items, such as raw materials, incoming stock, and finished goods, per applicable Engineering drawings and product specifications, and records the acceptance or rejection status and the inspection date on the Purchase Order for use by the Production Manager and Quality Control Manager IN-PROCESS INSPECTION. Under the scope of QA, In-Process Inspection assures complete inspection and acceptance testing coverage and surveillance throughout the manufacturing process, including compliance with workmanship, packaging, and shipping container requirements. Inspects and compiles all records pertaining to Oxygen-Clean finished goods and replacement parts. Prepares all In-Process Inspection records and forwards them to the Production Manager for retention CALIBRATION & FINAL INSPECTION. Operating within the King Nutronics Corp. pressure, temperature, and torque/force calibration laboratories under the scope of QA, Calibration & Final Inspection tests, inspects, and calibrates all assembled systems, i.e., finished goods, for compliance to technical specifications, workmanship standards, and Customer requirements. Additionally, Calibration & Final Inspection inspects all replacement parts prior to shipment to the Customer to ensure completeness and conformance to Quality Control policies and procedures. Compiled calibration data and final acceptance test reports are forwarded by Calibration & Final Inspection to the Production Manager for records retention DOCUMENT CONTROL OFFICER. Operating under the scope of QA, the Document Control Officer is responsible for revising, modifying, and cataloging all Engineering drawings and Company documentation per the Quality Control Program policies and procedures in this manual. The Document Control Officer is responsible for maintaining the current Engineering drawing revisions in the Active Drawings File and a History file of obsolete Engineering drawings and Company documents. The Document Control Officer is also responsible for Engineering drawing changes as specified on an Engineering Change Order (ECO) SALES AND MARKETING PERSONNEL. Sales and Marketing personnel are responsible for communications with customers regarding products and services delivered by the Company. Sales & Marketing is also responsible for producing and maintaining Company price lists and marketing materials as directed by Senior Management. Sales & Marketing shall ensure that all marketing materials and external communications to customers are accurate and reflect current Engineering drawing revisions, product specifications, and product configurations. 5

22 KNC PUB NO. QC-1000, Rev. D CALIBRATION LAB MANAGER. The Calibration Lab Manager is responsible for the calibration, service, and maintenance of Company-manufactured finished goods and units repaired for service using certified M&TE and Calibration Standards. The Calibration Lab Manager schedules the laboratory workload and supervises personnel in the proper use of laboratory equipment. The Calibration Lab manager also trains personnel in the laboratories, reviews their work for accuracy, and maintains records of calibration and service work performed. The Calibration Lab Manager coordinates with the Quality Control Manager to schedule the maintenance and recertification of the lab's Calibration Standards and M&TE. Working with the Quality Control Manager, the Calibration Lab Manager investigates customer complaints, discrepancies, and other non-conformances affecting finished goods, replacement parts, or services. The Calibration Lab Manager reviews the procedures in use for accuracy, and makes recommendations to the Quality Control Manager for revisions as required. 2 MANUFACTURING, INSPECTION, AND ACCEPTANCE TEST INSTRUCTIONS 2.1 RESPONSIBILITIES PURCHASING. Under the scope of the Production Manager, Purchasing is responsible for ensuring that Purchase Orders (Form QA-305) for raw materials, stock items, supplies, and processing by subcontractors and vendors contains all information required for Receiving Inspection to verify compliance with the Engineering drawings and product specifications PRODUCTION MANAGER. The Production Manager is responsible for ensuring that work travelers, i.e., Shop Orders (Form No. QA-300) and production checklists, contain all instructions and procedures required for in-process and final inspection of machined parts, electronic assemblies, etc., fabricated within the company s facilities per approved Engineering drawings and product specifications. Items covered under the scope of these Quality Program policies and procedures shall be referred to as finished goods and replacement parts within this manual ENGINEERING PERSONNEL. Engineering personnel are responsible for preparation of Acceptance Test Procedures (ATPs) for use by personnel to ensure conformance to the Engineering drawings, product specifications, customer requirements, and Quality Control Program policies and procedures QUALITY CONTROL MANAGER. The Quality Control Manager is responsible for final approval of Acceptance Test Procedures (ATPs), production checklists, work instructions, and other documents that affect finished goods and replacement parts under the scope of the Quality Control Program policies and procedures. 2.2 REQUIREMENTS RECEIVING INSPECTION INSTRUCTIONS. Receiving Inspection instructions shall be noted on Purchase Orders (Form QA-305) as applicable. Characteristics to be inspected, and the acceptance/rejection criteria, shall be specified in the PO or applicable Engineering drawing, specification, or catalog description. The PO shall also specify requirements and acceptance criteria for material certifications and test reports IN-PROCESS INSPECTION INSTRUCTIONS. In-Process Inspection instructions shall be part of the applicable work traveler (Shop Order Form QA-300 or production checklist). Characteristics to be inspected and/or tested, and the acceptance/rejection criteria, shall be specified on the work traveler or applicable Engineering drawing. The work traveler shall require an inspection stamp imprint to indicate the inspection status. Appendix B contains examples of Shop Order and production checklist forms. 6

23 KNC PUB NO. QC-1000, Rev. D ACCEPTANCE TEST PROCEDURES. Acceptance Test Procedures (ATPs) shall be prepared for each type of assembly, component or system to be inspected. Distribution of ATPs shall be controlled to ensure that only the latest revision is utilized. ATPs shall contain the information listed below. Appendix C contains examples of typical Acceptance Test Procedures (ATPs). ATPs shall fall under the scope of Final Inspection as a Quality Assurance (QA) function. Acceptance Test Procedures (ATPs) shall document the following information: 1) Test procedure form number. 2) Date the procedure was released to the Production Manager for manufacturing. 3) Revision letter of the procedure. 4) Item nomenclature. 5) Item model number and part number, as applicable. 6) Serial number, software revision, control number, or other unique identifiers. 7) Contract number, as applicable. 8) Date inspection was initiated. 9) Step-by-step procedures for conducting the inspection, including all parameters and tolerances that require verification. 10) Identification of the inspection equipment to be used. Space should be provided to record the serial numbers and calibration expiration date information for the inspection equipment. 11) Space, adjacent to each step, for the technician to indicate that a particular procedural step has been completed. 12) Space to record the date the inspection was completed. 13) Space for a signature or initial of the technician performing the inspection. 14) Space for a Quality Assurance inspection stamp imprint indicating the status of the inspection. 3 QUALITY ASSURANCE (QA) INSPECTION PROGRAM 3.1 RESPONSIBILITIES RECEIVING INSPECTION. Under the scope of Quality Assurance (QA), Receiving Inspection is responsible for the following functions: 1) Ensuring the acceptability of test reports and certifications that accompany material purchased or processed outside the company s facilities. 2) Verifying that part numbers, descriptions, quantities of incoming items are correct per purchase order and customer invoice. Verifying that required documentation such as calibration and Oxygen-clean certificates are included with relevant items. Rectifying discrepancies and shortages with Purchasing. 7

24 KNC PUB NO. QC-1000, Rev. D 3) Completion of the Receiving Inspection Report Form QA-317, when applicable, for material received and inspected, as defined per customer contract or purchase order IN-PROCESS INSPECTION. Under the scope of QA, In-Process Inspection is responsible for ensuring that all acceptance tests defined for company manufacturing processes are performed. In-Process Inspection shall verify that work travelers (Shop Order Form QA-300 and production checklists) are stamped to indicate that required inspections and/or ATPs have been performed, and that Inspection Report QA-318 is completed, when applicable per customer contract or purchase order. Appendix E contains an example of In-Process Inspection Report Form QA CALIBRATION & FINAL INSPECTION. Under the scope of QA, Calibration & Final Inspection is responsible for ensuring that all final acceptance tests have been completed and that the production checklist has been stamped by In-Process Inspection to indicate that the required tests and inspections have been performed. Calibration & Final Inspection is also responsible for ensuring that finished goods have been standardized and calibrated to current specifications and acceptance criteria, and for forwarding all test and calibration data to the Production Manager for records retention PRODUCTION MANAGER. The Production Manager is responsible for retaining all inspection and test records, and final acceptance test reports, with the Bookkeeping copy of the Purchase Order, shop order, and other pertinent documents. Inspection and test records defined in this policy shall be maintained for a period of five years, per the policies and procedures in Section 11 of this manual, Document Control. 3.2 REQUIREMENTS RECEIVING INSPECTION. Under the scope of QA, Receiving Inspection is responsible for the following functions and duties: 1) Test reports and certifications that accompany purchased material shall be checked 100% against applicable specifications. 2) The quantity accepted and/or rejected, together with all pertinent data, shall be noted on the receiving copy of Purchase Order Form QA-305, or in the Remarks column of the Receiving Inspection Form QA-317, when applicable. The designated area shall be marked with a QA inspection stamp to signify approval. 3) One copy of all test reports and certifications and the packing slip shall be filed with the Bookkeeping copy of the PO. 4) When a Non-Conformance is found, the procedures outlined in Section 6, Non-Conforming Materials Control and Disposition, shall be followed IN-PROCESS INSPECTION. Under the scope of QA, In-Process Inspection is responsible the following functions and duties: 1) In-process and final inspection reports shall be an integral part of all work travelers. 2) Inspection reports shall include characteristics inspected, number of observations made, number and type of deficiencies found, and quantities accepted and rejected. 3) When a Non-Conformance is found, the procedures outlined in Section 6, Non-Conforming Materials Control and Disposition, shall be followed CALIBRATION & FINAL INSPECTION. The following items are required for Calibration & Final Inspection Records submitted to the Production Manager: 8

25 KNC PUB NO. QC-1000, Rev. D 1) QA Acceptance reports compiled by Calibration & Final Inspection shall consist of completed ATP forms, standardization and calibration data, and related documents, such as the Certificate of Traceability issued by the Quality Control Manager for calibrated finished goods. 2) Calibration & Final Inspection shall present all completed ATP forms to In-Process Inspection for review and inspection to applicable requirements. After review and inspection is complete, In-Process Inspection shall stamp the ATP s to signify QA Acceptance of the item. 3) Upon QA Acceptance, Calibration & Final Inspection shall forward a report, consisting of copies of the stamped ATP forms and standardization and calibration data to the Production Manager for retention with the Bookkeeping copy of the Purchase Order (Form QA-305), Shop Order (Form QA-300), and other relevant documents. Documents shall be retained by the Production Manager in accordance with the policies and procedures in Section 11 of this manual, Document Control. 4) The Production Manager shall make all compiled records available for review by Company personnel, customer representatives, auditors, government inspectors, and others with authorized access. A filing system for the purpose of archiving and retrieving inspection and test records shall be maintained. 5) When a Non-Conformance is found, the procedures outlined in Section 6, Non-Conforming Materials Control and Disposition, shall be followed. 4 INSPECTION PROCESS CONTROL 4.1 RESPONSIBILITIES SHIPPING & RECEIVING CLERK. The Shipping & Receiving Clerk is responsible for receiving, processing, and routing all incoming materials RECEIVING INSPECTION. Under the scope of Quality Assurance (QA), Receiving Inspection is responsible for inspecting all materials intended for production use that have been purchased or processed inside the Company s facilities. Receiving Inspection shall be completed before materials can be placed in stock or distributed to manufacturing by the Shipping & Receiving Clerk IN-PROCESS INSPECTION. Under the scope of QA, In-Process Inspection is responsible for inspecting and/or testing all machined parts, electronic assemblies, etc., that are fabricated within the company s facilities, and by outside vendors. Inspections shall take place after the completion of each discrete step of the manufacturing process, as determined by Engineering and the Quality Control Manager. In-Process Inspections shall be documented on the production checklist for the equipment per the procedures in Section 3 of this manual, Quality Assurance (QA) Inspection Program CALIBRATION & FINAL INSPECTION. Under the scope of QA, Calibration & Final Inspection is responsible for conducting and compiling Acceptance Test Procedures (ATPs), as well as standardization and calibration data, as defined per the procedures in Section of this manual QUALITY CONTROL MANAGER. The Quality Control Manager is responsible for implementing sampling inspection plans for the inspection of materials intended for processing to verify their conformance to Engineering and product specifications, material certifications, acceptance test reports, and Customer requirements ALTERNATE QUALITY CONTROL MANAGER. An Alternate Quality Control Manager shall be designated in the event that the Quality Control Manager is absent. The Alternate Quality Control Manager shall be selected from among trained Calibration Lab and Quality Assurance personnel or Senior Management. 9

26 KNC PUB NO. QC-1000, Rev. D 4.2 REQUIREMENTS SHIPPING & RECEIVING CLERK. The Shipping & Receiving Clerk is responsible for the following functions and duties: 1) All purchased materials, stock items, finished parts, pressure gauges, etc., shall be routed to the Shipping & Receiving clerk for distribution or placement into inventory. No exceptions to this requirement shall be made, regardless of delivery method, i.e., vendor or company truck, commercial shipping, or by any other means. 2) A copy of all applicable Purchase Orders (Form QA-305) shall be forwarded to the Shipping & Receiving Clerk to note discrepancies. 3) The Shipping & Receiving Clerk shall verify that the material description and quantity delivered are in agreement with the shipping documents. The shipping documents shall be compared to the PO to verify compliance. All discrepancies shall be noted on the receiving documents. The PO and shipping documents shall be verified by Receiving Inspection and marked with an inspection stamp and date to document receipt of the material. 4) Materials requiring certification or test reports shall be held by the Shipping & Receiving Clerk pending receipt of these documents. Upon receipt of the required certifications or test reports, the material, certifications, shipping documents, and PO shall be forwarded to Receiving Inspection for review. 5) Semi-finished parts requiring additional in-plant operations shall be forwarded, with certifications, shipping documents, and the PO to Receiving Inspection by the Shipping & Receiving Clerk. 6) Upon completion of Receiving Inspection and QA Acceptance, all certifications, shipping documents and POs shall be compiled by the Shipping & Receiving Clerk and forwarded to the Production Manager. The Shipping & Receiving Clerk shall route the Accepted material to the warehouse inventory or in-plant production, as appropriate. 7) The Production Manager shall forward the original shipping documents and PO to Bookkeeping for payment. These documents will be returned to the Production Manager when the Bookkeeping tasks are complete. The original shipping documents and PO shall be retained by the Production Manager per the policies and procedures in Section 11 of this manual, Document Control RECEIVING INSPECTION. Receiving Inspection is responsible for the following requirements: 1) Receiving Inspection shall inspect all incoming materials purchased or processed outside the company s facilities and shall accept only those materials which conform to the applicable Engineering drawing or specifications, catalog descriptions, or Purchase Order instructions. 2) Receiving Inspection shall inspect the workmanship of all incoming materials processed outside the company s facilities. The accept/reject criteria shall be based on MIL-HDBK-454B, Guideline 9, when applicable. 3) Receiving Inspection shall inspect all materials received 100% unless otherwise instructed by Engineering or Senior Management. 4) Sampling inspection plans used for Receiving Inspection shall be designed to meet the requirements of the applicable project or job. 5) QA Acceptance by Receiving Inspection shall be noted on the receiving documents and PO. If Non- Conformances are determined by Receiving Inspection, the Receiving Inspection Report Form QA-317 shall be completed for use per the polices and procedures in Section 6 of this manual, Non-Conforming Materials Control and Disposition. 10

27 KNC PUB NO. QC-1000, Rev. D 6) Accepted raw materials accompanied by test reports or certifications shall be clearly marked by Receiving Inspection to indicate the project number and type of material. 7) Non-Conforming Materials rejected by Receiving Inspection shall be processed per the policies and procedures in Section 6 of this manual, Non-Conforming Materials Control and Disposition. 8) After last-piece delivery, the tooling used in-house and by any third-party vendors or subcontractors for fabrication of Company materials shall be inspected. If Non-Conformances are noted, the tooling shall be reworked prior to storage unless a waiver is received from the Production Manager. Tooling with an approved waiver shall be tagged indicating the nature of the Non-Conformance IN-PROCESS INSPECTION. In-Process Inspection is responsible for the following requirements: 1) First Article Inspection shall be performed for each new manufacturing operation. 2) After the First Article Inspection, subsequent inspections shall be conducted per the following sampling plan. The sampling plan lot size used shall be recorded on the Shop Order Form QA-300. Lot Size Inspection Sample Size % % % % % % 3) When required by Contract or Customer specifications, the acceptable quality level (AQL) shall be determined by the procedures in MIL-STD ) Parts and assemblies shall be inspected between operations as specified on Shop Order Form QA-300. Non-Conforming Materials and related processes shall be documented on Form QA-318, In-Process Inspection Report for use by the Material Review Board and the Quality Control Manager. 5) Shop Order Form QA-300 shall be issued for each job to be performed and remain with the materials through all manufacturing processes. 6) Modifications to Shop Order Form QA-300 shall only be made by authorized personnel and approved by the Production Manager. 7) Implementation of parts modifications and other work specified on the Engineering Change Orders (ECOs) shall be documented on the Shop Order Form QA-300. ECO implementation shall be verified by In-Process Inspection to ensure conformance to Engineering and Quality Control Program requirements. In-Process Inspection shall be furnished copies of revised Engineering drawings and Specifications, as appropriate. 8) Unscheduled inspections may be conducted at the discretion of the Quality Control Manager and Senior Management. 9) Completed assemblies shall be inspected prior to final system assembly as described in Section 3 of this manual, Quality Assurance (QA) Inspection Program. The inspection status shall be documented on the Shop Order by means of a QA inspection stamp and the inspection date. 11

28 KNC PUB NO. QC-1000, Rev. D 10) All completed materials or parts shall be inspected for compliance to dimensional specifications prior to the application of protective treatment, unless otherwise noted on Shop Order Form QA ) All material, parts, or assemblies shall be inspected for correct part number identification, inspection stamp imprints, workmanship, etc., after the application of finishing processes, e.g., plating, anodizing, painting, as defined on Shop Order Form QA ) In-Process Inspection shall verify the workmanship of all completed parts as defined per the policies and procedures in Section 3 of this manual, Quality Assurance (QA) Inspection Program. The acceptance/rejection criteria shall be based on MIL-HDBK-454B, Guideline 9, when applicable. Inspection status shall be documented on Shop Order Form QA-300 by means of a QA inspection stamp and the inspection date FINAL INSPECTION. Visual and physical inspection of finished goods and replacement parts shall be conducted per the following procedures: 1) An inspection prior to shipping, consisting of visual inspection for damage, omissions, and an evaluation of the appearance of the product, shall be performed under the scope of Final Inspection. The shipping container and packaging shall also be inspected for compliance with applicable regulations and Contract requirements. 2) Final Inspections shall be conducted on all (100%) products ready for shipment to the Customer unless otherwise specified in the Contract or Customer specifications. 3) Final Inspection shall be conducted per the applicable Acceptance Test Procedures (ATPs) or instructions on the production checklist. 4) The workmanship of all finished goods and replacement parts shall be inspected. The acceptance/rejection criteria shall be based on MIL-HDBK-454B, Guideline 9, when applicable. 5) Final Inspection of finished goods serviced and calibrated in the Company Calibration Laboratories shall be inspected for proper function and completeness. Final Inspection of calibrated and serviced finished goods shall be documented on Form QA-307, Final Inspection Checklist. 12

29 KNC PUB NO. QC-1000, Rev. D 5 INSPECTION STATUS INDICATORS 5.1 RESPONSIBILITIES All Quality Assurance (QA) inspection status indicators, i.e., inspection stamps and assembler identification stamps, are under the direct control of the Quality Control Manager. 5.2 REQUIREMENTS 1) Inspection stamps shall be issued only to personnel authorized by the Quality Control Manager. 2) Authorization shall be limited to Quality Assurance inspectors who, through related experience, on-the-job training, or a combination thereof, have demonstrated technical competence in the assigned tasks. 3) A stamp control record, Form QA-380, shall be maintained. Appendix F contains an example of Stamp Control Record Form QA-380. The record shall include the following information: a) Name of Quality Assurance employee receiving the stamps. b) Stamp issue date. c) Stamp control number. d) Stamp imprints. e) Stamp return date. 4) Loss of any inspection stamp shall be immediately reported to the Quality Control Manager. A notation of LOST and the date will be made on the stamp control record. 5) Upon termination of employment, the employee shall return all assigned inspection stamps. Returned stamps shall be re-issued to new personnel. 6) The inspection stamp number 1 shall be reserved for use by the Quality Control Manager. 13

30 KNC PUB NO. QC-1000, Rev. D 5.3 DESCRIPTION OF INSPECTION STAMPS Table 5.1 describes the types of Quality Assurance inspection stamps authorized for use, by imprint, description, and stamp material. All symbols are inscribed in a ½ diameter circle. Table 5.1 Authorized QA Inspection Stamp Imprints Imprint Description Material Acceptance Stamp: Indicates material conforms to all inspection requirements. Steel, vinyl, plastic, or etching. Withheld For Material Review Stamp: Indicates material is not in conformance with inspection requirements and is subject to Material Review Board action. Steel, vinyl, plastic, or etching. Material Review Acceptance Stamp: When stamped over the Withheld for Material Review Stamp, this stamp indicates Material Review Board acceptance of previously withheld material. Steel, vinyl, plastic, or etching. 5.4 ASSEMBLER IDENTIFCATION STAMPS 1) Steel stamps indicating the identity of assembly personnel shall be maintained and distributed by the Quality Control Manager. Such stamps shall be used for embossing serial number identification plates for newly manufactured equipment in the designated areas. 2) Assembler stamps shall consist of a unique identification number above the abbreviation KNC, inscribed within a ¼ diameter circle. 3) A unique identification stamp shall be issued to each assembler by the Quality Control Manager upon the assumption of work assignments. The identification stamp shall be returned to the Quality Control Manager upon termination of employment, or transfer to non-assembly related work. Returned stamps shall be reassigned to new personnel. 4) A card recording the assembler stamp numbers and assigned personnel shall be maintained and updated when changes dictate. This record shall be stored in the Tool and Gage Cabinet card file. 14

31 KNC PUB NO. QC-1000, Rev. D 6 NON-CONFORMING MATERIALS CONTROL AND DISPOSITION 6.1 RESPONSIBILITIES RECEIVING INSPECTION. Under the scope of Quality Assurance (QA), Receiving Inspection is responsible for identifying materials procured by Purchase Order that do not conform to applicable Engineering drawings, product specifications, certifications, or test reports, i.e., Non-Conforming Materials. The category of non-conforming materials is also applicable to Company services delivered to the Customer that do not conform to Quality Control Program processes and procedures. The Receiving Inspection Report Form QA-317 shall be used by the inspector to document the Non-Conformance IN-PROCESS INSPECTION. Under the scope of QA, In-Process Inspection is responsible for identifying materials processed within the company s facilities that do not conform to applicable Engineering drawings or product specifications, i.e., Non-Conforming Materials. The In-Process Inspection Report Form QA-318 shall be used by the inspector to document the Non-Conformance CALIBRATION & FINAL INSPECTION. Under the scope of QA, Calibration & Final Inspection is responsible for identifying assembled finished goods and replacement parts that do not conform to Contract requirements, Engineering drawings, or product specifications, i.e., Non-Conforming Materials. Non- Conformances occurring at the Final Inspection stage shall be brought to the direct attention of the Quality Control Manager and Production Manager for immediate action MATERIAL REVIEW BOARD (MRB). The Material Review Board (MRB), described in Section 7 of this manual, shall investigate and determine the root cause and disposition of all Non-Conforming Materials. 6.2 REQUIREMENTS IDENTIFICATION OF NON-CONFORMING MATERIALS. Non-Conforming Materials shall be identified per the following requirements: 1) Non-Conforming Materials shall be marked with the appropriate inspection stamp imprint. The imprint shall be located close to the Part Number, but shall not adversely affect the function or appearance of the materials. Type of marking, e.g., steel, vinyl, etc., shall be per the applicable drawing requirement. 2) Non-Conforming Materials shall also be identified by a Rejection Tag that has been signed, dated, and stamped by the inspector. Appendix G contains an example of a Rejection Tag. The rejection tag shall contain, as applicable, the following information: a) JOB NO. (Job Order No.). b) P.O. NO. (Purchase Order No.). c) PART NO. d) SERIAL NO. e) PART NAME. f) NUMBER OF PIECES REJECTED. g) REASON (Inspector s opinion as to who is responsible for the deviation). h) DISPOSITION (Final disposition of Non-Conforming Material noted). 15