ACR Electronics 8L2ACR-RLB-33 User Manual 8

ACR Electronics, Inc. 8

1. 8
2. 8a

8

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Date Submitted	1999-06-02 00:00:00
Date Available	1999-06-16 00:00:00
Creation Date	2001-06-15 22:54:02
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Document Lastmod	2001-06-15 22:54:04
Document Title	8

ACR
Electronics Inc.
5757 Ravenswood Drive
Ft. LaLuderdaIe, FL 33312
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ISO 9001: 1994
EN ISO 9001:1994: BS EN ISO 9001:1594: ANSIIASQC QQDD1:1994
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Inter-qfﬁce Memofmm . . .
Operations
To: ISO-9001 Audimrs
From: Ed Wolf, Director of Operations
Date: 04-27-98
Subject: ISO-9001 Management Representative
As theISO-9001MmagununkepresmlxﬁveJamleadingtheACReﬂ'ontoimplm
aQualitySystunincompﬁanoewiﬂnﬂwlSO—Ml QualitySmndardOncethe
implemmhﬁmphaseismwoasﬁrﬂyemnplﬁmdACRismgiMﬂnDheﬂmof
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RepresentaﬁwasﬂleDiecmronuaﬁtyinmﬁcipaﬁonofomsuccessﬁﬂregisuaﬁm
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M4
Paul M. Frank
0115 _ President
Edward A. Wolf
Director of
ubject:
Corporate Quality Manual Revision Record
Date Section ParagrapMs) Revision Description Approved By
Revised
7-I 5-9] All All C Rewrite William Smith 1
3-12-92 2200, All D Add sections William Smith I
2300
l . .
2 5 95 All All E giraelralel‘ipszte Ed Wolf
9-26-95 All Al] F Include FAA ACSEP Ed Wolf l
Include ISO Structure
10-10-97 All All G Bldg 2 consolidation Josef Menashe
&Scheduled Updates
5 18~98 All All H Incorporate ISO-900I Ed Wolf/
Josef Menashe
__ Z‘
__
—
1—
_ __
_—‘
s—I—e—
OI-QA-Ol-Ol Rev, A
SECTION
Ia
I]
III
IV
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
QUALITY MANUAL TABLE OF CONTENTS
DESCRIPTION
Revision Record
Amendment Record
QA Manual Distribution Log
Corporate Quality Policy
Cross Reference Aide (ISO-9001)
Management Responsibility
Quality Systems
Contract Review
Design Control & Review
Document Control
Purchasing
Customer Supplied Equipment
Product Identiﬁcation & Traceability
Process Control
Inspection & Test
Measuring & Test Equipment Calibration
Inspection & Test Status
Nonconforming Material
Corrective/Preventative Action
Handling, Storage, Packaging, & Delivery
Records
Audits
Training
Service Difﬁculties
SQC
PLANNING DEPARTMENT
Quality Assurance
Quality Assurance
Quality Assurance
Upper Management
Quality Assurance
Upper Management
Quality Assurance
Sales, Marketing & CS
Engineering
Engineering
Purchasing
Quality Assurance
Manufacturing
Manufacturing
Quality Assurance
Quality Assurance
Quality Assurance
Quality Assurance
Quality Assurance
Manufacturing
Quality Assurance
Quality Assurance
Human Resources
Sales, Marketing & CS
Quality Assurance
ubjectz
Corporate Quality Manual Distribution Log
Serial Number Location _I_ Revision
Master Quality Director I
#2 FAA Representative I
#3 Final / In-process Inspection I
#4 Receiving Inspection I
#5 DOD Representative I
#6 Purchasing I
#7 Sales & Marketing I
#9 Production Planner / Inventory Management I
MO Corporate Ofﬁces (HR) I
#1 1 Director of Operations I
#12 ISO Auditor (Jim Tone) I
—L 7
____’_______f
__I__——_______
II
CORPORATE QUALITY POLICY
" We will build qualigz products knowing they are used to save lives. "
CORPORATE QUALITY INTRODUCTION
The Corporate Quality Manual deﬁnes quality policies, and establishes methods and procedures
used by ACR Electronics, Inc. to assure high levels of product quality and reliability.
The Manual is intended to be consistent with the intent and general requirements of United States
Department of Defense MlL-l-45208A, “Inspection System Requirements”, and the Federal Aviation
Agencies ACSEP program including FAR Part 21, (Subpart G, O, K, and AC21-303-1) and ANSI/ASQC
Q9001-l994, which both outline the requirements of a Quality Assurance System. It is also consistent with
corporate policies that are applicable to all company departments and operations, as well as outside sub-
contractors and procedures.
ACR Electronics, has engaged in the designing, testing, and manufacturing of hardware for the Mercury,
Gemini, Apollo, and other National Aeronautics and Space Administration (NASA) programs Products
are manufactured under rigid quality speciﬁcations. A government DCASR Quality Assurance
Representative services our facility on a resident or itinerant basis, based on the present level of
government contract activity at ACR Electronics, Inc.
The inherent reliability of ACR products is achieved through the application of the highest levels of design
and development which address the physical laws governing the behavior of electronics and electro-
mechanical components, assemblies and products under varying environmental conditions. Maintenance of
the designed-in quality and reliability is assured through the implementation of the policies described
herein. These policies are based on the principle of continuous monitoring and veriﬁcation of ACR
standards of quality and customer requirements throughout every operation contributing to the ultimate
quality and reliability of products, from incoming inspection to shipment of ﬁnished products.
The Quality Manual outlines only the general philosophy and methods of ACR for attaining and
maintaining the high quality and reliability of products. Detailed speciﬁcations, procedures, instructions,
and processes are provided for general operation or are modiﬁed to reﬂect speciﬁc customer requirements.
However, they will not supersede applicable government, FAA, or prime contractor speciﬁcation
requirements.
It is the mandated responsibility of the Director of Quality Assurance to ensure that all of these policies and
supporting procedures are properly implemented and that the quality, reliability, and safety of ACR
products are assured through the usage of adequate and proven manufacturing facilities, process standards,
and quality controls.
The Quality policies outlined in this Manual may be modiﬁed only by the Director of Quality Assurance,
with the approval of the Chief Operating Ofﬁcer.
Josef Men-she Paul M. Frank
Director, Quality Assurance President
ACR Electronics, Inc, ACR Electronics, Inc.
ISO 9001
ACR Quality Manual Cross Reference
This cross reference is an auditor‘s aid only and includes but is not limited to the sections in the ACR Quality
Manual that may be reviewed in an effort to answer the associated ISO 9001 Questions in the Keene! Auditor’s
Companion.
Paragraph Quality Manual References
Page lll onA Manual
04/16/99 Iv 02014—0107 1 of 10
ISO 9001
ACR Quality Manual Cross Reference
Paragraph Quality Manual References
4.2.1
2— LI, 5.3, 5.4
2~5,6 7.1 3.1,9,1,1o.1 11.1 12.1
2.5.7L9,1,1_3._1
3—716, 7.1.8
04/16/ 99 N 02-QA-01-07 2 of 10
ISO 9001
ACR Quality Manual Cross Reference
Paragraph Qualhy Manual References
04/15/99 W 02-QA-01-07 3 of 10
ISO 9001
ACR Quality Manual Cross Reference
Paragraph Quality Manual References
5 - 7.1 7.1.20
5 —7.I.6. 7.1.7 7.1.20
5,_6&—711.6, 7.1.7 7.1.20
5 - 7.2.8. 7.2.1]
04/ 16/ 99 17 020140107 4 of 10
ISO 9001
ACR Quality Manual Cross Reference
Paragraph
4.5.3
Quality Manual References
5-7.1.2,7.1.6.7,1,7,7.1As,7.m
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6-5,l
6-5.1,2,5.I.4
4.62
4.63
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4.6.4.1
4.6.42
04/15/99 W 02-QA-01-07 5 of w
ISO 9001
ACR Quality Manual Cross Reference
Paragraph Quality Man-ml References
8 - 6.1,6.2,6.3.—1~0
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9—_ 7.1.7 7.3 7.3.2 7.3.5, 7.3.8
9 - 4.1.71], 7.3.2, 7.3.4, 7.3.5 7.3.6 7.3.8
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04/16/99 W 02~QA~OI~07 6 of 10
ISO 9001
ACR Quality Manual Cross Reference
Paragraph Quality Mann-l References
IO — 6.4. [, 6.4.2. 6.4.3, 6.4.4, 6.4.5.~ 6.4.6
10—6.4.6
10—6.1.19,6.1.ZO
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04/16/99 W 02»QA-OI-O7 7 of 10
ISO 9001
ACR Quality Manual Cross Reference
Paragraph
Quality Manual References
J—
IZ—S.—l-6.l
12 —5.—|—6.l,6.—I736.l.6
I24 .5, 6.1.6
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13 - 6,1,63
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14 -611.4‘ 6.1.8
04/16/99
o2-QA-ow7
Sofia
ISO 9001
ACR Quality Manual Cross Reference
Paragraph Quality Manual References
4.15.1
|5-5.4,5.5 5.6 5.3, 5.9, -5.10
15-5.1,5.9
15 - 5,5, 59, 5.10
15 -5,2, 5.5, 5.8, 5,9
[16-712, 7.1.4. 7.1.5, 7.1.6, 7.1.9
16-7.l.10
04/16/99 W mole-ow? 9 of m
ISO 9001
ACR Quality Manual Cross Reference
Paragraph Quality Manual References
l7-6,1,l
I7-6.l.l,6,|.3
17-6.1.ll
I7~6,I.IO
17-6.l.2, 6,1,3
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04/16/99 W 02~QA~01~O7 10 of 10
Subject: Sectio 01 Revis' I
MANAGEMENT RESPONSIBILITY Pages: 1 of 5 Date: 9-17-98
1.0 POLICY
1.1 ACR will deﬁne and document its policy for quality and will deﬁne the functions,
responsibilities and authorities of each of the organimtions Within ACR Electronics to
satisfy the corporate commitment to Quality. (1M2-2)
2.0 SCOPE
2.1 This procedures applies to the management staff of ACR Electronics, Inc.
3.0 REFERENCES
3.1 MlL-I—45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 01-MG-01-Ol Management Organizational Chart
3.4 Ol-QA-Ol -01 Quality Organizational Chart
3.5 Ol-EN-Ol-Ol Engineering Organizational Chart
3.6 01 -MF-01 -01 Manufacturing Organizational Chart
3.7 01-SM-01-01 Sales, Marketing & Customer Service Organizational Chart
3.8 01-FI-01-01 Finance Organizational Chart
3.9 Ol-PH-Ol-Ol Purchasing Organizational Chart
3.10 Ol-HR-Ol-Ol Human Resource Organimtional Chart
3.11 01 -TA-Ol -01 Technical Administration Chart
3.12 ANSI/ASQC Q9001-1994
3.13 The ISO 9000 Auditor’s Companion by Kent A. Keeney
4.0 STATEMENT OF AUTHORITY
4.1 ACR Electronics has developed a comprehensive Quality System that establishes control
of the product from Design to Delivery. The President of ACR has appointed the
Director of Quality Assurance as the management representative. The President of ACR
has delegated the responsibility and authority for ensuring full implementation of the
Quality System to the Director of Quality Assurance. The only person authorized to
overrule the Director of Quality Assurance is the President of ACR Electronics Inc.
[4.1.2.3A] [4.1.2.3B]
4.1.1 See Figure 01-MG-01-0l (lMZ-l) [4.1.2.1C] [4.1.21A] [4.1.2.lB]
Subject:
Section: 01 Revision: I
MANAGEMENT RESPONSIBILITY Pages: 2 of 5 Date: 9-17-98
5.0 RESPONSIBILITIES OF ADMINISTRATIVE MANAGEMENT [4.1.2.1A] [4.1.2.1B]
5.1
5.2
5.3
Management Reviews
5.1.1
5.1.2
5.1.3
The President of ACR is responsible for conducting management reviews at
deﬁned intervals. (a minimum of once per year) [4. 1 .3A] [4.1.3B]
Records of the meetings shall be maintained and utilized to ensure that the quality
system is still suitable and effective in meeting the requirements of the Q9001
standard, the quality policy and the objectives of ACR. [4.1.3C] [4.1.3D]
The President shall provide direction, give support and provide people and budget
for the management review program, and which will be used to evaluate the
effectiveness and efﬁciency of the Quality system, [4.1.3E]
Management and Department Heads are responsible for the following:
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
The documentation of company policies for quality. [4.1.1A]
Ensuring that the quality policy and supporting procedures/work instructions are
known and understood by staff at all levels. [4.1.1B]
Ensuring that the quality policy is relevant to ACR goals, expectations, and
customer needs. [4.1,1C]
The identiﬁcation and recording of any problems relating to the product, process
and quality system and for the notiﬁcation of the Director of Quality Assurance.
[4.1.2.lD-l] [4.1.2.lD-2]
The resolution of quality problems and the implementation of preventative
actions. [4,1.2.lD-3] [4.1.2.1D-4]
The adequate in-house resources for performing work and veriﬁcation activities
including internal audits. [4. l .2.2A]
The veriﬁcation and monitoring of activities such as the implementation of
inspection, product testing, and reviewing installation processes. [4.1,2.2B]
The Quality organization provides guidance, direction, and support to all functional
organizations in fostering an environment of procedural compliance, innovation, and
employee contributions, in an effort to satisfy the customer. (I Q1-3)
5.3.1
The Director of Quality Assurance is responsible for ensuring the creation,
performance, and maintenance of quality plans and procedures for all inspection
functions, supplier/vendor control, audits, non-conforming materials, corrective
and preventative actions, calibration, record retention, revision control, and
Subject: Section: 01 Revision: I
MANAGEMENT RESPONSIBILITY Pages: 3 of 5 Date: 9-17-98
distribution of the Corporate Quality Manual, and reporting to upper management
on these activities when appropriate at the management review meetings. The
Director of Quality Assurance has the authority to control ﬁrrther processing,
delivery or installation of non-conforming product until the deﬁciency or
unsatisfactory condition has been corrected The Director of Quality Assurance,
or designee, is also responsible for the Notiﬁcation System and Reporting
Requirements to the FAA including any changes to the Quality manual or to
Quality Management and for maintaining the integrity of the FAA production
approval certificate and it’s exhibit. The Director of Quality Assurance is
authorized to make changes to the Quality system and the FAA notiﬁcation
system with concurrence from upper management and the FAA representative
respectively.
(4M1,4M2, lC2-2,1Q2-2,1C1, 1M1)[4.l.2.3C] [4.1.2.3D] [4.1.2.1]
5.3.2 See Figure Ol-QA-Ol-Ol (ICI-l, lC2-l,1Q1‘2, lQ2—l)
5.4 The Engineering organization provides research, development, and product reliability
assessment to assure a continuous ﬂow of innovative products that meet customer
requirements and regulatory and corporate objectives. (lEl-2)
5.4.1 The Vice President of Engineering is responsible for ensuring the creation,
performance, and maintenance of Engineering plans and procedures for research
and development, product design, Engineering standards, drawing and change
control, documentation control, and reporting to upper management on these
activities when appropriate The Vice President of Engineering is also responsible
for notifying the FAA of any proposed major design changes to the FAA
approved design data and notifying the Director of Quality Assurance of this
occurrence The Vice President of Engineering is authorized to make changes to
the Engineering system with concurrence from upper management.
(1132-2, 1M1-1,2)
5.4.2 See Figure Ol—EN—Ol-Ol (1E1-1,1E2-1)
5.5 The Manufacturing organization provides the tools and processes for producing a
reliable product to approved design data, quality requirements, and speciﬁcations to
support corporate commitments and objectives. (1P1-2)
5.5.1 The Director of Operations is responsible for ensuring the creation, performance,
and maintenance of manufacturing plans and procedures for production planning,
inventory, material control, parts fabrication, test, receiving, shipping, factory
service, maintenance, custodial duties, safety, security, and reporting to upper
management on these activities when appropriate. The Director of Operations is
authorized to make changes to the Manufacturing system with concurrence from
upper management. (1P2-2, 1M1-l,2)
5.5.2 See Figure 01-MF-OI—01 (lPl-I, lP2-l)
Subject: Section: 01 Revision: I
MANAGEMENT RESPONSIBILITY Pages: 4 of 5 Date: 9-17-98
5.6 The Sales, Marketing, and Customer Service organization provides the deﬁnition of
new products, including quality, reliability, features, and customer repair, as a step in
satisfying the needs of our customers from conception to delivery, while expanding the
marketplace. (I S l -2)
5.6.1 The Vice President of Sales/ Marketing and Customer Service is responsible for
ensuring the creation, performance, and maintenance of plans and procedures for
market research, sales, commercial contracts, advertising, promotion, customer
service, and reporting to upper management on these activities when appropriate.
The Vice President of Sales, Marketing and Customer Service is also responsible
for notifying the Quality department of any FAA related product returns or
correspondence The Vice President of Sales, Marketing and Customer Service is
authorized to make changes to the Sales, Marketing and Customer Service system
with concurrence from upper management (182—2, 1M1-1,2)
5.6.2 SeeFigureOl-SM—Ol—Ol (18141, 182-1)
5.7 The Finance organization safeguards the assets of the corporation and monitors the
integrity of ﬁnancial transactions and records to provide the necessary direction and
support to all functional areas to ensure that the corporation’s ﬁnancial goals are
achieved.
5.7.1 The Controller is responsible for ensuring the creation, performance, and
maintenance of plans and procedures for cash management, credit and collections,
cost accounting, accounts payable, billing, material planning, communication
systems, computer systems, and reporting to upper management on these
activities when appropriate. The Controller is authorized to make changes to the
Finance system with concurrence from upper management. (lMl-l ,2)
5.7.2 See Figure 01-FI-01-Ol
5.8 The Purchasing organization provides a means of central communication with ACR
vendors to allow for cost negotiation, a clear understanding of Purchase Orders and
Contracts, including any changes that may follow, when ordering materials/ parts.
5.8.1 The Purchasing Manager is responsible for ensuring the creation, performance,
and maintenance of plans and procedures for planning/ forecasting, selecting the
vendor, material procurement, vendor rating, and reporting to upper management
on these activities when appropriate. The Purchasing Manager is authorized to
make changes to the Purchasing system with concurrence from upper
management. (1M 1-1 ,2)
5.8.2 See Figure Ol-PH-Ol-Ol
Subject: Section: 01 Revision: I
MANAGEMENT RESPONSIBILITY Pages: 5 of 5 Date: 9-17-98
5.9 The Human Resource organization provides guidance and support in maintaining a
qualiﬁed work force in an environment of goodwill, safety, ethics, and fair and unbiased
work practices in keeping with regulatory and corporate objectives.
5.9.1 The Director of Human Resources is responsible for the creation, implementation,
and administration of departmental policies and procedures The principal areas of
responsibility are employment, payroll, employee beneﬁts, compensation,
employee conununication, training, and legal compliance with regulatory
agencies. The Director of Human Resources is authorized to make changes to the
Human Resource system with concurrence from upper management. “Ml-1,2)
5.9.2 See Figure Ol-HR-Ol-OI
5.10 The Technical Administration Organization provides technical guidance and support
to maintain the competitive position of the company.
5.10.1 The Vice President of Technical Administration is also responsible for concept
deﬁnition, development of products, manufacturing tooling, automation
deﬁnition, development and control of offshore contract manufacturing.
5.10.2 See Figure Ol-TA-Ol»0[
Subject: Section: 02 Revision: I
QUALITY SYSTEMS Pages: 1 of 8 Date: 9-17-98
1.0 POLICY
1.1 ACR will establish the quality management principles and the structure of quality system
procedural elements of ACR Electronics The quality and reliability of the products! services
offered by ACR shall meet or exceed the expectations of our customers and our contractual
requirements. (lQI-l) [4.2.2A] [4.2.1A] [4.1.1A] [4.2.3.4] [42.13]
2.0 SCOPE
2.1 ACR’s quality system applies to, but is not limited to, all functions within ACR that affect
the quality of the goods or services provided.
3.0 REFERENCE
3.1 MIL-l-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 Work Instructions Matrix (02-QA-Ol-Ol)
3.4 ACSEP Cross Reference to QA manual (02-QA-01-02)
3.5 Documentation structure outline (Appendix I)
3.6 ANSI/ASQC Q9001-1994
3.7 The ISO 9000 Auditor’s Companion by Kent A. Keeney
4.0 RESPONSIBILITIES
4.1 The Management of ACR Electronics is committed to reaching the objectives and goals set
forth in this manual, and to provide the resources necessary.
4.2 The Director of Quality Assurance is responsible for ensuring the performance of the
activities described within this procedure.
5.0 QUALITY SYSTEM PRINCIPLES / STRUCTURE
5.1 The quality loop within ACR Electronics applies to interactions among marketing, design
engineering, product engineering, purchasing and procurement, process planning and process
Subject: Section: 02 Revision: I
QUALITY SYSTEMS Pages: 2 of 8 Date: 9-17-98
control, production and manufacturing, inspection and testing, packaging and storage, sales
and distribution, installation and technical support.
5.2 ACR Electronics quality assurance organization is responsible for ensuring the
implementation and maintenance of the Quality system. Upper Management is responsible
for establishing quality policies and for the implementation and maintenance of the quality
system
5.3 The structure for ACR documentation is outlined in Appendix 1 of this section. [4.2.1B]
5.4 Quality system procedures are maintained in the quality manual which is audited against the
applicable standards several times armually. [4.2.2A][4.2.1B] [4.2.1C]
5.5 Quality plans are generically addressed by the overall quality system documentation,
speciﬁcally the lower level work instructions [4.2.2A] [4.2.3A] [4.2.3B] [4.2.1C]
5.6 ACR shall have procedures for updating quality control, inspection, testing techniques,
development of new instruments and identiﬁcation of measurement requirements. [4.2.3C]
5.7 Measurement requirements shall be identiﬁed in sufﬁcient time for measurement techniques
to be developed prior to production. [4.2.3D]
6.0 QUALITY RELATED COSTS CONSIDERATIONS
6.1
The quality system shall include the recording of speciﬁc quality costs when required by
contract. The Director of Quality may use quality costs to determine areas that need
improvement and/ or track the effectiveness of speciﬁc changes to the quality system in
general. These costs may include the cost of prevention, appraisals, and failure. These
summaries may be analyzed by management and the quality organization to determine the
impact of these costs as they relate to the ability and responsibility of the company to meet its
quality objectives and maintain the economic well being of the company.
7.0 QUALITY IN MARKETING
7.1
To meet customer expectations, it is the responsibility of the marketing organization to
clearly evaluate, determine and communicate exactly what the customers are requiring and
expecting. Customer requirements are communicated by the preparation of a product brief.
Marketing, engineering, and quality shall cooperate in identifying quality requirements of all
new contracts at the earliest possible stage. The initial quality planning phase shall include
sufﬁcient research to identify any special testing or inspection required and to ensure
compatibility throughout manufacturing, inspection, and testing. The marketing element is
also responsible for timely communication of customer feedback to the appropriate people
within the organization. [4.2.3C]
Section: 02 Revision: I
Subject:
QUALITY SYSTEMS Pages: 3 of 8 Date: 9-17-98
8.0 QUALITY IN SPECIFICATION AND DESIGN
8,1
The Engineering organization ofthe company has the overall responsibility for translating
customer expectations communicated by marketing’s product brief into detailed technical
designs and speciﬁcations. This will enable the company to manufacture products and
provide services that comply with the customer and/or the contractual quality requirements at
an acceptable and competitive price. Product designs and speciﬁcations and their associated
processes shall be reviewed, tested and veriﬁed prior to production as an integral part of the
quality system. Qualiﬁcation and veriﬁcation of designs shall include evaluation of
performance, durability, safety, reliability and maintainability. Changes and/or modiﬁcations
to designs and speciﬁcations shall be controlled and approved by the Engineering and
Quality organizations. Engineering, with concurrence from Quality, shall issue detailed work
instructions for performing the work and establishing acceptable workmanship standards,
Quality shall verify that work instructions are properly used at all levels of the company and
that obsolete instructions and speciﬁcations are removed [4.2.3C]
9.0 QUALITY IN PROCUREMENT
9.1
The Purchasing and Quality organizations have the overall responsibility to ensure that all
raw material, assemblies and components integrated into the end product offered by ACR
Electronics are purchased/ procured only from approved sources who have demonstrated the
ability to consistently meet the quality required Purchasing and Quality shall conduct on-site
audits of vendors manufacturing parts to ACR drawings when economically feasible, shall
maintain a vendor’s folder to assess their capabilities and shall maintain a receiving
inspection program to further conﬁrm and document that all incoming material does in fact
comply with all quality requirements as well as to monitor vendor performance. The level of
receiving inspection is commensurate with the vendor performance and rating. The
Purchasing, Engineering and Quality organizations are responsible for providing suppliers
with clear documentation, speciﬁcations, drawings, and quality requirements. Vendors who
consistently fail to deliver required quality will be deleted from the approved supplier list.
Quality and Purchasing shall ensure that all applicable contractual requirements are
communicated to the suppliers, including the use of statistical methods and the use of an
adequate calibration program for all instruments and equipment used by the vendor/supplier.
When contractually required, Purchasing shall notify the vendor/ supplier that the purchase
order requires source inspection at the subcontractor’s plant by a Govemment/ customer
representative. Copies of purchase orders requiring source inspection shall be available to the
designated Govemment/customer representative [4,2.3C,D]
10.0 QUALITY IN PRODUCTION
10.1
All production and manufacturing shall be conducted under controlled conditions at all times.
Controlled conditions include control of raw material, equipment, processes, personnel and
environment. During production, the inspection status (acceptance/ rejection) shall be clearly
indicated. Clear work instructions prepared by Engineering stating the acceptance/ rejection
Subject:
Section: 02 Revision: I
QUALITY SYSTEMS Pages: 4 of 8 Date: 9-17-98
criteria are provided at all stages of the manufacturing and inspection process.
Nonconforming material shall be properly segregated to prevent intenningling with
conforming material. [4,2.3C,D]
11.0 CONTROL OF PRODUCTION
12.0
13.0
11.1
Conditions involving quality from raw material to ﬁnished product are controlled during the
entire manufacturing cycle to ensure conformity to all applicable speciﬁcations. Approved or
rejected products are clearly identiﬁed as to their inspection status. Process control and
equipment’s preventive maintenance are maintained to ensure continued process capabilities
The Engineering and Quality organizations control, review and approve any proposed
process changes and verify the effect such changes may have on the end product. When
manufacturing involves more complex processes, Quality shall ensure that more detailed
work instructions are issued and that proper personnel training or certiﬁcations are provided.
Quality is responsible for ensuring that only current instructions and speciﬁcations are used
in the production process, [4,2.3C,D]
PRODUCT VERIFICATION
12.1
The quality system shall provide three stages of product veriﬁcation beginning with receiving
inspection, followed by in-process inspection and completed product ﬁnal inspection and
testing. During each stage, the inspection status of each item shall be clearly indicated as to
conformance or nonconformance. The extent and level of product veriﬁcation is based upon
contractual and customer requirements. Should a product be found to be deﬁcient, and it was
reworked or repaired, it shall be fully reinspected and tested. [4.2,3C,D]
CONTROL OF MEASURING AND TEST EQUIPMENT
13.1
One of the most critical elements of the quality system is the continuous control of measuring
and test equipment used in product inspection, veriﬁcation and acceptance, Management
shall provide the resources necessary for quality to have adequate MT&E to perform product
veriﬁcation and acceptance Quality maintains an adequate calibration program, traceable to
the National Institute of Standards & Technology (NIST), to control all MT&E and insure
that all equipment is operated within speciﬁed tolerances A maintenance and traceability
program is implemented to eliminate the possibility that out of tolerance equipment is used.
A recall procedure is implemented so that in the event of out-of-tolerance conditions are
found, customers can be promptly notiﬁed and the product recalled if necessary. The Quality
organization shall make the necessary equipment and personnel available to Government or
customer representatives when ﬁnal inspection and acceptance is conducted at the company’s
plant or otherwise contractually required to do so. Furthermore, with DOD contracts, the
Director of Quality shall notify the Government representative immediately when a contract
requires precision measurements that exceed state of the art technology. [4.2.3D]
Subject:
Section: 02 Revision: 1
QUALITY SYSTEMS Pages: 5 of 8 Date: 9-17-98
14.0 NONCONFORMITY
14.1
The quality system shall provide an effective and positive method for the identiﬁcation and
segregation in a holding area of all nonconforming material and product awaiting disposition.
Upon detecting a nonconformity, Quality shall make a determination to rework, repair or
scrap the item in accordance with approved written procedures and such nonconforming
material shall be clearly identiﬁed and held in a holding area pending disposition When
contractually required, such rework/repair shall be approved by the appropriate
Govemment/customer representative and required documentation maintained
Nonconforrnities shall be documented and evaluated to prevent recurrence. Costs associated
with repair/ rework and scrap shall be documented and maintained for review by
management and Government! customer representatives.
15.0 CORRECTIVE ACTION
15.1
Upon detecting a quality problem and determining its importance, the Quality organization
shall take the necessary steps to request that the responsible organization within the company
take the necessary corrective action to prevent recurrence. Quality shall regularly appraise
management as to the status of corrective action and disposition of nonconforming material
and product. Each Corrective Action Request shall be investigated, documented and analyzed
by Quality and appropriate preventive action taken. Corrective actions shall be reviewed by
management and, when required, by the customer.
16.0 HANDLING AND POST-PRODUCTION FUNCTIONS
16.1
As part of the quality system, the Engineering and Quality organizations shall obtain and
maintain adequate procedures and issue speciﬁc work instructions to handle, store, identify,
package, clean, preserve, install and deliver accepted end products to maintain quality
integrity and prevent damage. Products in storage shall be periodically inspected to prevent
deterioration or damage Items with limited shelf life shall be monitored closely. Proper
instructions and procedures shall be provided for ﬁeld assembling, installation and use.
Marketing shall notify Quality of reports of product failure aﬁer delivery so that appropriate
action may be taken.
17.0 QUALITY DOCUMENTATION AND RECORDS
17.1
As part of its quality management program, ACR Electronics has established a procedure for
the identiﬁcation, collection, indexing, ﬁling. storage, maintenance, retrieval and disposition
of pertinent quality records essential to establish objective evidence of quality and the
integrity of the quality system. The Director of Quality shall have overall responsibility to
maintain quality records to be used in the effective management of the quality system.
Inspection records and work instructions shall indicate the quantitative degree of acceptance
Subject:
Section: 02 Revision: I
QUALITY SYSTEMS Pages: 6 of 8 Date: 9-17-98
and/ or rejection of product and workmanship. Company and Quality management shall
utilize these quality records in the evaluation of the effectiveness of the quality system.
Records shall be retained for periods consistent with customer/ contract requirements and
shall be made available to Government and/or customer representatives when contractually
required.
18.0 GOVERNMENT / CUSTOMER PROPERTY
19.0
20.0
21.0
18.1
The quality system shall provide for strict control of all Govemment/ customer furnished
material such as tooling, raw material, machinery, measuring and testing equipment. Upon
receiving such material necessary for the performance of a contract, the Quality organization
shall examine and inspect said material for damage and completeness. Periodic inspection
shall be conducted and adequate storage provided to prevent damage and/ or deterioration. As
required, functional testing shall be conducted to determine satisfactory operation. Detailed
inventory and condition reports shall be maintained and provided to the Govemment/
customer representative for review when requested. All Govemment/ customer fun-iished
material shall be used only for the speciﬁc contract or purchase order for which it is provided.
USE OF STATISTICAL METHODS
19.1
In achieving its quality goals and objectives, the company shall use modern statistical
methods in all phases of the quality loop. The Quality, Engineering, Production, Purchasing,
Human Resources and Marketing organizations within the company shall develop and utilize
statistical techniques appropriate to control and verify the quality of their work as it relates to
the quality of the end products manufactured by ACR Electronics. Contractually required
sampling plans shall be in accordance with, and approved by the Govemment/ customer
representative.
PRODUCT SAFETY AND LIABILITY
20.1
The quality system shall ensure the safety and reliability of its products by optimizing quality
during all phases of the manufacturing process. The objective is to ensure the safety of our
products’ users and reducing the product liability factor which could be detrimental to the
company. Quality, Engineering and Safety shall ensure that all products are in compliance
with all applicable safety standards.
PERSONNEL
21.1
Management recognizes the need for maintaining an adequate training program at all levels
as part of the company‘s quality system. New employees shall receive indoctrination into the
quality and safety policies and procedures of the company. When required, special
qualiﬁcation and! or certiﬁcation training shall be provided to comply with speciﬁcation and
Subject:
Section: 02 Revision: I
QUALITY SYSTEMS Pages: 7 of 8 Date: 9-17-98
customer requirements. ACR Electronics management further states its commitment to
providing proper motivation and quality awareness to its personnel as part of the quality
system.
22.0 COMMUNICATION WITH THE FAA
22.1
The Quality and Engineering departments shall maintain communication with the FAA in all
functions relating to the FAA including 24 hour notiﬁcation in the event of failures,
malfunctions, and/ or defects, and the approval of minor design changes to PMA and TSO
products, major design changes, including changes to manufacturing and special process
speciﬁcations, and proposed major design changes to PMA and TSO products, changes
resulting from the incorporation of AD’s (including the distribution of changes to
Instructions for Continued Airworthiness), and changes which may contribute to the safety of
the product. In the event that the approved manufacturing facility is relocated or additional
facilities are added at other locations or changes in the Quality management, the Quality
department shall notify in writing to the FAA, within [0 days. (2Cl ,2,3,4,5-14C4)
23.0 GLOBAL PRODUCTION
23. l
The Quality department will provide an interface quality document to any international
manufacturing facility contracted to produce a product for ACR Electronics and to he sold to
the FAA. Products manufactured by these facilities will be controlled and data collected to
evaluate their performance The quality department shall submit applications for all products
to be exported and a list maintained of the products receiving export airworthiness approvals.
All exported products shall meet the special requirements of the importing country and if
deviations are requested and approved, an annotation on the exporting documentation and the
letter of acceptance from the importing country shall be included. Airworthiness Approval
Tags and Export Certiﬁcates of Airworthiness shall be issued and copies retained by the
quality department. (16Q1,2,3,4)
24.0 CHANGES TO PROCEDURES
24.1
Changes to the following procedures / Work Instructions including drawings, shall be
processed in accordance with document control work instructions.
- Work Instructions
- Procedures
' Forms
' Drawings
Subject: Section: 02 Revision: l
QUALITY SYSTEMS Pages: 8 of 8 Date: 9-17-98
The ACR Documented System
The “What" is always at the top.
Corporate Quality Policy
Section Policies Every level below the Quality
— Manual glves greater detail
Quality regarding “How" we expect to
carry out the policies stated in the
Manual QM.
Appendix 1
Section 02
Quality System
Procedures
Work Instructions
Product Speciﬁc
Work Instructions
Subject: Section: 03 Revision: I
CONTRACT REVIEW Pages: 1 of 2 Date: 9-17-98
1.0 POLICY
1.1 ACR will provide a system for establishing the criteria used for reviewing contracts and all
documents associated with the goods and services that ACR provides. [4.3.1 A]
2.0 SCOPE
2.1 This procedure applies to all contracts requiring the sale of ACR products or services.
3.0 REFERENCES
3.1 MlL-I—45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 ANSI/ASQC Q900l-1994
3.4 The ISO 9000 Auditors Companion by Kent A. Keeney
4.0 DEFINITIONS
4.1 Bilateral Airworthiness Agreement (BAA): A Government to Government executive
agreement between the USA and the government of another country to facilitate the
airworthiness approval or acceptance of civil aeronautical products exported from one
country to another. BAA‘s are not trade agreements, rather they are technical cooperation
agreements, intended to provide a framework for the airworthiness authority of the importing
state to give maximum practicable credit to airworthiness certiﬁcation functions performed
by the airworthiness authority of the exporting state using its own domestic certiﬁcation
system.
4.2 FAA Export Airworthiness Approval procedures list all of the bilateral export agreements.
5.0 RESPONSIBILITY
5.1 The Vice President of Sales and Marketing is responsible for ensuring the performance of the
activities described within this procedure.
6.0 GENERAL
6.1 All contracts shall be reviewed at the earliest possible phase of customer interface.
Subject: Section: 03 Revision: I
CONTRACT REVIEW Pages: 2 of 2 Date: 9-17-98
7.0
PROCEDURE
7.1
7.2
7.3
7.4
7.5
Procedures shall be established which will incorporate the following criteria:
7.1.1 An established work team which should include Sales Managers, lead discipline
engineers, manufacturing managers, and a quality assurance representative. If the
contract content requires additional support such as product support, purchasing, or
scheduling they should also be part of the work team.
7.1.2 A detailed review of the scope of work to be accomplished.
7.1.3 All applicable speciﬁcations and standards are available and at the latest revision.
7.1.4 A check that all materials are available including the appropriate size and quantity.
7.1.5 A review of all test and inspection requirements, including the certiﬁcation process.
7.1.6 A review of manufacturing processes, including internal capabilities to meet accepted
tender, contract, and order requirements. [4.3.2A] [4.3.2D]
7.1.7 A review of the requirements for a Bilateral Airworthiness Agreement when
applicable.
7.1.8 The resolution of differences. [4.3.2A]
7.1.9 Acceptance of non-standard orders (verbal or documented). [4.3.2B]
7.1.10 The method of communication and interface with the customer for resolving
contractual matters. [4.3.4A]
Special/speciﬁc requirements shall be clearly identiﬁed and communicated to the
Engineering, Purchasing, Manufacturing and Quality organizations when applicable. (4P3)
Amendments to a contract or changes to a verbal order shall be communicated to the proper
departments and documented. [4.3.2C] [4.3.3A]
Records of contract reviews are maintained. [4.3.4B]
See Section 16 for the requirements of retention, maintenance, and storage of records.
[4.3.4.B]
1.0
2.0
3.0
4.0
Subject:
DESIGN CONTROL & REVIEW
POLICY
1.1
9-17-98
Section: 04 Revision'
Pages: 1 of 4 Date:
To establish and maintain procedures used for Design control and Design Review planning
from conception to delivery of the completed product.
SCOPE
2.1
This procedure applies to all ACR designed products.
REFERENCES
3.1
ACSEP 8100 (Appendix 6)
AD is a document issued by the FAA to the operator of the
equipment requiring corrective or preventive action of a known
or suspected deﬁciency.
The FAA design approval document for aircraﬁ, engines, and
FAA design approval for changes to TC’s as well as stand-
alone FAA design approval for aﬁer market equipment &
A production approval issued from the FAA to manufacturers
who produce parts, equipment, and components under the
design authority of a TC or STC either through direct
ownership of design or through a licensing agreement.
The FAA production approval issued to qualiﬁed
manufacturers of aircraft, engines, and propellers,
3.2 SECTION 05 (Documentation Control)
3.3 ANSI/ASQC Q9001-l994
3.4 The ISO 9000 Auditor’s Companion by Kent A. Keeney
3.5 MIL-I-45208A
DEFINITIONS
4.1 Airworthiness Directive-
4.2 Type Certiﬁcate (TC)-
propellers
4.3 Supplemental Type
Certiﬁcate (STC)-
components.
4.4 Pans Manufacturer’s
Approval (PMA)
4.5 Production Certiﬁcate (PC)-
4.6 Technical Standard Order-
TSO’s are FAA design speciﬁcations for speciﬁc equipment or
components.
Subject: Section: 04 Revision: I
DESIGN CONTROL & REVIEW Pages: 2 of 4 Date: 9-17-98
4.7 Technical Standard Order- A design and production approval for products designed in
Approval (TSOA) accordance with a TSO.
5.0 RESPONSIBILITY
5.1 The Vice President of the Engineering department is responsible for the performance of the
activities described in this procedure.
5.2 The Vice President of the Engineering department is responsible for ensuring that the
Engineering procedures are fully implemented and that speciﬁed requirements are met.
[4.4. 1 B]
6.0 GENERAL
6.1 The Engineering department is responsible for designing products that meet customer
requirements by using recognized industry design standards to meet known and defined
speciﬁcations.
7.0 PROCEDURE
7.1 ACR shall establish and maintain documented procedures to control and verify the design of
products in order to ensure that the speciﬁed requirements are met. These procedures are
available at all points ofuse. [4.4.1A] [4.4.1.3]
7.2 ACR shall prepare plans for each design and development activity. The plans shall describe
or reference these activities and deﬁne responsibility for their implementation. The design
and development activities shall be assigned to qualiﬁed personnel equipped with adequate
resources. The plans shall be updated as the design evolves. [4.4.2A,B]
7.3 ACR shall deﬁne technical interfaces between different groups which input into the design
process, and the necessary information documented, transmitted, and regularly reviewed.
[4.4.3ABCD]
7.4 Design-input requirements relating to the product, including applicable statutory and
regulatory requirements, shall be identiﬁed, documented, and their selection reviewed by
Engineering personnel supplier for adequacy. Incomplete, ambiguous, or conﬂicting
requirements shall be resolved with those responsible for imposing these requirements.
[4.4.4A,B]
Design input shall take into consideration the result of any contract-review activities.
[4.4.4C]
7.5 Design output shall be documented and expressed in terms than can be veriﬁed against
design-input requirements and validated. (see 7.8). [4.4.5A]
Subject: Section: 04 Revision: I
DESIGN CONTROL & REVIEW Pages: 3 of 4 Date: 9-17-98
7.6
7.7
7.8
7.9
7.10
Design output shall:
a) meet the design-input requirements;
b) contain or make reference to acceptance criteria;
0) identify those characteristics of the design that are crucial to the safe and proper
functioning of the product (e.g., operating, storage, handling, maintenance, and
disposal requirements.)
d) Complies with the appropriate regulatory requirements. [4.4.5B]
Design-output documents shall be reviewed before release. [4.4.5B]
At appropriate stages of design, formal documented review of the design results shall be
planned and conducted. Participants at each design review shall include representatives of all
functions concerned with the design stage being reviewed, as well as other specialist
personnel, as required Records of such reviews shall be maintained. (see section 16).
Note: see 710 for more on design review [4.4.6A,B]
At appropriate stages of design, design veriﬁcation shall be performed by competent
personnel to ensure that the design-stage output meets the design-stage input requirements,
including safety consideration, compatibility of facilities and validation of soﬁware. The
design—verification measures shall be recorded (see section 16). [4.4.7 A,E,F,G]
In addition to conducting design review, design veriﬁcation may include activities such as
performing alternate calculations, comparing the new design with a similar proven design, if
available, undertaking tests and demonstrations, and reviewing the design—stage documents
before release. These activities shall be controlled and recorded. [4.4.7 B,C,D]
Design validation shall be performed to ensure that product conforms to defined user needs
and/or requirements.
- Design validation follows successful design verification.
- Validation is normally performed under deﬁned operating conditions,
- Validation is normally performed on the ﬁnal product, but may be necessary in earlier
stages prior to product completion.
- Multiple validations may be performed if there are different intended uses. [4.4.8A]
All design changes and modiﬁcations shall be identiﬁed, documented, reviewed, and
approved by authorized personnel before they are implemented. [4.4.9A,B]
ACR shall provide procedures for design review using the following criteria:
7.10.1 Identiﬁcation of Airworthiness Directives incorporated into the FAA approved
design, when applicable (2E4)
7.10.2 Design changes which affect the content of Instructions for Continued Airworthiness
are incorporated into the FAA approved design, when applicable. (2155)
Subject: Section: 04 Revis' n: I
DESIGN CONTROL & REVIEW Pages: 4 of 4 Date: 9-17-98
7.10.3 The Type Certiﬁcate process must be completed prior to submitting a Supplemental
Type design for approval, (ZEIO)
7.10.4 A method to provide for the incorporation of Airworthiness Directives when
applicable (13El)
7.10.5 A method to provide for the identiﬁcation, tracking, and compliance to Airworthiness
Directives and for fumishing the customer with AD status when the product is
delivered (13131)
7.11 Records:
7.11.1 See Section 16 for the requirements of retention, maintenance, and storage of records.
Subject: Section: 05 Revision: I
DOCUMENT CONTROL Pages: 1 of 6 Date: 9-17-98
1.0 POLICY
1.1 ACR will provide a system for establishing the method used for the maintenance, retention,
distribution, retrieval, and storage of the Drawings and Document Control functions.
2.0 SCOPE
2.1 This procedure applies to all documents and data that relate to the requirements of the ACR
quality system, including, to the extend applicable, documents of external origin such as
standards and customer drawings.
3.0 REFERENCES
3.1 MIL-I—45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 04 (Design Review)
3.4 SECTION 06 (Purchasing)
3.5 SECTION 16 (Records)
3.6 ANSI/ASQC Q9001-1994
3.7 This ISO 9000 Auditor’s Companion by Kent A. Keeney
4.0 DEFINITIONS
4.1 Major Design Change— Has a signiﬁcant effect on the weight, balance, stmcrural
strength, reliability, operational characteristics, or other
characteristics affecting the safety (airworthiness) of the
product,
4.2 Minor Design Change- Any change which is not considered a Major change.
4.3 Technical Data Package- A package that might include drawings, technical
speciﬁcations, technical instructions, test instructions, soﬁware,
and any other related technical data,
4.4 External Documents- Any documents developed externally to ACR such as customer
drawings, quality standards, etc.
Subject: Section: 05 Revision: I
DOCUMENT CONTROL Pages: 2 of 6 Date: 9-17-98
5.0
6.0
7.0
RESPONSIBILITY
5.1 The Vice President of the Engineering department is responsible for the performance of the
activities described in this procedure.
5.2 The Vice President of Engineering is responsible for ensuring the control of supplier design
data and all changes. (lOEl)
5.3 The Director of Operations is responsible for ensuring that the manufacturing department
reviews all design and technical data changes. (2Pl)
5.4 The Director of Quality Assurance is responsible for ensuring that the quality department
reviews all design and technical data changes. (2Ql)
5.5 The Vice President of Sales and Marketing is responsible for ensuring that the Customer
Service department reviews all design and technical data changes when applicable. Changes
to instructions for airworthiness will be made available to the appropriate personnel.
(2S 1)(2$2)
GENERAL
6.1 Under no circumstances shall a drawing or document be released for production without the
documented approval of the Change Control Board (CCB) [4.5.2A]
PROCEDURE
7.1 Procedures shall be established for the Control of Drawing and Document Changes
(including external documents) incorporating the following requirements:(2E2)[4.5.1A]
7.1.1 A method which will identify/document intended design documentation changes,
including design changes. (2El-A1) [4.5.3C]
7.1.2 A description of the change approval cycle. (2El-A2) [4.5.23] [4.5.3A] [4.5.3B]
7.1.3 Personnel identiﬁed who are authorized to approve changes. (ZEl-AZ)
7.1.4 To deﬁne a method for appropriately documenting and approving changes to
technical data, speciﬁcations, installation instructions, and airborne soﬂware
documentation. (2E3)
7.1.5 A method for classifying design changes as either Minor or Major. (2E8)
7.1.6 All drawings/ documents shall be identiﬁed using an established system to ensure
adequate. complete, accurate, and legible documentation,
(2E2-Al.2) [4.5.13] [4.5.2A] [4.5.3A] [4.5.35]
Subject:
Section: 05 Revision: 1 1
DOCUMENT CONTROL Pages: 3 of 6 Date: 9-17-98
7.1.7
7.1.8
7.1.9
7.1.10
7.1.11
7.1.12
7.1.13
7.1.14
7.1.15
7.1.16
7.1.17
There shall be an indication of drawing, document, and data approval. including FAA
approval when applicable, for ensuring adequacy by authorized personnel prior to
issue. (252-143) [4.5.3.4] [4.5.33] [4.5.1A] [4.5.2A] [4.5.15]
All Manufacturing/ lnspection procedures! work instructions shall be controlled with
a revision level and continuing sequentially with each approved change and a record
kept ofthe current revision levels and changes. (9E2, 4Pl) [4.5.3A] [4.5.3B]
All deliverable product Test procedures shall be approved and controlled through the
Change Control Board (CCB) system. (8132, SP], 8Q1)
Documents which are used to enhance the procedures/work instructions i.e.: tags,
forms, etc, are to have samples and instructions available for use. Any changes to
these documents shall be controlled and documented through Document Control.
(1Q5)
Manufacturing! Inspection process procedures and work instructions shall be
evaluated and approved by manufacturing, quality, and engineering as a minimum to
verify that the required steps, including tests, are taken to conﬁrm that the approved
design data and all related technical specifications including Airworthiness
Directive’s (if applicable) can be accomplished for product quality. Any changes to
the documents aﬂer the approval must be resubmitted.
(9Q3, 9131, 4P1, 492, 4P3, 4132) [4.5.3A] [4.5.33] [4.5.3c1 [4.5.3D]
Any design changes made as a result of AD incorporation or improvements which
contribute to the safety of the product shall have the descriptive data and infon-nation
available to all users of the product. (283)
A deﬁned method of identifying minor design changes which is approved by the
FAA. (2C1)
A deﬁned method of handling major design changes, including process speciﬁcation
changes, changes resulting from AD‘s, and changes made to contribute to the safety
of the product, which is submitted to the FAA for approval. (2C2)
If changes are made to established procedures for distributing changes to the FAA
regarding Instructions for Continued Airworthiness, these procedural changes shall be
submitted to the FAA for approval. (2C3)
Procedures provide for the type of data to be submitted to the FAA when minor
changes are made to the TSO article, these procedures agree with the part number
speciﬁed in the original application. (2C4)
Procedures provide for assignment of a new type or model designation to the changed
article and for prompt application for a new TSO authorization as a result ofa major
design change to the original TSO, (2C5)
Subject:
Section: 05 Revision: l
DOCUMENT CONTROL Pages: 4 of 6 Date: 9-17-98
7.2
7.3
7.1.18 A master list for all forms, drawings, documented procedures and work instructions,
including the associated current revision. [4.5i3D][4.5.3E]
7.1.19 Procedures provide for use of special processes identiﬁed and documented in
FAA approved design data. (SEl .Al)
7.1.20 External documents shall be reviewed, approved, and controlled. [4.5.1A] [4.5.2A]
Procedures shall be established which will provide for a system of controlling the issuance,
distribution, and retrieval of all drawings, changes, and technical design data incorporating
the following requirements: (2E7) [4.5.2B]
7.2.1 Responsibility for design and technical data document control. (2E7-A 1)
7.2.2 Control of, and persons authorized to obtain documents, including the retrieval of
obsolete documents (2E7—A2)
7.2.3 A method for notifying employees of changes in technical data or drawings. (2E7-A3)
7.2.4 Veriﬁcation that correct documents are in use for the product being produced.
(2E7-A4)
7.2.5 Current design and technical data document distribution lists. (257-A5)
7.2.6 A method of controlling the issuance and distribution of design changes. (2131 -A3)
7.2.7 All drawings/ documents shall be maintained and secured. (2E2-A4)
7.2.8 A system for allowing only current drawings to be in use. (2E2-A5) [4.5.2C]
7.2.9 List of drawings and speciﬁcations to deﬁne conﬁguration of the FAA approved
design. (2E2-A6)
7.2.10 Control of preliminary/ experimental drawings. (2E2-A7)
7.2.11 Obsolete documents retained for legal preservation are suitably identiﬁed. [4.5.2C]
Procedures provide for the Control of Software incorporating the following
requirements:
7.3.1 Integration of soﬁware with hardware to specify a unique version for incorporation
into the product (2E2-A8)
Subject:
Section: 05 Revision: I
DOCUMENT CONTROL Pages: 5 of 6 Date: 9-17-98
7.3.2 Combination of soﬁware for more than one processor within one product. That
combination of soﬂware with associated hardware permits the speciﬁcation of a
unique version for incorporation into the product. (2E2-A9)
7.3.3 Cross-reference of soﬁware documents to their associated soﬁware. (2E2-A10)
7.3.4 Soﬂware veriﬁcation methods that permit veriﬁcation of the soﬁware conﬁguration in
the completed product. The drawing control system includes software identiﬁcation
methods at the media level and at the product level. The media level identiﬁcation is
incorporated into the software, and the product level identiﬁcations are marked on the
outside of the product indication soﬁware conﬁguration. (2E2-Al 1)
7.3.5 Changes to speciﬁcations and installation instructions are appropriately documented
and approved, when applicable. (2E3-1)
7.3.6 Identiﬁcation of software for an application. (3BE1-l)
7.3.7 Control of approved versions for product acceptance. (3BEl-2)
7.3.8 Control of obsolete and non-current soﬂware. (3BE1-3)
7.3.9 Identiﬁcation of software with a Software Conﬁguration Identiﬁcation. (3BE1-4)
7.3.10 Procedures provide for a method to change and approve product acceptance software,
providing a record showing reason for change, revisions to the software, approvals,
and effectivity. (3BE2-1)
7.3.11 A method for reporting, tracking, and resolving software-related product acceptance
problems.
(3353)
7.3.12 Methods for the control of product acceptance soﬂfware to prevent unauthorized
changes and limited access to software ﬁles, (3BE4-1,2)
7.3.13 A method for keeping separate archives for masters and duplicates, and that masters
and duplicates are not available for corruption in the same machine at the same time.
(3354.3,4)
7.3.14 An independent means to verify product acceptance soﬁware, and subsequent
revisions, to ensure that it accomplishes its intended function. (3BQ1-l)
7.3.15 A method of verifying software/ ﬁrmware/ hardware is capable of discriminating
between good and bad parts or assemblies. (3BQl-21)
7.3.16 A formal means of identifying approved product acceptance software. (3BQl-3)
Subject: Section: 05 Revision: l
DOCUMENT CONTROL Pages: 6 of 6 Date: 9-17-98
7.3.17 Conﬁguration control of the product acceptance software as it relates to the product
being accepted. (3BQ1-4)
7.4 Records:
7.4.1 All design documents (including magnetic media, if applicable), shall be stored,
maintained, and protected to preserve their integrity (2E6)
7.4.2 A complete and current ﬁle of technical data, including design drawings and
speciﬁcations shall be established and maintained. (2129)
7.4.3 See Section 16 for the requirements of retention, maintenance, and storage of records.
1.0
2.0
3.0
4.0
Subject' Section: 06
PURCHASING Pages: 1 of 4
POLICY
1.1 ACR will provide a system to control, maintain, and document the procurement of materials
and parts, and for the evaluation and control of suppliers and subcontractors to meet the
approved design data, speciﬁcations, and contractual requirements as applicable for all ACR
products. [4.6. l A]
SCOPE
2.1 This procedure applies to all ACR products.
REFERENCES
3.1 MIL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 10 (Inspection & Test)
3.4 SECTION 16 (Records)
3.5 SECTION 17 (Audits)
3.6 ANSI/ASQC Q9001-1994
3.7 The ISO 9000 Auditor’s Companion by Kent A. Keeney
RESPONSIBILITY
4.1 The Purchasing Manager is responsible for ensuring the performance of the activities
described in this procedure,
4.2 The Purchasing Manager is responsible for ensuring that the Quality Director is notiﬁed of
any communication with a vendor/ supplier regarding quality related issues. (10Q7)
4.3 The Purchasing Manager is responsible for ensuring that the Purchase Order documents are
submitted to quality for review and approval prior to issue. (I 0Q6)
4.4 The Purchasing Manager is responsible for ensuring that the supplier/ vendor is notiﬁed of
any forthcoming survey/ audits and making arrangements for the visits.
4.5 The Purchasing Manager is responsible for ensuring that a clause stating Govemment/
Customer source inspections required is on the Purchase Order when requested by the
Government / Customer and that all documents are available for review and copies available
when requested. [4.6.4.2A]
Subject:
5.0
4.6
4.7
4.8
4.9
Section: 06 Revi ’
PURCHASING Pages: 2 of 4 Date:
9-17-98
The Director of Quality Assurance is responsible for ensuring that the Purchasing Manager is
notiﬁed of any planned Supplier Quality System Survey/ Audits.
The Director of Quality Assurance is responsible for reporting to the FAA of any:
1. Delegation of authority to suppliers to perform major inspections of products/ parts.
2. New suppliers located in other countries and of their ﬁrst articles upon receipt.
3. Authorizations for suppliers from other countries to direct ship. ( 10C], 10C2, 10C3)
The Director of Quality Assurance is responsible for ensuring the notiﬁcation of the
Govemment / Customer representative of defects found at source and for coordinating the
flow of the corrective action through the supplier/ vendors and Government / Customer
representative.
The Vice President of Engineering is responsible for ensuring the control of supplier design
data and all changes through the use of speciﬁcation and source control drawings. (lOEl)
PROCEDURE
5.1
Control of Purchased Material shall be accomplished by the Selection and Control of
suppliers using the following established criteria: [4.6.2A]
5.1.1 Initial and periodic evaluations of suppliers to detem'iine their capability to meet
requirements. (lOQ 1 -1)
5.1.2 Methods established for determining the extent of evaluations, dependent on the type,
complexity, method of control, and importance of products or services procured, and
provide for on-site evaluation, process reviews, document reviews, or independent
product evaluations. (10Q1-2) [4.6.2B]
5.1.3 Implementing and documenting effective corrective action when deficiencies are
found. (10Ql-3) [4.6.2B]
5.1.4 Criteria is established for supplier acceptability, based as a minimum on evaluation
results and quality performance history for the commodities or services provided.
(1002-1) [4.6.2B]
5.1.5 Suppliers quality performance data shall be collected, evaluated and reported on.
(10Q2-2)
5.1.6 A list shall be created and maintained for all suppliers who have been reviewed and
evaluated and found to be acceptable which shall include the suppliers name, address,
telephone numbers, fax numbers, name of contact person, list of the products or
services they have been approved to supply, the quality level at which they were
approved, the country, and dates of the last and next audits, when applicable.
(1002-145)
Subject: Section: 06 Revision: I
PURCHASING Pages: 3 of 4 Date: 9-17-98
5.1.7 A method of procurement shall be established for suppliers that require special
control. (10Q2-6)
5.1.8 Suppliers of sub tier sources that were evaluated by ACR, shall be ﬁlmished a current
list of approved suppliers. (10Q2-7)
5.1.9 Procedures shall provide a method for reviewing and approving a priority part
supplier’s quality system data. (10Q3)
5.1.10 The following technical data and quality requirements shall be included in the
purchase documents as applicable:
1. Special processing speciﬁcations/ engineering requirements for suppliers
performing special processing.
2. Calibration traceable to a national standard and submittal of certiﬁcates for
suppliers performing calibration services.
3. Software speciﬁcation requirements for suppliers providing software.
4. Submittal of certification test reports for shipments of raw material.
5. Identiﬁcation of raw and process material in accordance with industry and/or
customer speciﬁcations.
6. Appropriate identiﬁcation and marking of products and pans.
7. Identiﬁcation of the actual manufacturers of the supplies provided by
warehouses and distributors.
8. Delegation of authority for major inspections or material review (see Section
13)
9. Authorization and requirements for direct shipment when applicable.
10. Supplier shipping document requirements for direct shipment shall include:
1. Declaration that pans were produced under the terms of the production
approval.
2. Identiﬁcation of the product on which the part is eligible for
installation.
11. Special packaging and preservation requirements, when warranted for material
protection.
12. Identiﬁcation of appropriate technical requirement revision levels.
13. Notice of FAA review of supplier's facilities and products as necessary.
14. Incorporation of design changes as speciﬁed.
15. Notiﬁcation to the evaluated facility of any latent defects in products or parts
previously supplied.
16. A formalized SQC policy when required.
17. Requests for copies of control charts and other pertinent statistical data
applicable to the time period during which the supplied product! parts were
produced
18. Submittal of supplier design and changes to the evaluated facility for approval
prior to incorporation, when required.
19. Submittal of changes to a supplier’s quality system that may affect inspection.
conformity, or the airworthiness of the product.
Subject:
Sectio
PURCHASING Pages: 4 of 4 Date: 9-17-98
5.2
5.3
5.4
5.5
20. Record retention requirements.
21. Use of the English language for quality data e.g., supplier quality procedures.
certiﬁcates, reports, or other similar data as required by ACR. (lOQS) [4.6.3A]
Purchasing Data:
5.2.1 Purchasing documents should provide speciﬁcations or other design data in the detail
necessary to procure articles or services that meet approved design data. [4.6. lA]
5.2.2 Purchasing documents shall be reviewed and approved for adequacy of speciﬁed
requirements prior to release. Quality will document that the review was successfully
completed. [4.6.3B]
Veriﬁcation of Purchased Product:
5.3.1 See Section 10 Inspection & Testing [4.6.1A]
5.3.2 When applicable the method of product release from the subcontractors premise shall
be documented in the purchase document and the veriﬁcation of the product
speciﬁed. [4.6.4.1A]
5.3.3 None of our customers specify visits to our subcontractors, however, should a
customer specify to visit our subcontractors in their contract it would be coordinated
in accordance with Section 3, Contract Review. [4.6.4.2A] [4.6.4.2B]
5.3.4 ACR is responsible for providing an acceptable product even in the event our
customer veriﬁes our processes and or our product at our facility or our subcontractor
facility. [4.6.4.2C]
Direct Shipment from Suppliers:
5.4.1 The authority to direct ship will be based on past performance over a predetermined
length of time, or quality source inspection. Direct ship will not be allowed at the
beginning of a program.
5.4.2 Each FAA part which is direct shipped must be accompanied by a shipping ticket,
invoice, or other document containing a declaration that the individual part was
produced under the production approval and is authorized to direct ship.
5.4.3 See parat 5.1.10, number 10, for shipping documents data requirements.
Records
5.5.1 See Section 16 for the requirements of retention, maintenance, and storage of records.
Subject: Section: 07 Revision: 1
CUSTOMER SUPPLIED PROPERTY Pages: 1 of 2 Date: 9-17-98
1.0 PURPOSE
1.1 ACR will provide a system for the inspection, storage, and maintenance of Government or
Customer furnished property.
2.0 SCOPE
2.1 This procedure applies to all customer/govemment furnished property/material.
3.0 REFERENCES
3.1 MIL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 1 1 (Calibration)
34 SECTION 13 (Nonconforming Material)
3.5 SECTION 16 (Records)
3.6 ANSI/ASQC Q9001-1994
3.7 The ISO 9000 Auditor’s Companion by Kent A. Keeney
4.0 RESPONSIBILITY
4.1 The Director of Quality Assurance is responsible for ensuring the performance of the
activities described within this procedure.
4.2 The Director of Quality Assurance is responsible for ensuring the availability of all records to
the Government or Customer upon request.
5.0 PROCEDURE
5.1 Receipt of Government or Customer fumished property shall be inspected and veriﬁed by
the following requirements: (10Q4) [4.7A]
Note: For GFP the government QAR will be notiﬁed prior to inspection.
Subject:
Seetio
CUSTOMER SUPPLIED PROPERTY Pages:
5.2
5.3
5.4
5.5
l. The Materials shall be examined for damage during transit.
2. The Material shall be examined for completeness and proper type.
3. The Materials shall be examined for proper identiﬁcation.
4 The quantity of the Materials shall be veriﬁed.
5A The Materials shall be functionally tested if contractually required
6. The Materials shall be examined for conformance to FAA design data (if applicable)
7. The Materials shall be identiﬁed prior to storage,
8. The Materials shall be properly protected when stored.
Storage of Government or Customer furnished property shall be controlled following the
criteria listed below: [4.7A]
1. Stored Materials shall be examined periodically to detect any signs of deterioration,
mishandling, shelf life limitations, and assure maintenance of storage conditions.
2. Stored Materials shall be protected from unauthorized use.
Prior to installation or use of Government or Customer furnished property the following
requirements shall be considered:
1. Does the contract or speciﬁcations require functional testing prior to installation or
use?
2. Does the contract or speciﬁcations require functional testing after installation or use?
3. Does the contract or speciﬁcations require functional testing prior to and after
installation or use?
Damaged, lost or unsuitable Govemment or Customer fumished property shall be recorded to
include the probable cause, and the Government or Customer notiﬁed. [4,7B]
5.4.1 See Section 13 for nonconforming material procedures.
See Section 16 for the requirements of retention. maintenance, and storage of records.
Subject: Section: 08 Revision: I
PRODUCT IDENTIFICATION
AND TRACEABILITY Pages: 1 of 4 Date: 9-17-98
1.0 POLICY
1.1 To provide guidelines for the systematic approach with respect to the identiﬁcation and
traceability of materials/ products from receipt through delivery. [4.8B]
2.0 SCOPE
3.0 REFERENCES
3.1 MIL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 09 (Process Control)
3.4 SECTION 15 (Handling, Storage, Packaging, Preservation, and Delivery)
3.5 SECTION 16 (Records)
3.6 ANSI/ASQC Q9001-1994
3.7 The ISO 9000 Auditor’s Companion by Kent A. Keeney
4.0 RESPONSIBILITY
4.1 The Director of Operations is responsible for ensuring the performance of the activities
described in this procedure,
4.2 The Director of Operations is responsible for ensuring the creation and maintenance of
documentation which will fulﬁll the manufacture, inspection and test product identiﬁcation
and traceability requirements.
4.3 The Vice President of Engineering is responsible for ensuring the preparation and distribution
of guidelines for the interpretation and application of approved data, standards, and
speciﬁcations to the manufacturing of a product. (4El)
5.0 GENERAL
51 All materials / products / parts shall be identiﬁed from receipt of acceptance through
installation (if applicable), using tags, travelers/ work orders, or markings directly on the part
to identify the material / product / part by part number, or date code, and Quality acceptance.
5.2 Whenever possible serial numbers should be applied as early as possible in the build cycle
for traceability to a work order, tag, traveler, etc.
Subject:
6.0
PRODUCT IDENTIFICATION
AND TRACEABILITY Pages:
Section: 08 Revision: I
2 of 4 Date: 9-17-98
5.3 The Part number is referenced by the associated drawing.
PROCEDURE
6.1 Product Identiﬁcation shall be incorporated and maintained using the following
criteria: [4.8A]
6.1.1 All products shall be identiﬁed with a part number, revision level, or date code and
6.1.2
6.1.3
6.1.4
6.1.5
indication of quality acceptance as a minimum.
Parts shall be identiﬁed by one of three methods.
1. Pan number, date, QC acceptance stamp directly on the product.
2. Part number, date, QC acceptance stamp on a tag attached to the part. ‘(tags
to be removed by authorized quality personnel only)
3. Part number, date, quantity and/ or serial number, QC acceptance stamp
applied to the work order/ traveler, or QC card.
Products manufactured under a PMA (Parts Manufacturer Approval) shall be
permanently marked with the following information: (4P9-5)
1. Part Number
2. Letters FAA-PMA
3. Name of the holder of the PMA.
4. Name and model designation of Type-Certiﬁed product on which the part is
eligible for installation,
5. Indication of inspection acceptance,
Products manufactured under a TSO (Technical Standard Order) shall be identiﬁed by
the following information: (4p9.4)
Name and address of the manufacturer.
Name, type, part number, or model designation of the product.
Serial number or date of manufacture of the product, or both.
TSO number.
Indication of inspection acceptance.
meson-or
All identiﬁcation marking on parts shall be veriﬁed for accuracy and legibility prior
to stock or delivery to customer. (4P9-BZ)
Subject:
6.2
6.3
Section: 08 Revision: I
PRODUCT IDENTIFICATION
AND TRACEABILITY Pages: 3 of 4 Date: 9-17-98
6.1.6 All critical components are permanently and legibly marked with a part number (or
equivalent), and a serial number (or equivalent). (4P9-6)
6.1.7 Identiﬁcation of complete and accepted products in accordance with approved design
and quality data requirements. (4P9-bl)
In-Process Identiﬁcation shall be incorporated and maintained using the following
criteria: [4.8A]
6.2.1 Shall include predetermined areas of inspection based on the types of process being
employed to manufacture the product.
6.2.2 Any step required in the manufacture of a product that will inherently cover up a
previous step shall constitute an inspection step.
6.2.3 All manufacture and inspection steps shall be referenced to a specific product or lot
by part number, revision, serial number or quantities on tags or work order/ travelers.
6.2.4 Nonconforming material must be indicated on the identiﬁcation documentation
referencing the MRN number for indication of status.
6.2.5 Appropriate inspection marking shall be accomplished for products and parts
throughout the manufacturing cycle including acceptance, rejection, nondestructive
test processes, etc.. (4Q10)
Product Traceability shall be incorporated and maintained using the following criteria:
[4.8A]
6.3.1 The most common method of traceability is the Part Number and Serial Number
combination. Date codes and batch numbers are also used for traceability when
narrowing down the time period in which the product was manufactured. This may
include the shop order the product was associated with during the build cycle,
[4.8C,D]
6.3.2 Engineering will determine when a date code or serial number is required on the
product, and document this appropriately. [4.8B]
6.3.3 Serial Numbers shall be applied to all applicable documentation for a direct link to
the products.
6.3.4 If the product is too small for permanent identiﬁcation, a tag may be used and applied
to the packaging of the product. *Note-For FAA deliverables this method must be
approved by the FAA prior to implementation.
6.3.5 This paragraph has been intentionally leﬂ blank.
Subject:
6.4
Section: 08 Revision: I
PRODUCT IDENTIFICATION
AND TRACEABILITY Pages: 4 of 4 Date: 9-17—98
6.3.6
6.3.7
6.3.8
6.3.9
Nonconforming material must be documented by part number and serial number (if
applicable) on the nonconforming material reports.
Split lot traceability must be maintained for accountability of the product through the
completion of manufacturing and inspection operations, including accountability for
shortages and overages as successive operations are performed. (4P8)
Should ACR be required to provide traceability beyond the standard Quality system,
it shall be identiﬁed in assembly records. (4Q8)
Products requiring traceability shall be documented to allow for traceability from the
completed part to issue of raw material through the marking of the parts and record
keeping requirements. (4Q9-l,2)
6.3.10 Provisions shall be made for the handling of rejected and scrapped traceable pans.
(4Q9-3)
Records
6.4.1
See Section 16 for the requirements of retention, maintenance, and storage of records.
Subject: Section: 09 Revision: I
PROCESS CONTROL Pages: 1 of 5 Amd. Date: 10-15-98
1.0
2.0
3.0
4.0
5.0
POLICY
1.1 To provide a system for the identiﬁcation and planning of production processes which
directly affect quality, and to ensure these processes are carried out under controlled
conditions. [4.9A,E]
SCOPE
2.1 This procedure applies to all manufacturing processes used to build ACR products.
REFERENCES
3.1 MIL-I—45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 08 (Product Identiﬁcation and Traceability)
3.4 SECTION 10 (Inspection and Test)
3.5 SECTION 16 (Records)
3.6 AN SI/ASQC Q9001-1994
3.7 The ISO 9000 Auditor’s Companion by Kent A. Keeney
DEFINITION
4.1 Special Processes - Where the results of processes cannot be fully veriﬁed by subsequent
inspection and testing of the product and where, for example, processing deﬁciencies may
become apparent only aﬁer the product is in use, the process shall be carried out by qualiﬁed
operators and/or shall require continuous monitoring and control of process parameters to
ensure that the speciﬁed requirements are met, for conﬁrmation of acceptability of the ﬁnal
product, [4.9G]
RESPONSIBILITY
5.1 The Director of Operations is responsible for ensuring the performance of the activities
described in this procedure
5.2 The Director of Operations is responsible for ensuring the creation and maintenance of
documentation which will fulﬁll the inspection and test product acceptance criteria
(4P2) [4,9B]
Subject: Section: 09 Revision: I
PROCESS CONTROL Pages: 2 of 5 Amd. Date: 10-15-98
5.3 The Director of Operations is responsible for ensuring that all process changes are approved
and controlled by authorized personnel, (4P1) [4.9B]
5.4 The Vice President of Engineering will be responsible for distributing guidelines interpreting
the applications of design data to the manufacturing and quality departments to support them
in generating accurate procedures/ work instructions when applicable. (4El)
5.5 The appropriate Engineering personnel shall provide for veriﬁcation/ testing of new or
changed manufacturing processes to ensure the process will produce what the design
requires. (4E2)
6.0 GENERAL
6.1 All processes which employ multiple steps to manufacture an ACR product, or directly affect
the quality of, will be deﬁned in a work instruction to beneﬁt the overall manufacturing/
inspection/ test system in evaluating, improving, and identifying products which are
produced at ACR Electronics. [4.9A, D]
6.2 The instructions may be generic or detailed depending on the contractual requirements, but
must allow for inspection steps prior to assembly which would cover up previous work.
[4.9D]
6.3 All cleaners, solvents, and other ﬂuids used in the work area shall be identiﬁed and in the
case of misuse of a chemical on a product, the product shall be submitted to the MRB. (4Q6)
7.0 PROCEDURE
7.1 The creation of manufacturing work instructions shall include the following criteria:
7.1.1 The work instructions shall reﬂect the approved technical data including the
appropriate revision level, speciﬁc requirements, etc, and any purchase order
requirements if applicable. (4P3)
7.1.2 The work instructions shall adequately control the manufacturing process which
includes the following: [4.9C]
1. The function to be performed.
2. The sequence of operations.
3. Inspection points. [4.9D]
4. Accept] reject criteria.
5. Tools. gauges, and inspection equipment.
Subject:
PROCESS CONTROL Page
7.1.3
7.1.4
7.1.5
7.1.6
7.1.7
Section: 09 Re sion: 1
3 of 5 Amd. Date: 10-15-98
6. The drawing number and revision level.
7. Workmanship criteria.
8. Inspection methods.
9. Tolerance limits.
10. Environmental conditions.
11. Sampling plans.
12. Special drawing notes.
13. Whether or not skilled (certiﬁed) personnel is required.
14. Any special precautions for critical product protection.
15. Part marking and identiﬁcation, and part stamp location requirements, when
deﬁned by approved data. (4P4) [4.9C,D,G]
The work instructions shall be reviewed, approved, controlled, and documented,
including a system to control changes, and temporary changes, and the number of
revisions allowed before incorporation. (4P5) [4.9B]
The manufacturing employees must be familiar with the speciﬁcations affecting the
jobs they perform and have them available for use. (4P6)
Special identiﬁcation and control methods for parts which are introduced into
production prior to full acceptance from incoming inspection. To be used for “critical
need" only. (4P7)
The work instructions may be individually written for the different types of
applications as described below (7.1 ,7), but must include provisions for indicating
acceptance or rejection of the product at any given process. (5Q4) [4.9D,E]
The written work instructions will generate records which will provide as a minimum:
nature and number of observations [4.9E]
number and type of discrepancies found
lot identity and size
sample sizes (if applicable)
corrective action (if applicable)
results of inspection and tests for ﬁrst production conﬁguration articles
inspection/ test product acceptance
in~process inspection steps
”HFV'PP‘PP‘
Subject:
7.2
7.3
Section: 09 Revi ' : l
PROCESS CONTROL Pages: 4 of 5 Amd. Date: 10-15-98
9. ﬁnal impaction acceptance
10. periodic inspection and controls of tools used for inspection
11. test data directly traceable to the material, parts or products tested (4Q5)
12. complete and continuous monitoring of special processes (5Q4) [4.9D,E,F]
Routine Processes:
7.2.1 Daily processes used to manufacture products include but are not limited to:
Solder techniques
Component preparation and installation
Wire preparation (cutting, stripping, timing)
Pot-ting, RTV, Epoxies (shelf-life)
Mechanical assembly (loctite, torque)
Marking
Packaging
Cleaning and Pre—cleaning methods
Pﬂ95hPPP'."
7.2.2 There should be an indication of inspection status that relates to each of these
processes determined by the contractual requirements or speciﬁcations. [4.9E]
7.2.3 The identiﬁcation and monitoring of environmental conditions and the responsibility
for enforcing these conditions shall be recorded. (4Q7)
Special Processes shall be identiﬁed, deﬁned, and detailed in process speciﬁcations:
7.3.1 Special processes used to manufacture products might include but are not limited to:
[4.9F,Cv]
1. Welding
2. Anodizing
3. Painting
4. Ultrasonic
7.3.2 Special processes need speciﬁc detailed work instructions prior to being used in the
manufacture of the product. (5E1) [4.9F]
73.3 Equipment and environmental conditions must be closely monitored when using
special processes.
713.4 Tools, and equipment must be identified and available for controlling and monitoring
special processes. (SQI) [4.9G]
7.3.5 Periodic review of processes to qualify them including the equipment, and ensure
speciﬁcation compliance. These qualiﬁcations are documented and maintained.
(SQZ) [4.9E,F,G]
Subject:
Section: 09 Revision: 1
PROCESS CONTROL Pages: 5 of 5 Amd. Date: 10-15-98
7.4
7.5
7.6
7.3.6 Periodic review of personnel certiﬁcations to ensure qualiﬁed operators are
performing special processing tasks. (5Q2) [49,6]
7.3.7 Completion of all requirements listed in process speciﬁcations. (5Q3-1)
7.3.8 Criteria for distinguishing between acceptable and unacceptable products.
(5Q3-2) [4,9,F,G]
7.3.9 Control of monitoring equipment and/ or personnel when physical inspection of
processed material is impossible or disadvantageous. (5Q3-3)
7.3.10 Personnel is assigned inspection approval authority. (503-4)
7.3.11 Corrective action is taken when a process is found to be out of control. (5Q5-1)
7.3.12 An investigation is implemented to ensure the acceptability of products produced
while the process was out of control. (5Q5-2)
7.3.13 A corrective action is implemented as a result of the analysis of trends in process, to
prevent nonconforming material. (5Q5-3)
Supplier Processes:
7.4.1 All suppliers, manufacturing products for ACR, will be approved or disapproved
based on quality and delivery, and/ or evaluation of the following:
The speciﬁc process.
Equipment condition and capability.
Personnel training and abilities.
Records indicating the above criteria.
PPN!‘
7.4.2 For suppliers that are not easily accessible, it is recommended that a minimum of a
capabilities folder and a Quality survey, or Quality Manual, be kept on ﬁle in the
Quality department.
Preventive Maintenance
7.5.1 Equipment used to manufacture ACR products shall be properly maintained in an
effort to reduce deterioration or the potential cause of nonconforming product.
[49]
Records
7.6.1 See Section 16 for the requirements of retention, maintenance, and storage of records,
Subject: Section: 10 Revision: I
INSPECTION & TEST Pages: 1 of 7 Date: 9-15-98
1.0 POLICY
1.1 ACR will provide a system for the inspection and testing of a product to verify that it conforms
to the approved design, speciﬁcations, and contractual requirements.
2.0 SCOPE
2.1 This procedure applies to all ACR products. For products manufactured external to ACR only the
ﬁnal inspection and test methods apply.
3.0 REFERENCES
3.1 MlL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 12 (Inspection and Test Status)
3.4 SECTION 16 (Records)
3.5 SECTION 18 (SQC)
3.6 SECTION 20 (Training)
3.7 ANSUASQC Q9001-l994
3.8 The ISO 9000 Auditor’s Companion by Kent A. Keeney
4.0 RESPONSIBILITY
4.1 The Director of Quality Assurance is responsible for ensuring the performance of the activities
described in this procedure.
4.2 The Director of Quality Assurance is responsible for ensuring that the quality department
reviews test instructions and procedures.
(8Q1)
4.3 The Director of Operations is responsible for ensuring the creation and maintenance of
documentation which will fulﬁll the inspection and test product acceptance criteria.
(4P2)
4.4 The Director of Operations is responsible for ensuring that the manufacturing department
reviews test procedures and instructions prior to release to ensure that the product can be tested
in conformity to FAA approved design: (8Pl)
Subject: Section: 10 Revision: 1
INSPECTION & TEST Pages: 2 of 7 Date: 9-15-98
45 The Vice President of Engineering is responsible for ensuring the preparation and maintenance of
Test procedures and instructions. (8E1)
4.6 The Vice President of Engineering is responsible for ensuring that the engineering department
reviews inspection processes to ensure conformance to approved design data, including FAA
approved design data, and/ or purchase order requirements if applicable. (9E1)
5.0 GENERAL
5.1 The inspection/ test records generated will be used by the Quality department with support from
associated departments to evaluate the inspection/ test system to determine if adjustments need to
be made in an effort to produce a more reliable product and efficient system. (1Q7)
5.2 Statistical sampling plans will be based on minor, major, and critical product characteristics
which will be identiﬁed by speciﬁcations in the approved design data. (6Q1)
5.3 Materials that are to be used for deliverable products shall be inspected and documented at
incoming inspection. [4.10.2.3A]
6.0 PROCEDURE
6.1 Procedures and/ or instructions for inspection shall include the following requirements:
6.1.1 Inspection/testing processes shall be documented and controlled, so as to verify that
speciﬁc requirements for products are met. (9132) [4.10.1B] [4.l0.lA] [4.10.5A]
6.1.2 Inspectors shall have qualiﬁcation testing prior to issuance of stamps and be requaliﬁed
on a predetermined schedule. (9Q1-1,2)
6.1.3 Inspectors shall have a vision test and be retested on a predetermined schedule. (9Ql -3)
6.1.4 Inspectors shall provide identiﬁcation of the various levels of qualiﬁcations and various
levels of expertise. (9Ql-4)
6.1.5 Inspectors shall be qualiﬁed by authorized personnel only. (9Q1-5)
6.1.6 Identiﬁcation and notiﬁcation when requaliﬁcation and vision tests are required and
documentation of the employee’s qualiﬁcation. (9Q1-6,7)
6.1.7 Appropriate deceniﬁcation methods for operators failing to maintain qualiﬁcations.
(9Ql-8)
6.1.8 Only qualiﬁed operators may conduct tests and interpret the results, or write test reports.
(9Q2)
6.1.9 Inspection personnel shall use controlled and detailed methods of inspection for each area
of application. (9Q3)
Subject: Section: 10
INSPECTION & TEST Pages: 3 of 7
6.1.10 Tanks and solutions shall be sampled on a periodic basis to ensure compliance with
operating speciﬁcations (9Q4)
6.1.11 Test pieces and samples shall adequately reﬂect the part conﬁguration. (9Q5-l)
6.1.12 Test pieces and samples containing minimum size anomalies, as required, that would
cause rejection of the part, as applicable. (9Q5-2)
6.1.13 A method of identifying samples with known defects to prevent their introduction into the
production system. (9Q6)
6.1.14 Special holding ﬁxtures to facilitate inspection methodology, if necessary. (9Q7-3)
6.1.15 The selection of solutions that will preclude rust or corrosion. (9Q7-l)
6.1.16 The retention of protective covers on parts, such as caps, plugs, plates, etc., while in the
inspection process and to reinstall the protective covers once the inspection is complete to
prevent contamination, damage, or corrosion. (9Q7-2)
6.1.17 Acceptance/ rejection criteria shall be coordinated with the approved design data, or FAA
approved design data or PAH, if applicable. (9Q8-1)
6.1.18 Additional review of marginal inspection results by authorized personnel prior to
acceptance. (9Q8-2)
6.1.19 The use of acceptance/ rejection criteria during inspection to identify non-conforming
material. (9Q8-3) [4.10.3D]
6.1.20 Control of the revision level and removal of obsolete acceptance/ rejection criteria.
(9Q8-4) [4.10.3D]
6.1.21 The identiﬁcation of personnel authorized to review and update acceptance/ rejection
criteria. (9Q8-6)
6.1.22 The implementation of a corrective action and an investigation to ensure continued
acceptability of products accepted while an inspection process was out of control. (9Q10)
6.1.23 The location and type of inspection stations shall be identiﬁed and established. (4Q2)
6.1.24 In determining the amount and nature of Receiving/inspection ACR shall take into
consideration the amount of control exercised at the subcontractors location and the
recorded evidence of conformance available. This consideration shall also take place
prior to product release verifiCation. [4.10.2.2A] [4.10.2.3B]
Subject: Section: 10 Revision: I
INSPECTION & TEST Pages: 4 of 7 Date: 9-15-98
6.2 Instructions for test/inspection shall include the following requirements:
6.2.1 Preparation and maintenance of test/inspection instructions applicable to the products/
parts produced to ensure that each article conforms to the approved design data, and FAA
approved design data when applicable. (8E1) [4.10.1B] [4.10.1A] [4.10.5A]
6.2.2 Changes to test/inspection instructions are approved and controlled by authorized
personnel. (8E241) [4.10.1A]
6.2.3 Review and veriﬁcation of test/inspection instruction changes to ensure speciﬁc
requirements for products are met. (8E2-3) [4.10.1A]
6.2.4 Requirements for changing test/inspection procedures and instructions and
documentation of the change history by authorized personnel. (8E2-2,4)
6.2.5 The identiﬁcation of inspection/test points that ensure conformity to the approved design
data, and FAA approved design when applicable. (8Q1-la)
6.2.6 Inspection/test equipment is available to verify conformity to approved design, including
FAA approved design when applicable, and which can be controlled for accuracy, when
required. (8Q1-l b)
6.2.7 Only approved quality personnel to authorize additions, deletions, or changes to
inspection points in the test/inspection instructions or procedures, based upon inspection
results. (8Ql —2)
6.2.8 Products/ parts which have been adjusted or reworked after test acceptance shall be
retested/reinspected to approved procedures when the rework or adjustment could have an
impact on the performance of the products/ pans. (8Q4)
6.3 Incoming Inspection and Testing shall be accomplished incorporating the following
requirements:
6.3.1 New suppliers of ACR designed products will have ﬁrst article inspections and tests
performed prior to acceptance to ensure requirements are met. (10Q10) [4.10.2.1A]
6.3.2 Incoming materials which are accepted must be identiﬁed or segregated from items not
inspected. (IOQl 1) [4.10.2.2B]
6.3.3 Raw material (including process material) will be examined using statistical data, test
reports, Certiﬁcate of Conformance (C of C), veriﬁcation of identiﬁcation, shelf-life.
approved design data, speciﬁcations, and contractual requirements as applicable to ensure
conformance to speciﬁed requirements. (lOQS, 10Q9, lOQIO) [4.lO,2.lA]
6.3.4 Materials found to be nonconforming shall he segregated and identiﬁed to be evaluated
by the Material Review Board for disposition. [4.10223]
Subject: Section: 10 Revision: 1
INSPECTION & TEST Pages: 5 of 7 Date: 9-15-98
6.3.5 A Corrective Action will be addressed when a nonconfonnance is found during incoming
inspection and is submitted to the Material Review Board (MRB) for disposition. A
follow-up on the corrective action taken will be performed (lOQl)
6.3.6 Materials received which require additional testing out of the scope of incoming
inspection shall be submitted to the Test department or Engineering. The Test
department or Engineering will return the materials along with the acceptance data aﬂer
performing the tests.
6.3.7 Records shall be generated to contain the information from the criteria included in this
procedure. Records shall contain as a minimum per product or material inspected:
nomenclature, part number, supplier name, date accepted! rejected, inspector, lot size,
sample size, number of inspections made, conformance or nonconformance quantity,
description of non-conformances, and action taken. (10Q12)
6.3.8 Any incoming products released for urgent production purposes shall be identiﬁed and
recorded, for traceability, to enable a recall and replacement due to non-conformance to
speciﬁed requirements A sample will be held for incoming inspection to verify product
conformance. [4.10.2.3A]
6.4 In-process Inspection and Testing shall be performed incorporating the following
requirements:
6.4.1 ln-process inspection will involve all steps taken to manufacture a product after the
material is accepted through incoming inspection. As a rule, in-process inspection shall
be performed when a particular characteristic cannot be veriﬁed at ﬁnal inspection, such
as: prior to closing an area, prior to application of a surface treatment or covering, prior
to bonding processes, during torque veriﬁcations, or any other instance in which later
discovery could have an adverse effect on the quality or safe operation of a product.
[410.313]
6.4.2 Documentation which defines the responsibility for compliance to approved
design/technical data and for determining the appropriate inspection methods, attributes/
characteristics. (4Ql-1,2) [4.10.3B]
6.4.3 Physical inspection and process control methods whenever either method alone is not
capable of determining the quality of parts. (4Ql -3) [4.10.3B]
6.4.4 Controls of the manufacturing system when physical inspection of parts is impossible.
(4Ql-4) [4.10.3B]
6.4.5 ln-process inspection at points where accurate determinations can be made.
(4Ql-5) [4.10.33]
Subject:
Section: 10 Revision: l
INSPECTION & TEST Pages: 6 of 7 Date: 9-15-98
6.5
6.6
6.4.6
6.4.7
6.4.8
Inspection work instructions shall be evaluated and approved by manufacturing, quality,
and engineering as a minimum to verify that the required steps, including tests, product
identiﬁcation/veriﬁcation are taken to conﬁrm that the product conforms to the approved
design data and shall not be released until all inspection/test documentation has been
completed. Records of inspection shall be maintained. (903, 9131, 4Pl, 4P2, 4P3,
4E2) [4.10.3A,B] [4.1013C]
Periodic samples of tank solutions to ensure compliance to operating speciﬁcations.
(9Q4)
During inspection products are handled in such a way as to prevent damage, corrosion,
contamination, foreign objects, etc. (9Q7)
Final Inspection and Test shall be performed incorporating the following requirements:
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6
Final inspection shall verify that all previous inspections and tests are complete and have
been accepted and documented providing evidence of product passing inspection and/or
test. Inspection records shall be kept for this activity.
(4Q12) [4110.4A] [4.10.4B][4.10.5A]
All Final inspection and test criteria shall be planned and documented to ensure they meet
speciﬁed requirements and to preclude the shipping of ﬁnished product until all
inspection/test activities are completed. [4.1014A] [4.10.4B] [4.10.4C] [4.]0.5A,B]
All assemblies shall have been inspected prior to closure to verify that no foreign objects
have been entrapped in the assembly. (4Ql 1-1)
Veriﬁcation that parts or assemblies which have been reopened, disassembled, or
tampered with aﬁer established inspection and test points, have been re-inspected and
tested if required. (4Q11-2)
Inspection and/or test parameters will be clearly deﬁned to ensure compliance of product
speciﬁcations. [4.10.5B]
Only Inspectors shall be authorized for release of product. Records shall be kept for this
activity. [4110.5C]
Records: [4.10.5A,C]
6.6.1
6.6.2
All records generated shall be legible, accurate, and complete.
Inspection records shall be generated and maintained to accurately reﬂect compliance
with speciﬁcation requirements and shall include the following criteria:[4.l0.5A] (9Q9)
1. The contents of each record used.
2. Record legibility, completeness, and accuracy.
Section: 10 Revision:
INSPECTION& TEST Pages: 7 of 7 Date: 9-15-98
Subject:
3 Acceptance of material.
4 Inspector responsible for each area of test.
5. Date of acceptance.
6 Lot or serial number.
6.6.3 Qualiﬁcation records for inspectors shall include the following criteria as applicable:
Level of certiﬁcation.
Educational background and experience.
Statement of satisfactory completion of training‘
Results of most recent visual acuity examination.
Actual grades obtained in each examination.
Percentile weight assigned to each examination.
Composite grade of all examinations.
Date of certiﬁcation or recertiﬁcation, or both.
Signature of examiner
Pwsowewwr
6.6.4 See Section 16 for the requirements of maintenance, retention, and storage of records.
Subject: Section: 11 Revision: I
1.0
2.0
3.0
4.0
MEASURING AND TEST
EQUIPMENT CALIBRATION Pages: 1 of 5 Date: 9-17-98
POLICY
1.1 ACR will establish and maintain documented procedures to control, calibrate and maintain
all inspection, measuring and test equipment. including test soﬁware, that is used to
demonstrate the conformance of its products to the speciﬁed requirements. This includes
control of the facilities, handling, storage, and environment. [4.11.1A]
SCOPE
2.1 This procedure is only applicable to measuring and test equipment used to demonstrate
conformance to speciﬁed product requirements.
REFERENCES
3.1 MIL-l-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 MIL-STD-45662
3.4 SECTION 16 (Records)
3.5 AN SI/ASQC 09001-1994
3.6 The ISO 9000 Auditor’s Companion by Kent A. Keeney
RESPONSIBILITY
4.1 The Director of Quality Assurance shall be responsible for the performance of the activities
described within this procedure.
4.2 The Director of Quality Assurance shall be responsible for ensuring that the Engineering
department is involved in the selection of precision measuring devices used in fabrication,
inspection, and test. (7131)
4.3 The Vice President of Engineering shall be responsible for notifying the Quality Director
when tools or equipment are designed for use in the manufacture of products. (7E1)
4.4 The Vice President of Sales, Marketing, and Customer Service is responsible for participating
in the investigations of signiﬁcant out-of-tolerance conditions involving quality or safety.
(751)
Subject: Section: 11 Revision: 1
MEASURING AND TEST
EQUIPMENT CALIBRATION Pages: 2 of 5 Date: 9-17-98
5.0 GENERAL
5.1 All tools and gauges used for product acceptance shall be approved, inspected, and
calibrated.
5.2 All calibration shall be performed by qualiﬁed, authorized personnel only. (7Q2—4)
5.3 Inspection, measuring and test facilities, including test hard/software, shall be safe—guarded
from adjustments that would invalidate calibration settings. [4.1 1.26]
6.0 PROCEDURE
6.1 Measurement Methods and Standards shall be incorporated into the Calibration
methodology as follows: [4.11.20]
6.1.1 All calibrations are traceable to the National Institute of Standards and Technology,
or a recognized national standard, and if no standard exists the basis for calibration is
documented, (7Q4) [4.11.2B]
6.1.2 Standards used for calibration have an accuracy rate of at least 4 times more better
than the calibrated gauge. (7Q5)
6.1.3 A list of measurement devices and test equipment used to determine conformity of
characteristics being inspected. Including details of equipment type, identiﬁcation
numbers, location, check frequency, check method along with procedures that deﬁne
the process. (7Q2-1) [4.11.2C]
6.1.4 Precision measuring devices that are used for fabrication shall be selected for their
accuracy to determine the design criteria including determinations of adjustments and
tool wear. (7P1)
6.1.5 Methods established to identify, eliminate. or adjust measurement errors that may
contribute to variability. (7Q1-1)
6.1.6 Establishment of the accuracy of all measurement devices prior to initial use. (7Q1-3)
6.1.7 Provisions for the inspection and testing of equipment and tooling used for the
acceptance of drawing characteristics, (7Q2)
6.1.8 Calibration methods for each measurement device and standard which includes
acceptance criteria and action to be taken when results are unsatisfactory.
(7Q2-2) [4.11.18]
6.1.9 The degree of accuracy of all measurement devices and test equipment. (7Q7~l)
Subject: Section: 11 Revision: I
MEASURING AND TEST
EQUIPMENT CALIBRATION Pages: 3 of 5 Date: 9-17-98
6.2
6.3
6.1.10 Measurement devices and test equipment capable of the accuracy necessary and
adequate for the intended purpose including measurement devices and test equipment
substituted for those specified. (7Q7-2) [4.1 1 .2C]
The requirements for the identiﬁcation of equipment shall be incorporated as follows:
6.2.1 Procedures provide for the inclusion of personally owned gauges used for product
acceptance and identiﬁed in a unique method. (7Q8-l ,2)
6.2.2 Tools which are used in the production cycle as a means of acceptance are included in
the calibration system, have accurate and repeated use of product acceptance prior to
use, assigned unique identiﬁers, and have available current applicable tool drawings.
(7Q11)
6.2.3 Unique identiﬁcation of individual measurement devices and standards to provide
traceability to the calibration records. (7Q14-l) [4.1 1.2A] [4.1 IAZD]
6.2.4 Methods provide for standards, inspection tools, gauges, instruments, and jigs that are
inaccurate or beyond the scheduled calibration cycle are identiﬁed and precluded
from use until rework or recalibration is accomplished. (7Q16)
Scheduling requirements shall be incorporated as follows: [4.11.2F]
6.3.1 Periodic inspection and calibration of all measurement devices at predetermined
intervals, or just prior to use. (7Q1-3)
6.3.2 Assignment of calibration schedules to all measurement devices. (7Q1-4)
6.3.3 Establishment of initial calibration intervals and allowable conditions for adjusting
the intervals (7Q1-5)
6.3.4 Procedures provide for periodic calibration of instrumentation used for controlling
and monitoring special processes and for the generation and maintenance of records.
(7Q9)
6.3.5 Periodic calibration of NDI (Non-Destructive Inspection) equipment, if used. and the
generation and maintenance of records. (7Q10-l)
6.36 When applicable, measurement of black light intensity on a periodic basis (preferably
daily) using a calibrated black light meter, (7Q10-2)
6.3.7 When applicable, measurement of white lights on a periodic basis using a calibrated
White light meter. (7Ql0-3)
Subject:
Section: 11 Revision: l
MEASURING AND TEST
6.4
EQUIPMENT CALIBRATION Pages: 4 of 5 Date: 9-17-98
6.3.8 Interval schedules are adjusted based on analysis of previous calibration results, wear,
stability, purpose, and degree of usage. (7Q13)
A recall system shall be established using the following criteria: [4.1 1.2F]
6.4.1 A documented mandatory recall system (7Q3- 1)
6.5
6.6
6.7
6.4.2 Control of measurement devices and standards that are overdue for calibration
(703-2)
The Indication of Calibration Status shall incorporate the following requirements:
6.5.1 Indication of calibration status of measurement devices and standards and use of
status for monitoring adherence to calibration intervals. (7Q14-2,3) [4.11.2A]
[4.1 l.2D]
6.5.2 Procedures provide appropriate methods for rework of measurement devices and
standards, and include sufﬁcient reinspections to ensure accuracy (7Ql9) [4.1 1.2.F]
Environmental controls shall be established using the following criteria: [4.1 1.2E]
6.6.1 Procedure for the environmental controls, standards, and equipment to be used.
(7Q2-3)
6.6.2 The identiﬁcation of environmental conditions that are necessary for use and
calibration of measurement devices and standards and the appropriate use of this
equipment which might affect accuracy, stability, or calibration such as temperature,
relative humidity, vibration, electrical interference, cleanliness, or other controllable
factors. (7Q6-l ,2)
6.6.3 Compensating corrections to calibration or measurement results obtained in an
environment that departs from acceptable conditions. (7Q6-3)
SOT (signiﬁcant out-of-tolerance) conditions shall be met as follows: [4.11.2B,F]
6.7.1 A determination of what constitutes a significant out-of-tolerance (SOT) condition,
and the degree of uncertainty contributed to the measurement by a signiﬁcantly out-
of—tolerance device or standard, not to exceed 25% of the allowable tolerance.
(7017)
6.7.2 Procedure provides for documenting signiﬁcant out-of-tolerance conditions and
investigating the validity of previous measurements, (7Q18—1)
6.7.3 Notiﬁcation of signiﬁcant out-of-tolerance conditions to the user of the measurement
device or standard. (7Q18-2)
Subject: Section: 11 Revision: 1
MEASURING AND TEST
EQUIPMENT CALIBRATION Pages: 5 of 5 Date: 9-17-98
6.8 Handling! Storage: [4.11.2E]
6.8.1 Methods for handling, transporting, and storing measurement devices and standards
to ensure accuracy and reliability, and an established corrective action procedure to
determine the adverse effects of mishandling, (7Q15) [411 1.215]
6.9 Records: [4.11.2D]
6.9.1 Certiﬁcates, reports, or data sheets verifying accuracy of all calibration standards.
(7Q5-3)
6.9,2 Records are generated and maintained on all equipment with the content including as
a minimum:
1. Nomenclature
2. Serial Number
3. Location
4. Details of all adjustments
5. Repair or rework accomplished
6 Calibration history
7. Source and date next inspection is due
8. Legibility, completeness, and accuracy (7Q12)
6.9.3 See Section 16 for the requirements of retention, maintenance, and storage of records.
Subject: Section: 12 Revision: I
INSPECTION AND
TEST STATUS Pages: 1 of 3 Date: 9-17-98
1.0 POLICY
1.I ACR will provide a system for indicating the status of inspection and test criteria and
verifying the location of the inspection/ test in reference to the manufacturing build process.
2.0 SCOPE
2.1 This procedure applies to all products being manufactured at ACR.
3.0 REFERENCES
3.1 MlL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 08 (Product Identiﬁcation and Traceability)
3.4 SECTION 09 (Process Control)
3.5 SECTION 10 (Inspection & Testing)
3.6 ANSI/ASQC Q9001-1994
3.7 The ISO 9000 Auditor’s Companion by Kent A. Keeney
4.0 RESPONSIBILITY
4.1 The Director of Quality Assurance is responsible for ensuring the performance of the
activities described in this procedure.
4.2 The Director of Operations is responsible for ensuring the creation of documentation for the
series of steps necessary to build a product by part number in a controlled and sequential
method for the purpose of identifying the manufacturing build process and status of
inspection and test,
5.0 GENERAL
5.1 Procedures shall be created describing the controlled and detailed method of inspection/ test
for all areas of application. (9Q3)
5.2 Inspection/ test stamps shall be issued to qualiﬁed, authorized personnel only. (4Q3, 9Ql)
5.3 Inspection records will be used by the Quality department with support from associated
departments to evaluate the inspection/ test system to determine if adjustments need to be
made in an effort to produce a more reliable product and efﬁcient system. (lQ7)
Subject: Section: l2 Revision: I
INSPECTION AND
TEST STATUS Pages: 2 of 3 Date: 9-17-98
6.0 PROCEDURE
6.1 An indication of inspection/ test status shall be accomplished by using a controlled sequential
documented method that ensures accurate and positive identiﬁcation throughout the
manufacturing process. This method shall include, but is not limited to the requirements as
described in this procedure: (4Q10(2)) [4.12AB]
6.1.1 inspection marking methods shall consist of the following as a minimum:
1. Inspection marking that ensures conformance to FAA approved design data, or
purchase order requirements if applicable (4Q10(l)
2. Assurance that inspection stamps do not damage material. (4Q4)
3. Positive identiﬁcation throughout the manufacturing process. (4Q10(2)
6.1.2 Acceptance/ rejection criteria shall be used during the inspection/ test process and the
following requirements apply: (9Q8«3)
L Coordinate with the FAA, or PAH as applicable. (9Q8—I)
2. Identiﬁcation of personnel authorized to review and update criteria. (9Q8-5)
1 Identiﬁcation of personnel authorized to review marginal results. (908-2)
4 Control of the revision level and removal of obsolete criteria. (9Q8—4)
5. Samples with known-defects used for rejection criteria are identiﬁed. (906)
6. Test pieces and samples reﬂect the part conﬁguration (9Q5(l))
6.1.3 Prior to ﬁnal inspection the following criteria applies:
1. All inspections and tests shall be completed and documented. (4Q12)
2. All assemblies shall be inspected prior to ﬁnal closure. (4Q1 1( 1)
3. All assemblies which have been reopened, disassembled‘ or tampered with after
an inspection shall be reinspected. (4Q11(2)
6.1.4 To maintain a reliable inspection, test, and manufacturing environment the following
methods apply:
1. Periodic samples of tank solutions to ensure compliance with operating
speciﬁcations and the timely processing of lab reports to ensure “out of control”
conditions are responded to immediately during the inspection/ test cycle. (9Q4)
2. Solutions are selected to preclude rust or corrosion. (9Q7)
3. Caps, plugs, or plates used to protect parts/ assemblies during the manufacmring
process are reinstalled aﬂer the inspection or test process is completed. (9Q7(2)
4. Special holding ﬁxtures are available to facilitate inspection methodology if
required (9Q7(3)
6.1.5 Product that has not passed the required inspections/tests shall be documented and
processed per Section 13 (Non-Conforming Materials) [4.12C]
Subject: Section: [2 Revision: 1
INSPECTION AND
TEST STATUS Pages: 3 of 3 Date: 9-17-98
6.1.6 Only product that has passed the required inspections/tests or released under an
authorized concession will be dispatched, used or installed. [4.12B] [4.12C]
6.2 Records:
6.2.1 The contents of records used to establish inspection and test status may include but is
not limited to the following:
The nature and number of observations.
The number and type of discrepancies found (rejected material).
The lot identity and size.
Serial numbers.
Sample sizes
Corrective action taken.
Inspection and test product acceptance.
Date of acceptance.
Inspector responsible.
10. Drawing/ speciﬁcation number
11. Revision levels.
12. In-process inspections.
13. Final inspection acceptance.
14. Test data directly traceable to the material, pans, or products tested.
15. The results of inspection and tests for ﬁrst production conﬁguration articles (FAA
only).
16. Periodic inspection and control of tools used as a media of inspection, including
check ﬁxtures, inspection gauges, and measurement instruments. (4Q5, 9Q9(3,4)
PPT'F‘E".55“PE"
6.2.2 See Section 16 for the requirements of retention, maintenance, and storage of records.
Subject:
1.0
2.0
3.0
4.0
Section: 13 Revision: 1
NONCONFORMING MATERIAL Pages: 1 of 5 Date: 9-17-98
POLICY
1.1 ACR will provide a system for identifying, controlling, evaluating, and dispositioning
material/products/ parts which do not conform to approved design data, speciﬁcations, or
contractual requirements. [4. 13. IA]
SCOPE
2.1 This procedure applies to all material used for the manufacture of ACR products including
the products themselves.
REFERENCES
3.1 MIL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 14 (Corrective Action)
3.4 SECTION 16 (Records)
3.5 AN SI/ASQC Q9001-1994
3.6 The ISO 9000 Auditor’s Companion by Kent A. Keeney
RESPONSIBILITY
4.1 The Director of Quality Assurance is responsible for ensuring the activities described within
this procedure.
4.2 The Director of Quality Assurance is responsible for ensuring the review of non-conforming
material data with upper management and analyzing the data to detect trends and determine
corrective and preventive actions. (1 1M!)
4.3 The Director of Quality Assurance is responsible for establishing and directing the Material
Review Board (MRB) and maintaining a current list of all MRB members and their
designees. (1 1Q3)
4.4 The Director of Quality Assurance is responsible for ensuring the notiﬁcation of the
cognimnt customer representative when required by contract, to participate in the MRB
review of products/ parts for dispositioning.
4.5 The Director of Quality Assurance is responsible for ensuring the notiﬁcation ofthe FAA of
any non-conformances identiﬁed as major in the FAA approved design data. (1 lCl)
4.6 The Vice President of Engineering is responsible for ensuring the review of nonconforming
material to identify major or minor changes to the FAA approved design data. (1 1151)
Subject: Section: 13 Revision: 1
NONCONFORMING MATERIAL Pages: 2 of 5 Date: 9-17-98
4.7 The Vice President of Sales, Marketing, and Customer Service is responsible for ensuring
that users are notiﬁed and products recalled, when necessary, in the event nonconfon'nances
are suspected or known to exist in products in service. (l 181)
5.0 GENERAL
5.1 The dispositioning of any/ all nonconforming material shall only be performed through the
Material Review system, including Preliminary Review. (11Q1(4) [4.13.1B]
5.2 All nonconforming material shall be controlled from presentation through ﬁnal MRB
disposition, (11Q3(3)
6.0 PROCEDURE [4.13.1A]
6.1 Material Review Board members, responsibilities, and limitations include, but are not
limited to the following: (l 1Q3) [4.13.1B] [4.13.2A]
6.1.1 A Material Review Board (MRB) consisting of, as a minimum, representatives from
the Quality and Engineering departments (1 lQ3(1a)
6.1.2 Required qualiﬁcations of the Quality and Engineering members and how additional
members are chosen. (11Q3(1b)
6.1.3 A list of approved Quality and Engineering members and:
1. Frequency that the list is updated.
2. Areas the list can be found.
3. Facsimile of MRB members signatures. (l lQ3(1c)
6.1.4 Approval signature from both Quality and Engineering representatives on any MRB
documents dispositioning the material/ parts “accept as is", or “repair“. (11Q3(ld)
6.1.5 The completion of all necessary MRB documents, including all required signatures of
MRB personnel, prior to physical release of the products/ parts from MRB control.
(I 1Q3(3a)
6.1.6 A method for recording MRB decisions shall be implemented. (1 1Q3(3d)
6.1.7 A method shall be established for notiﬁcation ofMRB activity to functions
concerned.
6.1.8 Where required by contract "use as is" or "repair" of a nonconformance shall be
reported for concession to the customer. [4,132]
Subject: Section: 13 Revision: 1
NONCONFORMING MATERIAL Pages: 3 of 5 Date: 9-17-98
6.2 Identiﬁcation and Segregation of Nonconforming Material: [4.13.1B]
6.2.1 The identiﬁcation ofMRB material sent to the manufacturing areas for rework or
repair to preclude subsequent release without MRB approval. (1 lQ3(3b)
6.2.2 The identification of MRB material sent to the manufacturing areas for continued
processing and reinspection of the nonconformance aﬁer subsequent operations to
ensure reinspection of the speciﬁed characteristic. (11Q3(3c)
6.2.3 Methods shall be established for identiﬁcation, control, and disposition of
nonconfon-ning parts/ products in an expeditious manner. (1 1Q1(1,2)
6.2.4 Nonconforming materials shall be controlled through segregation, marking, or
tagging, in a manner which would preclude inadvertent release, or release by
unauthorized personnel. (1 1Q3)
6.2.5 An enclosed and secure holding area shall be designated with access limited to
authorized personnel. (1 1Q1(3)
6.3 Dispositioning of Material: [4.13.18] [4.13.2A]
6.3.1 The disposition of nonconformances which are MINOR changes to FAA approved
design data shall be limited to:
I. “accept as is”
2. “rework”
3. “repair”
4. “scrap”
5. “return to supplier” (llQS(2a)
6.3.2 The disposition of nonconformanees which are MAJOR changes to the FAA
approved design data shall be limited to:
1. “rework” (to eliminate the nonconfomwnce)
2. “scrap”
3. “return to supplier“
4. “accept as is” (only after the major change has been approved by the
FAA as a change to the FAA approved design data). (11Q3(2b)
6.3.3 Delegation of nonconforming material disposition authority to Preliminary Review
personnel for “scrap”, “return to supplier“, “rework", or “repair" to Standard Repair
Procedures. (1 lQ3(3e)
6.4 Nonconforming material dispositioned as “repair”:
6.4.1
Any Standard Repair Procedure used shall be controlled. (l lQl(5)
Subject:
NCONFORMING MATERIA
6.4.2 Instructions for processing parts/ products dispositioned as “repair” by the MRB: cg,
MRB repair traveler which includes: [4.13.2B]
1. Reinspection per the documented requirements of the repaired area and related
dimensions associated with the repair to ensure the repair was completed.
[4. I 3.28]
Retest of the product as necessary.
Assurance that the nonconformance meets the acceptance criteria of the MRB, or
is routed back to the MRB for ﬁnal disposition. (l 1Q5(2)
as
6.5 Nonconforming material dispositioned as “rework”:
6.5.1 Instructions for processing parts/ products dispositioned as “rework” or persons
assigned Preliminary Review authority: e.g., MRB rework traveler. These
instructions include:
1. Reinspection per the documented requirements of the reworked area to ensure
completion of the rework. [4.13.2B]
2. Retest of the product as necessary. (11Q5(1)
3. Assurance that the former nonconformance now meets FAA approved design
data.
6.6 Nonconforming material dispositioned as “scrap":
6.6.1 Any material dispositioned as “scrap” shall be identiﬁed as follows:
1. Material! parts shall be mutilated prior to release from the MRB.
2. Material/ parts shall be identiﬁed by attaching scrap tags or labels.
3. Material/ parts shall be physically segregated; e.g., “scrap retention” crib.
( 1 1 Q2)
6.7 Records:
6.7.1 Material review records shall include as a minimum:
Part number
Quantity
Date
Adequate description of nonconformance
Identiﬁcation of Major or Minor change
Disposition
Authorized approvals (l lQ4(1)
Records shall be complete, legible, and accurate (1 lQ4(3)
9°>'?‘E"PS“.N:"
6.7.2 Meeting records designed to handle disposal of scrap and rework shall be maintained.
[4.13.2C]
Subject: Section: 13 Revision: l
NONCONFORMING MATERIAL Pages: 5 of 5 Date: 9-17-98
6.7.3 There shall be “password” protection on all electronic signatures. (l lQ4(2)
6.7.4 See Section 14 for Corrective Action requirements
6.7.5 See Section 16 for the requirements of retention, maintenance, and storage of records.
1.0
2.0
3.0
4.0
CORRECTIVE / PREVENTATIV ACTION
Revision: 1
Date: 9-17-98
POLICY
1.1
To establish a documented system for corrective and preventative action used to discover the
root cause of nonconformances or potential nonconformances, both internally and for
suppliers, and to eliminate it in a controlled and documented manner. ACR will record and
control any changes made to the documentation as a result of these corrective and
preventative actions taken. [4.14.1A]
SCOPE
2.1 This procedure is applicable to all processes, and work operations which affect product
quality.
REFERENCES
3.1 MIL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 06 (Purchasing)
3.4 SECTION 13 (Nonconfonning Material)
3.5 SECTION 16 (Records)
3.6 ANSI/ASQC Q9001-1994
3.7 The ISO 9000 Auditor’s Companion by Kent A. Keeney
3.8 02-QA-01 Control of Work Instructions
RESPONSIBILITY
4.1 The Director of Quality Assurance is responsible for ensuring the use and follow-up of
corrective actions internally, and when warranted, for supplier/ vendor control.
(10Q1(3)
4.2 When a supplier notiﬁes ACR of suspect material which has already been delivered, it is the
responsibility of the Director of Quality Assurance to ensure that the material is segregated
and investigated to determine the nonconformance and resultant corrective action as
applicable. (10Q7)
4.3 The Director of Quality Assurance is responsible for ensuring the notiﬁcation of the
functional area when an “out of control" condition is found. (6Q10(2)
Subject: Section: 14 Revision: 1
CORRECTIVE/PREVENTATIVE ACTION Pages: 2 of 3 Date: 9-17-98
4.4 The Director of Quality Assurance is responsible for ensuring that corrective action is taken
when periodic reviews of the material review records identify repetitive nonconformances
and to monitor the response. implementation, and effectiveness of the corrective action.
(11Q6,11Q7)
4.5 The Purchasing Manager is responsible for ensuring that the supplier corrective action
request (SCAR) is sent to the supplier for review and a signature.
4.6 The Vice President of Sales, Marketing and Customer Service is responsible for ensuring
that:
l. A prompt corrective action is implemented for all ﬁeld returns.
2. A method for root cause determination is established for all ﬁeld returns. The
determination includes all service problems both in design and manufacturing. (1453)
5.0 GENERAL
5.1 Changes to documented procedures for controlling preventative and corrective action shall
be recorded and implemented in accordance with Work Instruction O2-QA-01 and Section 5,
Document Control. [4.14.1A] [4.14.2E]
5.2 Preventative actions shall be initiated for problems at a level corresponding to the risks
involved. [4.14.1A] [4.14.2C]
5.3 This procedure allows the application of controls to ensure that corrective actions are
effective [4.14.2D]
6.0 PROCEDURE
6.1 Corrective Action Procedure
6.1.1 All nonconforming materials processed through the MRB shall address corrective
action for the root cause.
6.1.2 Repeated/reoccurring discrepancies, deﬁciencies which have exceeded established
limits shall have a corrective action request (CAR) generated and an analysis
performed to determine the root cause of the nonconformancet Actions will be taken
to eliminate it and to determine the corrective measures needed to prevent
recurrence. (1 lQ6(1,2) [4.14.2A]
6.1.3 A corrective action shall be addressed on repetitive “use as is“ dispositions and an
evaluation of the design shall be performed as warranted. ( 1 lQ6(3,4)
Subject: Section: 14 Revision: I
CORRECTIVE/PREVENTATIVE ACTION Pages: 3 of 3 Date: 9-17~98
6.1.4 Manufacturing processes found to be “out of control“ either through inspection
examinations or statistical methods shall have a corrective action report generated to
identify the problems and correct them. (SQS) [4.14213]
6.1.5 When an SPC method is found to be “out of control”, the following steps shall be
taken.
1. All materials/ parts shall be inspected at the “tightened” level of the statistical
plan.
2. Control charts shall be implemented to verify the limits are controlled.
3. An evaluation shall be performed to determine a “purge“ action to remove
the nonconforming material.
4. A corrective action request shall be initiated to determine the cause and
corrective action while the above controls remain in effect,
(6Q10,6Q11)
6.1.6 When a nondestructive inspection process (NDl) is found to be “out of control“, an
investigation shall be initiated to determine if previously accepted material/ parts are
still acceptable. (9Q10)
6.1.7 Establish a method of control for any deviation from the established system to allow
the production ofproducts/ parts until the completion of the corrective action.
(1 1Q6(5)
6.1.8 Customer Service corrective actions shall have a method established for identifying,
investigating (including the magnitude and nature of the complaint), locating,
reporting, purging, or tracking of suspected and known unsafe conditions as well as
non-conforming products in order to detect and eliminate causes of nonconforming
product. , (1433) [4.14.2B]
6.2 Preventative Action Procedure
6.2.1 Procedures for preventative action shall include: appropriate sources of information
such as processes, work operations affecting quality, concession, audit results,
quality records, service reports and customer complaints to detect, analyze, and
eliminate potential causes of nonconfon‘nities. [4.14.3A]
6.2.2 Procedures shall determine steps to deal with any problems requiring preventative
action, initiate such action, and apply controls to ensure effectiveness,
[4.14.3B]
6.2.3 Relevant information on action taken and changes to procedures shall be submitted
for management review. [4.14.3C]
6.3 See Section 16 for the requirements of the retention, maintenance, and storage of records.
Subject: Section: 15 Revision: I
HANDLING, STORAGE,
PACKAGING, PRESERVATION
AND DELIVERY Pages: l of 4 Date: 9-17-98
1.0 POLICY
1.1 ACR will provide a system for handling, storage, packaging, preservation and delivery of
product. [4.15.1A]
2.0 SCOPE
2.1 This procedure applies to all materials, items, or assemblies that go into ACR products
including the ﬁnal product itself.
3.0 REFERENCES
3.1 MIL-1:45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 AN SI/ASQC 09001-1994
3.4 The ISO 9000 Auditor’s Companion by Kent A. Keeney
4.0 RESPONSIBILITY
4.1 The Director of Operations is responsible for ensuring the performance of the activities
described within this procedure.
4.2 The Vice President of Engineering is responsible for ensuring that appropriate methods of
protecting products are incorporated into the technical data package (drawings,
speciﬁcations, etc.), when recurrent damage is reported. (12E1)
4.3 The Director of Operations is responsible for ensuring the review and approval of all material
handling, storage, packaging, and delivery speciﬁcations and procedures. (12P1)
5.0 PROCEDURE
5.1 Controlling Removal and Issuance of Products! Materials: [4.15.3A]
I. Authorized methods for removal and/or replacement of parts. (12Q7—l)
2. Limited and controlled access to storage areas. (12Q7-2)
3. Records to be generated and maintained for parts removed from stock. (1207-3)
4. Issue of raw and process material accountable to a released production order. (12Q7-4)
5. Control of parts that have been quarantined as a result of a suspected nonconformance.
(12Q7-5)
First-in/ First-out system (FIFO) will be implemented for all materials/ parts.
?‘
Subject: Section: 15 Revision: l
HANDLING, STORAGE,
PACKAGING, PRESERVATION
AND DELIVERY Pages: 2 of 4 Date: 9-17-98
5.2 Packagiug/ Shipping/Delivery: [4.15.4A] [4.15.5A] [4.15.6A] [4.15.6B]
1. All products/ parts which are to be packaged and shipped meet established acceptance
criteria. (lZQS-l)
2. Compliance with shipping instructions. (12Q8-2)
3. Methods for packing, packaging, preservation, marking and shipping of completed
products. (1 208-3)
4. Aﬂer ﬁnal inspection the product is protected by its packaging until delivery to ﬁnal
5.3
5.4
5.5
5.6
destination. Product quality after ﬁnal inspection shall be veriﬁed through the packaging
inspection. Product quality during delivery will be tracked through Customer Service.
[4.15.6AB]
Incorporating Design Changes:
1. Establishment of effectivity of design change. (12Q6-l)
2. Use of shop order or traveler. (12Q6-2)
3. Stock purge requirements. (12Q6-3)
4. Rework to Engineering instructions. (12Q6-4)
5. Inspection requirements. (12Q6-5)
6. Reidentiﬁcation and restocking requirements. (12Q6-6)
Preventing Part Damage: [4.15.2A]
1. Instruction on the use of material handling equipment. (12Q1-l)
2. Methods for stacking parts. (l2Q1»2)
3. Methods for tying, wrapping, or properly supporting parts to preclude shifting and falling.
(12Q1-3)
4. Sealed type parts such as switches, circuit breakers, and relays, are protected from rough
handling and contact damage from like parts or other products. ( 1201 5)
5. Methods to protect critical machined surfaces, highly polished surfaces, or plated pans.
(12Q1-4)
6. Methods on the use of liﬁ ﬁxtures, covering on fork liﬁ contact surfaces, protective
containers, wrapping, interlayering with protective material, special racks. (12Q1—4)
Preventing Contamination: [4.15.3B] [4.15.5A]
1. Methods to protect electronic parts from corrosion, pin damage, or contamination from
dust or dirt. (12Ql -5)
2. Capping tubes prone to entrapment of foreign objects, both ends. (12Q1-6a)
3. Methods to prevent fingerprints from deteriorating the product or causing inadequate
adhesion. (l 2Q1-7a)
ESD Precautions: [4.15.2A]
1. Methods for identifying supplies and parts that require ESD handling. (lZQl-7d)
Subject: Section: 15 Revision: I
HANDLING, STORAGE,
PACKAGING, PRESERVATION
AND DELIVERY Pages: 3 of 4 Date: 9-17-98
2. Controlled work station conditions for removing ESD parts from special tote trays, boxes,
and packaging. (12Q1—7E)
5.7 Protection During Transit: [4.15.2A]
1. Bagging, boxing, or tying parts and material to prevent intermixing. (12Ql-8a)
2. Retaining product in the original containers as long as possible. (12Ql-8b)
3. Foam, pads, or special packaging for delicate parts that are susceptible to vibration and
shock damage. (12Q1-8c)
4. Covering, tying, or bundling pans and material that may be blown out of carts, trucks, or
dollies. (12Q1-8d)
5. Protecting parts and materials from adverse weather conditions that would affect the
product. (12Q1-8e)
5.8 Utilizing Environmental Controls: [4.15.2A] [4.15.5A]
1. Storage of environmentally sensitive material in original containers, and, if removed for
inspection, appropriately rescaled (1 202-1)
2. Survey of stock areas to ensure compliance. (12Q2-2)
3. Upper and lower temperature and humidity control limits, when applicable. (12Q2-3)
4. Recording requirements, corrective action procedures, and objective evidence that a
corrective action was taken when limits are exceeded. (12Q2-3)
5. Control of general housekeeping. (12Q2-4)
6. Training for stockroom personnel. (12Q2-5)
5.9 Product / Part/Material Segregation and Preservation: [4.15.2A] [4.15.3A,B] [4.15.5A]
1. Placement in stock of products/ parts/ materials that have met established acceptance
criteria. (12Q3—1)
2. Control of uncompleted parts to prevent stocking under an identifying part number until
complete as deﬁned by drawing or speciﬁcation. (1203-2)
3. Placement in stocking areas of parts and material under investigation for
nonconfonnances are properly identiﬁed to prevent distribution and usage. (12Q3-3)
4. Parts and materials that are alike or similar are segregated, (12Q4-1)
5. Identiﬁcation of bins, shelves, and storage areas as to their contents. (12Q4-2)
6. Protection from water, dust, and dirt damage. (12Q4-3)
7. Appropriate method for preservation, [4.15.5A]
5.10 Age-Sensitive Materials: [4.15.38]
1. Identiﬁcation and control of age-sensitive material, and material susceptible to corrosion.
(12Q5-1)
2. Determination of shelf life limits by type of material. (lZQS-la)
3. Detailed mixing instructions if different from the manufacturers, (lZQS-lb)
4. Instructions for retest and extension of shelf life. (lZQS-lc)
5. Permissible amount oftime shelf life may be extended. (lZQS-ld)
Subject: Section: 15 Revision: 1
HANDLlNG, STORAGE,
PACKAGING, PRESERVATION
AND DELIVERY Pages: 4 or 4 Date: 9-17-98
6. Identiﬁcation requirements for shelf life extension dates. (12Q5-l e)
7. Removal and segregation of out-of—date items in bonded areas until reinspection,
retesting, and dispositioning can be accomplished. (l2Q5-3)
8. Identiﬁcation of bins that contain limited shelf life items. (I 2Q5-2)
9. Records to be generated and maintained for raw materials used in composites to ensure
5.11
compliance with manufacturer’s speciﬁcations Records contain as a minimum, receipt
of material, initial testing, usage, and retesting. (12Q5-4)
10. A method for periodic assessments of product in stock. [4.15i2A] [4.15.3B]
See Section 16 for record retention, maintenance, and storage.
Subject:
1.0
2.0
3.0
4.0
5.0
6.0
POLICY
1.1 ACR will provide a documented system for the maintenance, identiﬁcation, collection,
indexing, access, ﬁling, disposition, and storage of complete, legible, and accurate quality
records. [4.16A]
SCOPE
2.1 This procedure applies to all records created through ACR’s corporate quality system.
REFERENCES
3.1 MIL-l-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 17 (Audits)
3.4 l6-QA-01-Ol (Record Identiﬁcation Label)
3.5 ANSI/ASQC Q9001-l994
3.6 The ISO 9000 Auditor’s Companion by Kent A. Keeney
DEFINITIONS
4.1 Records - Includes all technical data relating to the manufacture of a product, i.e.:
engineering drawings, speciﬁcations, quality / inspections, purchase orders, manufacturing
processes, tests, contracts, etc..
4.2 Active Records - Records representing products which are being manufactured.
4.3 Inactive Records - Records representing products which were shipped at least 12 months
earlier.
GENERAL
5.1 All departments will be audited on a predetermined basis for compliance with record
retention, maintenance, and storage requirements. (1Q6-2)
RESPONSIBILITY
6.1 The Director of Quality Assurance shall be responsible for ACR Electronics record maintenance
and storage. Records will reside in their associated departments/ areas and quality audits will
provide a method of determining compliance to established procedures.
Subject: Section: l6 Revision: 1
RECORDS Pages: 2 of 3 Date: 9-l7—98
6.2 The Director of Quality Assurance shall use these records to analyze the corporate quality
system to determine the systems effectiveness and adjust the system accordingly. (lQ7)
6.3 The disposal of inactive records will be at the direction of the Quality Assurance Director.
6.4 It is the responsibility of each department with data records to comply with this procedure
and to create work instmctions (when applicable) to ensure that a systematic approach to
record retention and storage is followed.
7.0 PROCEDURE
7.1 Corporate Quality System Records Include but are not Limited to the Following:
“ Quality Planning ’ Government Property
‘ Indication of Inspection Status " Quality System Audits
‘ Incoming Inspection “ Corrective Actions
‘ Material & Material Control * Supplier Ratings
‘ Product Identiﬁcation & Traceability ‘ Packaging & Shipping Inspection
‘ Completed Item Inspection “ ln-Process Inspection
* Measuring & Test Equipment * Design Data Control
‘ Nonconforming Material * Customer Service Difﬁculties
* Purchase Orders ‘ Test Reports
‘ Manufacturing Work Instructions * Manufacturing Process Plans
‘ Stockroom Control In/Out * Repair/Rework Speciﬁc
* Scrap Reports Instruction
‘ Training Records ' FAA Communication Reports
[4.16.A]
7.1.1 Records shall be described as Active and Inactive for the purpose of maintenance and
storage scheduling. [4.16.A]
7.1.2 Records may be ﬁled by numerical order, by date of creation, by contracthrogram
number or any other systematic way that allows for easy record retrieval and
identiﬁcation. [4.16.A,B]
7.1.3 Records may be kept in ﬁle cabinets, loose leaf binders, electronic media, or any
means which will ensure adequate record protection. (5Q4.3) [4.16.A]
7.1.4 Active records shall be maintained for a minimum of 1 year after the completion of
manufacture before being considered inactive and ready for storage. Note: Training
records will remain active records throughout an individual’s active employment.
[4.16.A] [4163]
7.1.5 Inactive records will be maintained for a minimum of 5 years after shipping has taken
place before being considered for disposal, Note: Training records will be
maintained for a minimum of 2 years after termination of an individual’s employment
with ACR. [4.16.B]
Fubject:
7.1.6
7.1.7
7.1.8
7.1.9
Section: 16 Revision: I
RECORDS Pages: 3 of 3 Date: 9-17-98
Inspection records shall be kept for a minimum of 2 years alter the part/ product is
completed before being considered for disposal. ( lQ6-la) [4.16.8]
FAA-TSOA technical data ﬁle shall be kept until the part/ product is no longer
manufactured, at that time copies of the records shall he sent to the FAA
administrator, and all inspection and test records verifying compliance to the product
shall be kept for a minimum of 2 years before being considered for disposal. (1Q6-1b)
The storage containers for the inactive ﬁles shall have the Records Identiﬁcation
Label (see 2.4) attached to all boxes to be stored. The label must be ﬁlled out
completely with all information supplied or an N/A in areas not applicable. Apply the
label to the box in a conspicuous place to make locating the records easier. [4.16.A]
Inactive records shall be stored in a protected, bonded area with ease of accessibility.
[4.16.A,B]
7.1.10 Subcontractor quality records shall be maintained in accordance with this procedure.
[4.16.C]
Subject:
1.0
2.0
3.0
4.0
Section: 17 Revision: 1
AUDITS Pages: 1 of 3 Date: 9-17-98
PURPOSE
1.1 ACR will establish and maintain an internal quality Auditing program. The program will
objectively obtain evidence regarding actions and events to determine the degree of adherence to
established criteria. It will ensure that corporate organimtion’s objectives are met both internally
and externally by evaluating that the general operations are efficient, effective, accurate, and
current.
SCOPE
2.1 This procedure applies to all documented practices at ACR.
REFERENCES
3.1 MIL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 SECTION 01 (Management Responsibility)
3.4 SECTION 02 (Quality Systems)
3.5 SECTION 16 (Records)
3.6 ANSI/ASQC 09001-1994
3.7 The ISO 9000 Auditors Companion by Kent A. Keeney
RESPONSIBILITY
4.1 The Director of Quality Assurance is responsible for ensuring the performance of the activities
described in this procedure.
4.2 The Director of Quality Assurance is responsible for reviewing the audit results and reporting
them to upper management.
4.3 The Director of Quality Assurance is responsible for ensuring the review of the audit results by
the personnel responsible for the audited area.
4.4 Upper Management is responsible for making provisions for periodic independent
comprehensive audits to verify the results of our internal auditing system.
Subject: Section: 17 Revision: 1
AUDlTS Pages: 2 of 3 Date: 9-17-98
5.0 GENERAL
5.1 The purpose of quality auditing is to examine the effectiveness of management directed control
programs. The philosophy of quality assurance programs is based on prevention rather than
detection of problems
5.2 Management implements control programs to prevent problems, and to prevent the reoccurrence
of problems.
5.3 Quality auditing provides management with objective feedback based on facts, enabling
management to make informed decisions. The primary directive of an audit is to be beneﬁcial to
the function being audited.
6.0 PROCEDURE
6.1 Procedures shall be established to implement an auditing program using the following
requirements:
6.1.1 Internal audits shall be planned and documented. Equipment, material, processes
performed, procedures, products, and records in all major ﬁlnctional areas shall be
audited to determine and maintain compliance to established systems and procedures and
to determine the effectiveness of the quality system. (1 SMl‘l ,3) [4.17.A,B]
6.1.2 Methods shall be established for conducting, accomplishing, and reporting the audits by
personnel independent of those having direct responsibility for the activity being audited.
(15M1-2) [4175].
6.1.3 Schedules shall be generated to establish time periods for auditing the ﬁmctional areas on
the basis of status and importance. (lSMl-4) [4.17.B]
6.1.4 Special audits shall be implemented when critical safety problems are detected.
(1 5M1-5)
6.1.5 Special audits may be implemented when there are signiﬁcant organizational changes.
(lSMl -5)
6.1.6 Special audits shall be implemented as a result of market feedback, non-conformity
reports, and surveys.
6.1.7 Methods shall be generated for identifying nonconfon'nances and for implementing
corrective actions. (ISM1-6)
6.1.8 The identification of personnel responsible for conducting the audits. (15Ml-7)
Subject: Section: 17 Revision: I
AUDlTS Pages: 3 of 3 Date: 9-17-98
6.1.9 Notiﬁcation to upper management of the results of audits. (15M2)
6.1.10 The review of audit results and timely corrective actions by management.
(15M2-l) [4.17.D]
6.1.11 Review of audit results by personnel having responsibility for the area that was audited.
(15M2-2) [4.17.C]
6.1.12 Quality systems or overall quality program improvement, in addition to correcting
reported noncompliance’s. (15M2-3)
6.1.13 Records of audit results shall be maintained. [4.17.F]
6.1.14 Follow-up audits record the implementation and effectiveness of corrective actions taken.
[4.17.0]
6.2 Records:
6.2.1 See Section 16 for the requirements of retention, maintenance, and storage of records.
Subject: Section: 18 Revision: I
TRAINING Pages: 1 of 4 Date: 9-17-98
1.0 POLICY
1.1 ACR will provide a documented system for identifying the training and experience needs and
provide for the training of all personnel performing activities affecting quality.
[4.18A]
2.0 SCOPE
2.1 This procedure applies to all ACR employees who perform activities that affect the quality of
ACR products
3.0 REFERENCES
3.1
3.2
3.3
3.4
3.5
3.6
ACSEP 8100 (Appendix 6)
SECTION 01 (Management Responsibility)
SECTION l6 (Records)
The ISO 9000 Auditor’s Companion by Kent A. Keeney, 1995 edition
ANSI/ASQC Q9001-1994
MIL-I—45208A
4.0 RESPONSIBILITY
4.1
4.2
4.3
4.4
Each department head is responsible for ensuring that the employees in their department have
been properly trained for the job duties that they are assigned to perform.
The Director of Quality Assurance is responsible for ensuring that each department head is aware
of any QA related training requirements for the people in their departments, including special
processes.
The Director of Human Resources is responsible for providing a corporate orientation program
for new employees which will include:
- Familiarization with the company’s quality policy and standards
0 A review of work rules
- A review of general safety rules
Supervisors are responsible for providing new employee orientation at the departmental leVEI.
The orientation will include instruction on:
o How the company‘s QA policy relates to theirjob responsibility
Subject:
Section: 18 Revision: l
TRAINING Pages: 2 of 4 Date: 9-17-98
5.0
6.0
4.5
4.6
4.7
0 The correct method for performing all quality related operations that they will be doing
0 The person to ask if they have any questions
Supervisors are responsible for identifying and providing any necessary OJT training for new
employees, existing employees and employees who are transferred into their department.
Department heads and supervisors are responsible for submitting documentation of all formal
and/or OJT training to the Director of Human Resources.
The Director of Human Resources is responsible for maintaining records of all formal and OJT
training documentation that has been submitted and for notifying department heads of any
renewal and/or recertiﬁcation training that is required.
GENERAL
5.1
5.2
ACR generally recruits and employs individuals who possess the technical skills, experience and
educational requirements of the position that is being filled.
As of May 1, 1998, ACR deems that all personnel are trained and qualiﬁed in their existing
position provided that they have been satisfactorily performing in that position for a period of at
least three months prior to this date. Training for these employees shall be documented and
maintained as new responsibilities become effective and training is provided to those affected
employees.
PROCEDURE
6.1
6.2
HIRING. it is the intent of ACR to recruit and employ individuals with the skills, experience
and educational background necessary to satisfactorily meet the requirements of the position for
which they are hired.
6.1.1 individuals hired who possess some, but not all of the requirements to ﬁll an open
position, will receive training on any skills that they are lacking. [4.18A,B]
6.1.2 Job descriptions will be utilized in determining the required skills, competencies and
educational background considered necessary when ﬁlling an open position at ACR.
[4.18A]
6.1.3 An individual’s demonstration of proﬁciency in speciﬁc tasks or jobs, may qualify them
as having met certain skill requirements.
ORIENTATION to the Company will be provided to new employees.
6.2.1 The Director of Human Resources will provide a corporate Orientation Program for new
employees.
6.2.2 Supervisors will provide new employee orientation at the departmental level.
Subject:
Section: 18 Revision: I
TRAINING Pages: 3 of 4 Date: 9-17-98
6.3
6.4
6.5
TRAINING NEEDS ASSESSMENT [4.18A] [4188] [4.18D]
6.3.1 Training needs for new employees, including training for those who will be performing
special processes and operations will be evaluated by, and arranged for by their
immediate supervisor.
6.3.2 Training for all employees, including training for those who will be performing special
processes and operations will be evaluated by, and arranged for by their immediate
supervisor based on any perceived need to improve skill efﬁciency, new or modiﬁed
processes or procedures, or recurrent training, as applicable.
6.3.3 The Director of Human Resources will track and monitor requirements for recurrent
training and provide notiﬁcation to supervisors through their department head of
impending renewal dates.
TRAINING to ensure that all employees affecting the quality of ACR’s products are properly
trained, may take place in any of the following forms:
6.4.1 Classroom training within the company by qualiﬁed ACR employees
6.4.2 On the job (OJT) training instruction by a supervisor or another trained and qualiﬁed
ACR employee
6.4.3 Written memorandums or instructions
6.4.4 Assigned reading or self—study instruction
6.4.5 Classroom training within the company presented by qualiﬁed third party providers
6.4.6 Attendance at seminars, classes or other types of training offered at trade schools,
colleges, and institutions of learning or independent seminar sites.
DOCUMENTATION in written form will be forwarded to the Director of Human Resources by
department heads and supervisors upon completion of any employee training. [4.18C]
6.5.1 Classroom training that takes place in-house will be documented.
6.5.2 OJT training will be documented.
6.5.3 Training accomplished through written memorandums, assigned reading or self-study
will be documented in the form of a signed acknowledgment by the employee.
6.5.4 Training received through attendance at seminars, classes or other types of training at
trade schools, colleges. institutions of learning or independent seminar sites will be
documented in the form of certiﬁcates or other written support given by the provider.
Subject:
Section: 18 Revision: l
TRAINING Pages: 4 of 4 Date: 9-17-98
6.6
6.7
FAA PRODUCTS manufactured by ACR are subject to the following procedures and
requirements:
6.6.1
6.6.2
6.6.3
6.6.4
6.6.5
All personnel having manufacturing, quality, test, maintenance, repair, and notiﬁcation
function responsibilities relating to FAA designed products shall have the appropriate
training and veriﬁcation documents, ifapplicable. (1C3, lS3, 1P3, lQ3)
Vision testing is required of all inspectors. Results are recorded and kept on ﬁle in
Human Resources. (9Ql-3,7)
A schedule has been established for the retesting of vision on a periodic basis.
(4P6, 5Q2, 901, 2, 9Q9(b))
Any area deﬁning special qualiﬁcations requiring certiﬁcations shall have the
requirements documented and the results keep on ﬁle for recertiﬁcation purposes.
Documentation of all test results and certiﬁcation veriﬁcation shall be forwarded to the
Director of Human Resources. The documentation will be maintained as part of an
employee’s training records.
TRAINING RECORDS will be maintained by the Director of Human Resources.
6.7.1
6.7.2
6.7.3
In order to maintain individual privacy rights, training records will be kept separate from
employee personnel ﬁles. [4.18C]
Training records will be maintained in the form of a computerized database for active
employees.
Training records for terminated employees will remain in archive ﬁles for a pre-deﬁned
period of time.
F—
Subject: Section: 19 Revision: 1
CUSTOMER SERVICE Pages: 1 of 3 Date: 9-17-98
1.0 POLICY
1.1 ACR will provide a system to ensure adherence to requirements in the areas of Customer
Service, and Manufacturer’s Maintenance Facility operations.
2.0 SCOPE
2.1 This procedure applies to all ACR products processed through Customer Service.
3.0 REFERENCES
3.1 ACSEP 8100 (Appendix 6)
3.2 SECTION 01 (Management Responsibility)
3.3 SECTION 02 (Quality Systems)
3.4 SECTION 16 (Records)
3.5 AN SI/ASQC Q9001-1994
3.6 The ISO 9000 Auditor’s Companion by Kent A. Keeney
3.7 MIL-I—45208A
4.0 RESPONSIBILITY
4.1 The Vice President of Sales and Marketing is responsible for ensuring the performance of the
activities described in this procedure.
4.2 The Vice President of Sales and Marketing is responsible for ensuring that the Director of
Quality Assurance is notiﬁed immediately of any major malfunctions, failures, and/or defects
(per 213) reported from the ﬁeld to ensure that the FAA will be notiﬁed within a 24 hour
time frame of the occurrence(s) as deﬁned in the FAR Part 21, Section 213. (I4Cl)
5.0 PROCEDURE
5.1 Customer Service shall ensure that the following requirements are met and documented
within their respective work instructions:
5.1.1 An identiﬁcation of the speciﬁc ﬁanction which will receive reports of all service
difﬁculties. (1481-1)
5.1.2 A determination must be made of the appropriate manufacturing or design
responsibilities in regard to the reported problem. (1431-2)
Su bject:
Section: 19 Revision: I
CUSTOMER SERVICE Pages: 2 of 3 Date: 947-98
5.1.3 A systematic approach for tracking the accountability of service problems. (l4Sl-3)
5.1.4 Records must be generated for all reported service difﬁculties, including when the
report was received, what was reported, and the actions taken. The records shall be
legible, complete, and accurate. (14S2)
5.1.5 In the event the records are on tape ﬁles, microﬁlm, etc., they must exhibit legible
data, acceptance stamps, and! or signatures as required. (1482-3)
5.1.6 A system created for informing the users of the service difﬁculties and notifying them
of ﬁeld purges for suspected or known unsafe conditions. (l4S4-a)
5.1.7 Service problems which have originated in design and/ or manufacturing shall be
investigated and a prompt corrective action implemented which shall include a root
cause determination and a correction of the deﬁciency. (l4S3 -l4S3-2a)
5.1.8 A method generated for identifying, locating, and reporting suspected unsafe
conditions. (14C2) (1483-1)
5.1.9 A method for investigating, reporting, purging, tracking, and for the accountability of
known unsafe features or characteristics of products. (14S3-2b, 14C2)
5.1.10 Speciﬁc organizational and individual functions must be deﬁned for approving and
issuing service bulletins, maintenance manuals, service difﬁculty reports, and any
other related communication. (1485)
5.1.11 A method for making available to all users of a product the descriptive data and
information resulting from the incorporation of AD’s which contribute to the safety of
the product. (283)
5.1.12 Service bulletins and maintenance manuals and any changes thereof shall be
coordinated with FAA engineering. (14C5)
5.1.13 Maintenance, return to service, and preventative maintenance on those products and
appliances for which the MMF has been issued. (17Ql)
5.1.14 Competent personnel, and adequate facilities and equipment. (l7Ql )
5.1.15 Work performed under the MMF is limited to the maintenance and retum to service
of products manufactured under the facilities production approval, and to preventative
maintenance on those products, (l7Q2)
5.1.16 For work to be performed according to the manufacturers maintenance procedure or
instructions for Continued Airworthiness. (17Q3)
5.1.17 Certiﬁed mechanics and repairmen to be directly in charge in all areas ofthe facility
where maintenance or preventative maintenance is being performed. (l7Q4)
Subject: Section: 19 Revision: 1
CUSTOMER SERVICE Pages: 3 of 3 Date: 9-17-98
5.1.18 Entering all maintenance and preventative maintenance in the appropriate
maintenance record. (I7Q5)
5.1.19 Entering the information listed in FAR 43.9 and/or 43.1 1 in the maintenance record.
(17Q5)
51.20 All requirements to be satisfactorily completed (I 706)
5.1.21 Procedures for performing and verifying that servicing meets speciﬁed requirements.
[4.19A]
5.1.22 Properly trained personnel are performing the servicing. [4.19B]
5.1.23 Spare parts lists, service literature and instruction are under document control.
[4.190]
5.1.24 All measuring and test equipment used is under the ACR calibration system. [4.19D]
5.1.25 Servicing responsibilities among supplier, distributor and user are clearly deﬁned.
[4.19E]
5.2 Records:
5.2.1 See Section 16 for the requirements of retention, maintenance, and storage of records.
1.0
2.0
3.0
4.0
5.0
6.0
Subject:
Section: 20 Revision: I
STATISTICAL QUALITY
CONTROL (SQC) Pages: 1 of 2 Date: 9-17-98
POLICY
1.1 ACR will provide a system for the identiﬁcation of statistical techniques required for
establishing, controlling and verifying process capability and product characteristics.
[4.20.1A]
SCOPE
2.1 This procedure applies to all processes and product characteristics that are identiﬁed to require
statistical techniques for control or veriﬁcation. [4.20.1A]
REFERENCES
3.1 MIL-I-45208A
3.2 ACSEP 8100 (Appendix 6)
3.3 Section 16 (Records)
3.4 ANSI/ASQC Q9001-1994
3.5 The ISO 9000 Auditor‘s Companion by Kent A. Keeney
3.6 ANSI Z] ,4 Sampling Procedure and Table
DEFINITIONS
4.1 Statistical Techniques - Any technique that uses statistical theory to reveal information.
RESPONSIBILITY
5.1 The Director of Quality, in conjunction with the Vice President of Engineering, shall be
responsible for identifying, implementing, training, controlling and applying statistical plans and
statistical techniques as deemed necessary. [4.20.2A] (6Q2)
5.2 The Director of Operations shall be responsible for determining additional statistical techniques
which may effect process controlr
PROCEDURE
6.1 ACR shall establish and maintain documented procedures to implement and control the
application of the statistical techniques identiﬁed by the SQC policy. [4.20.2A]
Subject: Section: 20 Revision: I
STATISTICAL QUALITY
CONTROL (SQC) Pages: 2 of 2 Date: 9-17-98
6.1.1 ACR sampling plans shall be based on industry recognized standards.
6.1.2 The following statistical methods may be used to help improve the control or veriﬁcation
of processes or characteristics:
1. Graphical techniques, such as histograms, sequence charts, scatter plots, Pareto
diagrams, cause and effect diagrams, etc.
2. Statistical control charts
3. Design of experiments
4. Regression analysis
5. Variance analysis
6. Other statistical methods, including pre-oontrol methods, techniques and SPC.
6.2 RECORDS (6Q3 — 6Q11)
6.2.1 See Section 16 for the requirements of retention, maintenance and storage of records.

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ACR Electronics 8L2ACR-RLB-33 User Manual 8

ACR Electronics, Inc. 8

Contents

8

FCC ID Filing: B668L2ACR-RLB-33

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