Quality Name Plate AS9100 Quality System


QNP AS9100 Main Index

 

 


Production Inspections

Production Inspections: OP-824-01 Revision C

Effective Date:12/20/2013
Owner Approval by Brian Darby, Quality Assurance Manager, on 12/20/2013
Management Approval by Craig O. Garneau, President, on 12/20/2013

Printed copies of this document are for information purposes only and are uncontrolled. Printed copies are not valid after the date of printing. This document was printed on

  1. PURPOSE

    To provide a consistent method for verifying that product requirements have been met at the appropriate stages in production at QNP.




  2. RESPONSIBILITY

    The table below identifies the people and their responsibility relating to this procedure:

     

    Person

    Responsibility

    Customer Service Personnel
    Engineering Personnel

    Verify information on Shop Orders, FM-710-01, prior to production.

    Record results of performed inspections on
    FM-824-01, Production Inspections Report.

    Production Personnel
    Proofreaders

    Perform inspections on customer orders as required.

    Record results of performed inspections on
    FM-824-01, Production Inspections Report.

    Inspection and Packaging Personnel
    Quality Team Personnel

    Perform final inspection on customer orders during shipping operation.

    Record results of performed inspections on
    FM-824-01, Production Inspections Report.

    MRB Members

    Assist in inspections when required.




  3. APPLICABLE FORMS OR REFERENCES

    The table below identifies the number and the title of the forms and references that are applicable to this procedure;

    Form/Reference Number

    Title

    AS9100

    Quality Management Systems - Requirements for Aviation, Space and Defense Organizations

    ASQR-20.1 UTC's Supplier Sampling Requirements
    OP-424-01 Control of Quality Records
    OP-710-01 Quality Planning

    OP-760-01

    Control of Inspection, Measuring and Test Equipment

    OP-830-01

    Control of Nonconforming Product

    AS9102 Aerospace First Article Inspection Report

    FM-710-01

    Shop Order

    FM-824-01 Production Inspections Report
    FM-830-02 QNP Certificate of Conformance
    FM-830-03 QNP First Article Inspection Report

    WI-751-01

    Tier 1 Inspection




  4. POLICIES

    1. All personnel at Quality Name Plate are responsible for quality, and have the authority to contain non-conformities.

    2. The results of Production Inspections are recorded on Production Inspections Report, FM-824-01:
      • Quality Plan Inspection
      • New Film Inspection
      • Paper Print Inspection
      • Print Inspection
      • Digital Print Inspection
      • Markem Print Inspection
      • Metalphoto Inspection
      • Etch, Paint, and Relieving Inspection
      • First Piece Inspection - Machining
      • Final Inspection
      • Ship from Stock Inspection
      • Other Custom/Special Inspections as required.

    3. A Production Inspection Report, FM-824-01, accompanies the Shop Order, FM-710-01 throughout the production process, and is retained as a quality record per OP-424-01, Control of Quality Records, and/or customer requirements.

    4. The criteria for acceptance or rejection may be determined from;
      • Blueprint tolerances and notes
      • Customer instructions
      • Instructions on the Shop Order, FM-710-01
      • Employee training and experience
      • Management direction
      • Production Inspection Report, FM-824-01

    5. The measuring equipment used for production inspections are typically micrometers and verniers, and are controlled through OP-760-01 Control of Inspection, Measuring and Test Equipment. If specific measuring instruments are required for an inspection point, it shall be specified on the Production Inspection Form, FM-824-01, or the Shop Order, FM-710-01.

    6. When sampling inspection is to be used as a means for product acceptance, the sampling plan shall be based on ASQR-20.1 which employs recognized statistical principles and is appropriate to QNP's inspection requirements.

    7. QNP does not typically release parts into production before all required inspections have been completed. Should that occur, the product shall be identified and recorded on the Production Inspection Report, FM-824-01 to allow for recall and replacement if it is subsequently found that the parts do not meet requirements.

    8. QNP does not typically release product to the customer before all planned arrangements have been satisfactorily completed. Should that be necessary, the customer or a relevant authority shall be contacted for approval. A record of the approval shall be documented on the Production Inspection Report, FM-824-01.

    9. When required by customer contract, QNP shall provide the necessary documented evidenced to demonstrate that product meets the defined requirements. This documentation may be presented as;
      • The Production Inspection Report, FM-824-01
      • A QNP first piece inspection report, FM-830-03
      • A QNP certificate of conformance, FM-830-02
      • A customer supplied inspection report or certificate of conformance
      • AS9102 Aerospace First Article Inspection Report
    10. All documents required to accompany the product shall be completed and delivered by the time of product delivery.

    11. Various methods may be used to monitor inspection points. They shall be used to determine the effectiveness of the inspection point, reduce the risk of nonconforming product being incorrectly accepted, and drive continuous improvement to the In Process and Final Inspection Process.

    12. The results of the Lacquer Quality Inspection are recorded in a Filemaker database and can be viewed by accessing the order's record within Job Tracking. Other inspection points may also be modified to have their results digitally recorded.

     



  5. PROCEDURE

    Production inspections of a customer order may involve the following individual inspections:

    5.1 Quality Plan Inspection
    Use the steps in the table below to inspect a shop order, FM-402-01, before it is released to production.

    Note: The purpose of this inspection is to verify the completeness and accuracy of the data on a Shop Order before beginning the production of a customer order.

    Step

    Action

    Person(s) Responsible

    1.

    Access Shop Order, FM-710-01, and assemble the following documents, as available:

    • Customer Purchase Order
    • Quote
    • Blueprint
    • Corresponding shop order from the previous order

    Customer Service Personnel or Engineering Personnel

    2.

    Use the information on the assembled documents to verify the following information on the Shop Order:

    • Shop Order
    • Purchase Order
    • Ship Date, Print Date, Dock Date
    • Quantity
    • Shipping/Billing Address
    • Part Number
    • Revision
    • Ship Method
    • Negative Number to indicate New or AB
    • Special Customer Requirements
    • Other

    Customer Service Personnel or Engineering Personnel

     3.

    Ask: Is the information on the Shop Order accurate and complete as compared to the customer purchase order and assembled documents?

    • If NO, go to Step 4.
    • If YES, go to Step 5.

    Customer Service Personnel or Engineering Personnel

     4.

    Reconcile information to assure that it is accurate and complete on the Shop Order and Price Card software.

    Customer Service Personnel or Engineering Personnel

     5.

    Record the results of the Quality Plan Inspection on FM-824-01, Production Inspections Report.

    Customer Service Personnel or Engineering Personnel



    5.2 New Film and Paper Print Inspection
    Use the steps in the table below to perform a New Film or Paper Print Inspection.

    Note: The purpose of this inspection is to assure that the film, a printed paper copy, or a prototype/sample has been made correctly before the customer order is sent to the next operation.

    Step

    Action

    Person(s) Responsible

     1.

    Access the film, a printed paper copy, or a printed prototype/sample to be inspected, and assemble one or more of the following available documents:

    • Shop Order, FM-710-01
    • Blueprint
    • Customer Proof
    • Sample
    • Printout of Customer Supplied Art File

    Photo Department Personnel
    Proofreaders

     2.

    Use the information on the assembled documents to verify the following customer order film requirements:

    • Type
    • Font
    • Pitch
    • Case
    • Text
    • Spelling
    • Punctuation
    • Emulsion Side
    • Cut lines/Die Lines/Cut registration marks
    • Positive vs. Negative Image
    • Objects
    • Order
    • Logo
    • Text Boxes/Pads
    • Hole Spots
    • Borders
    • Step and Repeat
    • Registration Marks
    • Bleeds & Traps
    • Film Print Order
    • Other

    Photo Department Personnel
    Proofreaders

     3.

    Ask: Is the film, paper print or prototype/sample accurate and complete as compared to the customer blueprint and/or assembled documents?

    • If NO, go to Step 4.
    • If YES, go to Step 5.

    Photo Department Personnel
    Proofreaders

     4.

    Reconcile inaccuracies and variations to requirements, and return to Step 1.

    Photo Department Personnel
    Art Department Personnel
    MRB Member, as necessary
    Proofreaders

     5.

    Record the result of the New Film Inspection or Paper Print on FM-824-01, Production Inspections Report.

    Photo Department Personnel
    Proofreaders

     

    5.3 Print, Metalphoto, Digital Print, and Markem Print Inspection

    Use the steps in the table below to perform a print inspection during the production of a customer order.

    Step

    Action

    Person(s) Responsible

     1.

    Access printed parts to be inspected, and assemble one or more of the following documents:

    • Shop Order, FM-710-01
    • Sample
    • Blueprint, if necessary

    Print Department Personnel

     2.

    Use the information from the assembled documents to verify the following on the printed parts as appropriate:

    • Registration
    • Colors
    • Correctness of Material
    • Grain of Material
    • Other

    Print Department Personnel

     3.

    Record the results of the print inspection on FM-824-01, Production Inspection Report

    Print Department Personnel

     4.

    Estimate the number of good parts required to complete the customer order, and record the number on FM-824-01, Production Inspections Report.

    Print Department Personnel

     5.

    Ask: Are enough good parts available to complete the customer order?

    • If NO, go to Step 6.
    • If YES, go to Step 8.

    Print Department Personnel

     6.

    Reconcile the number of parts needed.

    Print Department Personnel

     7.

    If more parts are produced to reconcile the number of parts needed, go back to Step 2.

    Print Department Personnel

     8.

    Dispose of flats determined to be bad.
    Reference:
    OP-830-01 Control of Nonconforming Product

    Print Department Personnel

     

    5.4 Etch, Paint, and Relieving Inspection

    Use the steps in the table below to perform a quality inspection for the etch, paint, relieving, and lacquer operations during the production of a customer order.

    Step

    Action

    Person(s) Responsible

     

    1.

    Access etched, painted, or relieved parts to be inspected, and assemble one or more of the following documents:

    • Shop Order
    • Sample
    • Blueprint, if necessary

    Etch, Paint, Relieving Personnel

    2.

    Use the information from the assembled documents to verify the following at the appropriate stage of production;

    • Depth of Etch
    • General Etch Quality
    • Paint Color
    • Paint Finish
    • Painted Flats are sufficiently clean
    • Relieved Parts are sufficiently clean
    • No excess scratches
    • Other

    Etch, Paint, Relieving Personnel

    3.

    Record the results of the Etch, Paint & Relieving inspection on FM-824-01, Production Inspections Report :

    Etch, Paint, Relieving Personnel

    4.

    Estimate the number of good parts required to complete the customer order.

    Etch, Paint, Relieving Personnel

    5.

    Ask: Are enough good parts available to complete the customer order?

    • If NO, go to Step 7.
    • If YES, go to Step 9.

    Etch, Paint, Relieving Personnel

    6.

    Reconcile the number of parts needed.

    Etch, Paint, Relieving Personnel

    7.

    If more parts are produced to reconcile the number of parts needed, go back to Step 2.

    Etch, Paint, Relieving Personnel

    8.

    Dispose of flats determined to be bad.
    Reference:
    OP-830-01 Control of Nonconforming Product

    Etch, Paint, Relieving Personnel

    5.5 First Piece Inspection
    Use the steps in the table below to perform a first piece inspection on machined parts. Note: The machining process may produce a finished part in a single operation, i.e. die stamping, or multiple operations may be required to produce a finished part, i.e. kickpress holes and round corners. The first piece inspection may be performed in multiple stages appropriate to the requirements of the part.

    Step

    Action

    Person(s) Responsible

     1.

    Access one or more of the following documents that contain the dimensional information and machining instructions for a customer order:

    • Shop Order
    • Blue Print
    • Sample
    • Other

    Machine Department Set-up Personnel or Supervisor

     2.

    Identify the dimensions to be measured and recorded on FM-824-01.

    Machine Department Set-up Personnel or Supervisor

    3.

    Measure the dimensions on an appropriate set up piece, and record the results on FM-824-01.

    • Blueprint Requirements
    • Actual Measured Dimensions
    • Equipment used for Measurement
    • Accept or Reject

    Machine Department Set-up Personnel or Supervisor

    4.

    Do all dimensions on the set up piece meet the requirements?

    • If NO, go to Step 5.
    • If YES, go to Step 7.

    Machine Department Set-up Personnel or Supervisor

     5.

    Make adjustments to the machinery as required.

    Machine Department Set-up Personnel or Supervisor

     6.

    Produce/Machine another sample piece, and go back to step 3.

    Machine Department Set-up Personnel or Supervisor

     7.

    Visually inspect selected set up piece for overall machining quality.

    Machine Department Set-up Personnel or Supervisor

     8.

    Ask: Is the set up piece's overall quality acceptable?

    • If NO, go to Step 9.
    • If YES, go to Step 15.

    Machine Department Set-up Personnel or Supervisor

     9.

    Make adjustment to the machinery operations.

    Machine Department Set-up Personnel or Supervisor

     10.

    Ask: Is it appropriate to create and measure another set up piece?

    • If NO, go to Step 14.
    • If YES, go to Step 12.

    Machine Department Set-up Personnel or Supervisor

     12.

    Produce/Machine another set up piece, and go back to Step 3.

    Machine Department Set-up Personnel or Supervisor

     14.

    Dispose of parts determined to be bad.
    Reference:
    OP-830-01 Control of Nonconforming Product

    Machine Department Set-up Personnel or Supervisor

     15.

    Insert the sample piece into the shop order envelope, FM-710-01 or into the Production Inspection Form envelope, FM-824-01, for future measurements and inspections.

    Machine Department Set-up Personnel or Supervisor

    5.6 Final Inspection
    Use the steps in the table below to perform a final inspection of a customer order during the shipping operation.
    Note: Final Inspection is a visual inspection. Orders which require a more comprehensive final inspection shall be processed in accordance with WI-751-01, Tier 1 Inspection.

    Step

    Action

    Person(s) Responsible

    1

    Customer order received in the inspection department.

    Inspection and Packaging Personnel

    2

    Access one or more of the following documents accompanying the customer order:

    • Blue Print
    • Sample
    • Shop Order, FM-710-01
    • Production Inspection Form, FM-824-01
    • Other

    Inspection and Packaging Personnel

    3

    Determine the final inspection requirements for the order;

    • If order should be inspected to Tier 1, Aerospace Customer, or Special Requirements, go to Step 4.
    • If order can be inspected to standard requirements, go to Step 5.
    Inspection and Packaging Personnel
    4

    Forward parts and documents to the Tier 1 Inspection Dept.

    Process ends here.

    Inspection and Packaging Personnel
    5

    Review the selected documents for the following order requirements;

    • All operations have been performed and signed off on the Shop Order, FM-710-01
    • Production inspections have been performed and the results properly documented
    • Colors
    • General Appearance
    • Correct number of holes, if required
    • Rounded corners, if required
    • Burrs/FOD
    • Other

    Inspection and Packaging Personnel

    6

    Visually inspect each part for the requirements identified in the previous step.

    Inspection and Packaging Personnel

    7

    Ask: Are there enough good parts to meet the customer's requirements?

    • If NO, go to Step 8.
    • If YES, go to Step 10.

    Inspection and Packaging Personnel

     8

    Notify the Lead Inspector, member of the Quality Assurance Team, or a MRB Member.

    Inspection and Packaging Personnel

     9

    Reconcile the number of good parts needed for shipment.

    Inspection and Packaging Personnel
    Lead Inspector
    Quality Assurance Manager

     10

    Record the results of the final inspection in the space provided on form, FM-824-01, Production Inspections Report.

    Inspection and Packaging Personnel

    11

     Dispose of parts determined to be bad.

    Reference: OP-830-01 Control of Nonconforming Product

    Inspection and Packaging Personnel

     12

     Record the completion of the final inspection on the back of the Shop Order:

    • Quantity of Parts to ship
    • Date of Shipment
    • Inspector’s Initials

    Inspection and Packaging Personnel

    5.7 Ship From Stock Inspection
    Use the steps in the table below to inspect parts which will be shipping from a previous production run, i.e. "Ship From Stock"
    .

    Step

    Action

    Person(s) Responsible

    1

    The Inspection department receives an order with parts that were manufactured and inspected as part of a previous production run.

    Inspection and Packaging Personnel

    2

    Access one or more of the following documents accompanying the customer order:

    • Blue Print
    • Sample
    • Shop Order, FM-710-01
    • Production Inspection Form, FM-824-01 for the current order
    • Production Inspection Form, FM-824-01 from the previous order, if available
    • Other

    Inspection and Packaging Personnel

    3

    Determine the final inspection requirements for the order;

    • If order should be inspected to Tier 1, Aerospace Customer, or Special Requirements, go to Step 4.
    • If order can be inspected to standard requirements, go to Step 5.
    Inspection and Packaging Personnel
    4

    Forward parts and documents to the Tier 1 Inspection Dept.

    Process ends here.

    Inspection and Packaging Personnel
    5

    Determine the criteria for acceptance or rejection based on the original inspection requirements and the current order requirements;

    • Overall print quality
    • Colors
    • Correct Material
    • Material Grain
    • Finish
    • Dimensional Characteristics
    • All operations complete
    • Age sensitive materials are not past the expiration date, and an appropriate amount of shelf life is still available.

    Inspection and Packaging Personnel

    6

    Inspect each part for the requirements identified in the previous step.

    Inspection and Packaging Personnel

    7

    Ask: Are there enough good parts to meet the customer's requirements?

    • If NO, go to Step 8.
    • If YES, go to Step 10.

    Inspection and Packaging Personnel

     8

    Notify the Lead Inspector, member of the Quality Assurance Team, or a MRB Member.

    Inspection and Packaging Personnel

     9

    Reconcile the number of good parts needed for shipment.

    Inspection and Packaging Personnel
    Lead Inspector
    Quality Assurance Manager

     10

    Record the results of the final inspection in the space provided on form, FM-824-01, Production Inspections Report.

    Inspection and Packaging Personnel

    11

     Dispose of parts determined to be bad.

    Reference: OP-830-01 Control of Nonconforming Product

    Inspection and Packaging Personnel

     12

     Record the completion of the Ship from Stock inspection on the back of the Shop Order:

    • Quantity of Parts to ship
    • Date of Shipment
    • Inspector’s Initials

    Inspection and Packaging Personnel




  6. RECORDS/OBJECTIVE EVIDENCE

    The retention duration for records referenced in this procedure are available on-line in the FM-423-01 Master Document List with Revision History.
    Records are maintained in accordance with OP-424-01 Control of Quality Records.


  7. REVISION HISTORY

    Revision, approved date, effective date, and a document change summary for this document is located on-line in the FM-423-01 Master Document List with Revision History.