QUALITY MANUAL REVISION G EFFECTIVE JANUARY 2007 R.T. BLACKHAWK MACHINE PRODUCTS, INC. 956 GARDNER STREET SOUTH BELOIT, IL 61080 ______________________________ Russell Tiritilli President ______________________________ Terrence Hatch Quality Manager ______________________________ Date TABLE OF CONTENTS 1.0 SCOPE OF QUALITY COMMITMENTS 1.1 STATEMENT OF GOALS AND PURPOSE 1.2 ORGANIZATION CHART 1.3 QUALITY MANUAL AUTHORITY AND REVISIONS 2.0 QUALITY PLANNING 2.1 QUALITY SYSTEM 2.2 NEW PRODUCTS 2.3 INSPECTION 2.4 PRODUCTION 3.0 DOCUMENTATION CONTROL 3.1 DRAWING CHANGES 3.2 ROUTINGS 3.3 WORKING STORAGE 3.4 ARCHIVING 4.0 MANAGEMENT QUALITY FUNCTIONS 4.1 PURCHASING CONTROL 4.2 CORRECTIVE ACTIONS 4.3 AUDITS 5.0 MATERIALS CONTROL 5.1 RAW MATERIAL RECEIVING 5.2 NONCONFORMING MATERIALS 5.3 INVENTORY 5.4 PACKAGING AND SHIPPING PROCEDURES 6.0 INSPECTION CONTROL 6.1 RECEIVING INSPECTION 6.2 INPROCESS INSPECTION 6.3 FINAL INSPECTION 6.4 MEASURING EQUIPMENT 6.5 NON-DESTRUCTIVE TESTING 7.0 MONITORING QUALITY COSTS 7.1 REWORK AND EXTRA INSPECTION 7.2 EMPLOYEE EFFICIENCY 7.3 QUALITY LABOR COSTS 7.4 COST OF DIRECT LABOR AND REWORK 8.0 EMPLOYEE TRAINING 8.1 BULLETIN BOARD 8.2 NEW EMPLOYEES 8.3 OUTSIDE TRAINING 8.4 IN HOUSE TRAINING 8.5 INSPECTION TRAINING 8.6 SPC TRAINING 8.7 EMPLOYEE AFFADAVIT 9.0 APPENDIX 9.1 QUALITY MANUAL REVISION LOG 9.2 EMPLOYEE AFFADAVIT 9.3 INSPECTION REPORT 9.4 INTERNAL QUALITY AUDIT REPORT 9.5 SPC RUN TIME CHART 9.6 CORRECTIVE ACTION REPORT 9.7 QUALITY MANUAL RELEASE LOG 9.8 CORRECTIVE ACTION LOG 9.9 SPC INSTRUCTION SHEET 9.10 NON-DESTRUCTIVE TESTING INSPECTION REPORT 9.11 SAMPLE SPC SOFTWARE PRINTOUT 9.12 STEEL INVENTORY CONTROL LOG 9.13 INSPECTION REPORT AUDIT LOG 9.14 FINAL INSPECTION SAMPLING PLAN 9.16 SAMPLE GEAR & THREAD SOFTWARE PRINTOUTS 9.17 SAMPLE KEYWAY SOFTWARE PRINTOUT 9.18 CUSTOMER SATISFACTION AUDIT 1.0 SCOPE OF QUALITY COMMITMENTS 1.1 STATEMENT OF GOALS AND PURPOSE 1.1.1 Profit and quality: The goals of R.T. Blackhawk Machine Products, Inc. include producing quality machined parts in a profitable and cost effective manner while reducing waste and inefficiency in order to meet and exceed customer requirements for quality service and timely delivery. 1.1.2 Environment: The most important assets of the company are the people that work here, and in recognition of this fact the company will strive to create a stable and pleasant work environment, to foster good relationships, and to build a sense of pride and accomplishment in the work being done. 1.1.3 Facilities: In addition, the tools, facilities and equipment of the company are also considered to be essential for its success, and their continued care and improvement should be important to all personnel. 1.1.4 Communication: In order to accomplish these goals the company will strive to maintain open lines of communication concerning quality issues and business in general, both internally, and with the customer. 1.1.5 Future growth: Though future growth due to necessity can be a good thing, Blackhawk will continue to consider stability and quality workmanship more important than expansion. 1.2 ORGANIZATION CHART ______________________ R.T. BLACKHAWK MACHINE PRODUCTS, INC. 956 Gardner Street South Beloit, IL 61080 BOARD OF DIRECTORS | | PRESIDENT/SHOP MANAGER Russell Tiritilli | | ------------------------------------------------------------- | | | | | | | | SECRETARY/TREASURER PRODUCTION MANAGER QUALITY MANAGER ADMINISTRATIVE ACCOUNTS RECEIVABLE Gina Tiritilli-Rand ENGINEER Gina Tiritilli-Rand PERSONNEL | Terrence Hatch Kay Tiritilli | | MFG PERSONNEL 1.3 QUALITY MANUAL AUTHORITY AND REVISIONS 1.3.1 Authority: This manual establishes standards and procedures necessary to insure product conformance as defined by customer purchase order requirements, and is the final authority for questions pertaining to quality issues. 1.3.2 Bi-annual revisions: The procedures contained herein will be revised on a regular basis in order to insure a dynamic and viable quality program. A maximum time period of two years will elapse between complete revisions. A complete revision is defined as a revision of the Quality Manual that brings the entire manual into agreement with current policies and working practices of the company. The Quality Manager, and ultimately the President of the company, are responsible for insuring that these revisions are performed on schedule. 1.3.3 Other revisions: Revisions may also be performed at any time by the Quality Manager or the President after adequate consultation with those affected by the changes per the Quality Planning policies included in this manual. 1.3.4 Revision log: All revisions must be noted in the revision log found in section 9.1 of the manual. 1.3.5 Record of copies released: A separate Quality Manual Release Log will also be maintained in the master copy of this manual, in which will be recorded a history of all copies of the master Quality Manual that are released. The log will track the revision levels of these copies, identification of who was responsible for their release, and who they were released to. 1.3.6 Title page: The revision letter and date of this manual will be published on the title page of the manual. 2.0 QUALITY PLANNING 2.1 QUALITY SYSTEM PLANNING When the Quality Manual is due to be revised, members of management will review the current revision and will meet to discuss changes needed and possible improvements to the quality system. Results of this meeting will be incorporated in the new revision of the Quality Manual. 2.2 NEW PRODUCTS PLANNING 2.2.1 Routings: The President, or an assignee that reports directly to the President, is to be responsible for planning the manufacture of all new products by means of creating a routing which will be followed during the manufacture and inspection of the parts. There are two possible types of routings which may be used, the card style and the sheet style. 2.2.2 Card style routings: A card style routing will consist of cards which will be stored by part number in a card file. These will be used when the amount of necessary information is minimal and can easily be contained on a 4 X 6 card. The card will include a list of operations and any special instructions necessary to make a good part. The information will then be copied by hand directly onto the print when a new job is released. 2.2.3 Sheet style routings: A sheet style routing will contain the same information as above, only unlimited sheets will be available for recording process dimensions and instructions. Routings will be stored in a master routing file by customer and part number. A copy will be made and stamped with the Shop Order number. Then it will be inserted in the job jacket when a new order/job is released to the floor. 2.3 INSPECTION PLANNING 2.3.1 Creating special inspection requirements: The person responsible for creating the routing will also determine any special inspection requirements and record them on the routing as described in the paragraphs on New Product Planning. 2.3.2 Creating inspection data sheets: The Floor Inspector will create an Inspection Data Sheet for jobs that require diagrams to describe unusual inspection methods, or that require computer printouts to determine gear or thread pin dimensions. The sheet may also be used to record notes about potential problems as a means of providing corrective action. The sheet will then be filed in the Inspection Data Sheets notebook, which will be kept in the inspection area. Data from gear, thread or keyway software may be included (section 9.16 & 9.17). 2.3.3 Creating inspection reports: When a job is released to the floor, the office clerk will include a copy of the Master inspection report in the job jacket after stamping it with the shop order number. Before or during the first piece inspection for the first operation the floor inspector will create a new Inspection Procedure if one does not already exist by recording routing and print requirements on the Inspection Report, and will create an Inspection Data sheet if applicable. (see appendix). As the parts progress through the manufacturing process, the Inspection Report will be used to record actual measurements. 2.4 PRODUCTION PLANNING 2.4.1 Job Data Report: The Office Clerk will maintain a delivery schedule that lists each job currently in the shop and the due date along with those operations that remain to be completed. This report will be available for the Shop Manager to aid in planning the order of job sequences in work centers, and will be available to the President to aid in planning backlog, and to both for providing information on expected completion dates to customers. As operations are completed, the Office Clerk will delete operations from the report. 2.4.2 Job sequence: When the job sequence has been decided for a work center, the Shop Manager will sort the job packets into the correct order and will place them in slots on the office wall that correspond to the various work centers. When an operator completes an operation, he will send the job packet along with the parts to inspection, and will pick the next job in line from the slot for his machine. In the case of large parts, the operator may opt to send only the packet to inspection, and the inspector may opt to inspect the parts where they lie. After inspection, the inspector will send the job packet to the office to be placed in sequence for the next operation. 2.4.3 Updating database: As jobs are completed and shipped, and as operations are completed, the Office Clerk will update the Production Schedule Report. 3.0 DOCUMENTATION CONTROL 3.1 DRAWINGS 3.1.1 Drawing changes: If it is necessary to make a change to a drawing that Blackhawk has created, a description of the change, along with the date, revision level, and initials of the person making the change will be noted on the master copy of the print. When applicable, copies of the print currently accompanying active jobs will be updated. 3.1.2 Matching revision levels: Prints that customers supply will be kept in files in the office. The Office Clerk is responsible for maintaining these files. When a new print is received from a customer, the Office Clerk will discard the old print and replace it with the new one. Prior to releasing a job to the shop floor, the Office Clerk will compare the revision level of the print from the file with the purchase order requirements. If they do not match, the Office Clerk will call the customer to request a current print. 3.2 ROUTINGS 3.2.1 Routing changes: If it is necessary to make a change or addition to a routing, the change will be made to both the master file copy and, when applicable, to the copy accompanying any jobs that have already been released to the floor. 3.2.2 Non-essential copies: The company will continue a policy of destroying all copies of routings other than: > the master copy > copies currently in use with active jobs > copies stored with paperwork from completed jobs 3.3 WORKING STORAGE 3.3.1 Access and maintenance: The master copies of routings and drawings will be kept in files in the office. Access to these files will be limited to office personnel to insure the integrity of the documents. The Office Clerk will be responsible for maintenance of the files. 3.3.2 Inspection notebook: Inspection Data Sheets will be stored in a notebook located in the inspection area. The Floor Inspector will be responsible for maintenance of the documents and will control access to the sheets and their application. 3.3.3 QA Documents notebook: The company will maintain a notebook labeled "Blackhawk Quality Assurance Documents" in the Inspection Dept. This notebook will contain sections for storing the master copy of the Quality Manual, copies of internal audits, corrective action reports, quality ratings from customers, and supplier ratings. The Quality Manager will be responsible for maintaining this notebook and for releasing copies of the Quality Manual. 3.3.4 Quality Manual Appendix: Master Samples of all quality related documents will be kept in the appendix of the Quality Manual. Changes to these documents will be noted in the revision log of the Quality Manual. The Quality Manager will be responsible for maintaining, updating and releasing these documents. 3.4 ARCHIVING When a job is completed, the Office Clerk will remove the file of current paperwork from the active files and will place it with the archive files. Once every year the Office Clerk will place the archive files for the past year in a box which will be stored in the attic for possible future reference. The files will be stored in order of company and purchase order, and will include copies of the purchase order, prints used, inspection report, material certs if applicable, and other miscellaneous related paperwork and packing slips. 4.0 MANAGEMENT QUALITY FUNCTIONS 4.1 PURCHASING CONTROL 4.1.1 Purchasing Policy: The President, after consultation with the Shop Manager and Quality Manager is responsible for approving all vendors, and is ultimately responsible for approving, either directly or by means of verbal policies, all purchases made within the company. In addition, purchases identified as involving significant cost will be adequately researched by the acquisition of more than one quote from more than one approved source. 4.1.2 Approved Vendors List: The President or his asignee will create a list of approved vendors reflecting the President's conclusions regarding the quality and service they provide. A copy of this list will be kept in the Blackhawk Quality Assurance Documents notebook, and will be updated whenever this Quality Manual is revised, or whenever a vendor's status changes. 4.2 CORRECTIVE ACTIONS 4.2.1 Internal Corrective Actions: All personnel employed by the company are responsible for reporting quality concerns that may require corrective action to management. Management is responsible collectively for conferring among themselves as is necessary to arrive at a consensus and implement solutions. The President, Shop Manager and Quality Manager are responsible for implementing solutions that in the office, on the shop floor, and in the inspection area, as required. The Corrective Action Log Sheet (see appendix) is to be filled out and initialed as a record for future reference, and will be kept in the Quality Assurance Documents notebook. It will be reviewed by management whenever the Quality Manual is revised. 4.2.2 Customer Corrective Actions: Corrective Action forms received from our customers will be completed and returned in a timely fashion before the required due date. The President is responsible for assigning responsibility for their completion. The person that completes the form is also responsible for making sure the corrective action is implemented. A copy of the completed form will be filed in a section of the Blackhawk Quality Assurance Documents notebook. 4.2.3 Means of Corrective Action: Corrective actions should be accomplished in ways that provide for permanency. Proven methods include adding notes to the routing, inspection procedures, or inspection reports, and making changes to tooling. Other possibilities include policy changes, revisions of the quality manual, creation of process prints or setup sheets, modification of forms, and changes in personnel. 4.3 AUDITS 4.3.1 Quality Manual Procedures: Audits will be conducted periodically to verify that standards and procedures contained in the Quality Manual are being adhered to. The maximum time period between audits will be two years. An Audit Report Form (section 9.4) will be completed by the Quality Manager at the time of the audit, and will be filed in the Blackhawk QA Documents notebook. Corrective Actions required to bring standards and procedures up to date should be documented on the audit forms. Information resulting from the audits should be available to those persons responsible for updating the quality manual (see paragraphs on Quality Manual revisions). 4.3.2 Inspection Reports: Inspection reports will be subjected to audits to determine accuracy and completeness. The auditing procedure will consist of comparing the report with the print, looking for missing dimensions or unacceptable readings, and double-checking the accuracy of critical readings. Any person in management may audit the report, but the Quality Manager has the added responibility of insuring that reports are audited periodically, with extra attention being given to the reports when a new Floor Inspector takes over. Whenever a report is audited, the Inspection Report Audit Log in the Internal Audits section of the QA notebook will be signed and dated. 4.3.3 Customer Satisfaction: A form letter (section ) will be available to mail to customers at the discression of the owner to gage our customer's satisfaction with our service, quality, price and delivery. Copies returned by customers will be filed for future reference. 5.0 MATERIALS CONTROL 5.1 RAW MATERIAL RECEIVING 5.1.1 Packing List: The cutoff operator will receive and sign for all raw material for Blackhawk Machine (Bar Stock, Castings, Customer furnished parts, Etc.). The cutoff operator will check material to verify correct size and quantity per packing list from supplier. This packing list will then be given to the Shop Manager who will match up the packing list with the corresponding shop order. 5.1.2 Cutting and Marking: The shop order will then be given to the cutoff operator and he will either cut the material per the instructions on the shop order or mark the material with the shop order number. If the material is to be cut there will be a tag placed with cut up material showing the shop order to which the material belongs. Any unused material will be marked with proper identification and put into stock for future use. 5.2 NONCONFORMING MATERIALS CONTROL 5.2.1 Separation of Nonconforming Materials: Nonconforming materials when created or found will be placed in barrels assigned for that purpose, or placed on the NonConforming Materials shelf located in the inspection area, or will be clearly identified as nonconforming by attaching tags, marking with an indelible marker, or permanently stamping or engraving. 5.2.2 Acceptance of Nonconforming Materials: Nonconformances that violate process dimensions may be accepted by the Floor Inspector. Parts rejected by the Floor Inspector may, after further review, be accepted by the Quality Manager, or in case of absence, the President. When nonconforming parts violate print dimensions and/or customer policies and standards, the readings must be communicated to the customer for approval. 5.3 INVENTORY CONTROL 5.3.1 Authority: Authority for authorizing additions or subtractions to inventory will be restricted to the Office Clerk and the Shop Manager. 5.3.2 Inventory reports: Master copies of a parts inventory report and a materials inventory report will be maintained by the office clerk. Copies of these reports will be located in the inventory areas, and will be updated as parts or materials are placed into inventory, or removed from inventory. Periodically, as the reports become marked up, the master copies will again be updated by the Office Clerk, who will then place new copies in the inventory areas. 5.3.3 Tooling Inventory: Tool numbers and locations will be assigned to dedicated tooling used for the completion of operations in the shop. Generic tooling may also be assigned tool numbers if beneficial to prevent their misplacement. Tool number information will be recorded in a database on a computer in the Inspection Department. The database will be available for routine searches, and will be backed up at regular intervals on the computer in the office. 5.4 PACKAGING AND SHIPPING PROCEDURES 5.4.1 Protecting Parts: When parts have been approved for shipping, the Shipping Clerk will count them, clean them (if necessary), and spray them with rust inhibitor (if applicable). Upon receipt of the shipping papers from the Office Clerk, the Shipping Clerk will then package parts for shipping in a manner appropriate for the intended shipping carrier. The parts will be packed so as to prevent damage by the carrier during handling. It is entirely the Shipping Clerk's responsibility to assure that parts are protected from damage during shipping. 5.4.2 Auditing: The Quality Manager will periodically spot check the packaging and shipping of parts. 5.4.3 Supplies: The Shipping Clerk is responsible for keeping necessary packaging supplies on hand and for notifying the Shop Manager of any problems or shortages. 6.0 INSPECTION CONTROL 6.1 RECEIVING INSPECTION 6.1.1 Machined Parts: Parts received from an outside supplier will be delivered to the inspection area for inspection. From this point on the parts will be treated as though they were machined within the company with respect to the inspection, recording of results, and disposition and handling of the parts. Procedures for these functions are contained elsewhere in this manual. 6.1.2 Supplier feedback: When dimensional or quality discrepancies are discovered among parts received from a supplier (of which the supplier did not previously notify us), the supplier will be notified of the discrepancies. 6.2 INPROCESS INSPECTION 6.2.1 First Piece Inspection: When an operation is set up on a machine, the operator will notify the Floor Inspector when the first piece is ready for inspection. The Floor Inspector will then inspect this piece and record the results. The operator will wait for the inspector's approval before beginning production. 6.2.2 SPC charting: The SPC Run Time Chart will be used to record measurements for those operations where the volume of parts and the nature of the dimension(s) being held make it applicable. Such charting may be requested by any person involved in the planning or production of the part, or may be instituted during the quality planning stage. The quality manager will be responsible for setting up and releasing the chart to the floor. The operator will be responsible for completing the chart. The chart will then be filed along with the Inspection Report in the office by the Office Clerk, for later archiving. 6.2.2.1 SPC software: SPC software is available in the office. At any time an operator can submit a list of dimensional readings from a 32 piece minimum sample along with the tolerance limits to the Quality Manager. The quality manager will enter these readings and will return a report that predicts what percentage of parts (if any) is expected to fall outside the tolerance limits. 6.2.3 Inprocess inspection: The operator is ultimately responsible for the quality of parts produced, and is responsible for checking a minimum of 1 in 10 parts as they are run. In addition, any dimensions that use most of the tolerance range should be checked 100 percent, and any special inspection instructions on the routing or print must be followed. 6.2.4 Inprocess auditing: On long running jobs defined as more than 25 pieces the Floor Inspector will visit the work center periodically to inspect the latest part from the machine. As he checks the part he will be alert for any inadequacies in the gages or procedures being used by the operator. 6.2.5 Inprocess corrective action: If parts are being scrapped during an operation, or are in danger of being scrapped, the Shop Manager will be notified and will initiate an investigation for the purpose of implementing corrective action. 6.2.6 Problem reporting: Whenever problems with parts are discovered, they will be noted on the Inspection Report and the Shop Manager will be notified. In addition, if problems with the inspection process are discovered, or the inability to check certain features, the Quality Manager will be notified. When problems with the routing or process are discovered, the President will be notified. 6.3 FINAL INSPECTION 6.3.1.1 Responsibility: The Floor Inspector or his assignee is responsible for performing a final inspection of all parts prior to packaging and shipping. 6.3.1.2 Sampling Plan: Sizes of random samples to be inspected for all non-critical dimensions will be a minimum of 5 pieces or 10 percent, whichever is greater. Sample sizes may also be determined by the sampling plan in section 9.14. 6.3.1.3 Critical Dimensions: Critical dimensions will always be inspected 100 percent unless the use SPC is warranted, or is requested by the customer. Critical dimensions are defined as those dimensions declared to be critical by the print, routing, floor inspector, or management. 6.3.2 Auditing inspectors: If the Floor Inspector assigns a person to perform inspection, the Floor Inspector is further responsible for performing an audit of the inspection process to insure that the results generated are accurate. 6.3.3 Recording readings: As first piece inspections, inprocess inspections, and final inspections are performed on parts, the Floor Inspector will record the results on the Inspection Report. If the first piece includes rough dimensions that will be finished at a later operation, the Floor Inspector will note their acceptance or actual readings in the designated column. 6.3.4 SPC final inspection: Whenever a lot quantity exceeds 320 pcs, SPC may be used to reduce inspection levels or it may be used on smaller quantities to increase the quality of inspection performed. To perform SPC on a dimension, the floor inspector will record readings from a minimum of 32 parts and will submit them along with the tolerance limits to the Quality manager. If the resulting report reveals no problems, no further inspection is required. For most dimensions, a 3 sigma quality level is acceptable. In the case of critical dimensions, a 4 sigma quality level will be necessary. If the results reveal a problem, 100 percent inspection will be necessary. 6.4 MEASURING EQUIPMENT 6.4.1 Definition: Measuring equipment is defined as all gauges, test equipment, and tools used to measure or test whether a part meets customer requirements. Such equipment is subject to periodic review and calibration as applicable. 6.4.2.1 Master Gage Blocks: A master set of gage blocks will be used as the final standard for all calibrations performed in the shop. This set of standards must be checked for accuracy and certified by an approved outside source at least once every five years. This source must be able to certify the blocks to the nearest 1 millionth inch accuracy, and must be able to certify traceability back to the National Institue of Standards and Technology (was National Bureau of Standards). 6.4.2.2 Working Gage Blocks: A working set of gage blocks will not be used to check tolerances closer than .002. This set must be checked against the master gage blocks once every five years and the readings must be recorded and kept near the blocks. 6.4.3 Calibration Schedule: All measuring gages and equipment be checked for accuracy and calibrated as applicable per the calibration schedule. Stickers with the initials of the person who performed the calibration and the next calibration due date will be applied to the gages or their containers. The process will be audited whenever the Quality Manual auditing process is performed (see section on Management Quality Function Audits). A calibration sequence as described in the 12 divisions of the calibration schedule (Section 9.15) will be adhered to. 6.5 Non-destructive testing: Non-destructive testing for cracks will be performed by the Floor Inspector or his assignee whenever it is required by the print or routing. A checklist form provided for that purpose (section 9.10) will be filled out at the time of the testing and will be signed and dated by the person doing the inspection when it is required by the customer. 7.0 MONITORING QUALITY COSTS 7.1 TIME REPORTING Time cards will be used by employees to report time spent on particular jobs. Employees will be able to clock in on rework and inspection in addition to the more direct labor categories. They will apply their time to specific jobs. This data will be used by the Office Clerk for preparing Efficiency Reports, and will be recorded on the Part Number History Cards. 7.2 EMPLOYEE EFFICIENCY 7.2.1 Efficiency Reports: The Office Clerk will prepare efficiency reports and post them on the bulletin board on a weekly basis. These reports will detail the time spent making parts compared to the time alotted in the rate for making the same parts. One of the purposes of these reports will be to provide employees with a source of feedback that will help employees make better decisions when faced with choices concerning the reworking, remaking, or scrapping of parts. 7.2.2 Applying Results: Additionally, these reports will provide a reference for making comparisons when assigning employees to particular jobs, when preparing employee performance ratings, when paying employee bonuses, and when terminating an employee. 7.3 QUALITY LABOR COSTS The company will employ a person whose primary purpose is to perform the duties of a Floor Inspector as described in this manual. His time will be considered to be indirect, and under normal circumstances will not be applied against a particular job. The cost of this labor will be referenced when re-calculating the standard hourly rate that is charged to customers. 7.4 COST OF DIRECT LABOR AND REWORK All direct labor applied toward completion of a job is recorded on the Part Number History cards. This data includes the costs of materials, the costs of outside operations, the times necessary to complete the operations on the routing, and the costs and time necessary to complete any rework that may be required. This information is referenced when determining the price that will be charged to the customer for future orders. 8.0 EMPLOYEE TRAINING 8.1 BULLETIN BOARD The company will maintain and update a bulletin board for the purpose of communicating policies and informational data to employees. This bulletin board will be located in proximity of the time clock to insure ready access. 8.2 NEW EMPLOYEES New employees will be given a copy of the Employee Handbook and a copy of the Quality Manual. When they have completed reading them they will be required to sign a form stating that they have read and understood the contents, and are in agreement with them. This form will be filed in a section of the Blackhawk Quality Assurance Documents notebook. 8.3 OUTSIDE TRAINING The company will provide outside training at company expense when necessary to train individuals to operate pieces of equipment requiring expertise beyond that available within the company. 8.4 IN HOUSE TRAINING Management will assign individuals to train employees who are assigned to operate machines for which they lack familiarity. 8.5 INSPECTION TRAINING It is the responsibility of the Quality Manager and the floor inspector to train individuals in the correct use and application of measuring equipment and quality procedures. Such training is to take place whenever the need is discovered. 8.6 SPC TRAINING A sheet describing the use of SPC charts and software currently exists. It will be given to new employees and handed out as needed to facilitate charting on the shop floor. The master copy will be kept in the appendix of the Quality Manual (section 9.9), and a copy will be placed in the Employee Handbook. 8.7 EMPLOYEE AFFADAVIT New employees will be asked to read the Quality Manual and the Employee Handbook and sign a statement (section 9.2) declaring that they have been read and understood. * * * 9.1 QUALITY MANUAL REVISION LOG Effective: Changes made: BY: APP BY:REV: Rev Ltr ___________________________________________________________________ Before 93|_Manual copied & adapted for our use____|_DJ_|_RT_|__A___ _________|________________________________________|____|____|______ 6/95_____|_Updated to reflect current policy______|_TJH|_RT_|__B___ _________|________________________________________|____|____|______ 1/96_____|_Complete re-write to better reflect way|_TJH|_RT_|__C___ _________|_we do things___________________________|____|____|______ _________|________________________________________|____|____|______ 6/19/96__|_Corrected organization chart to include|_TJH|_RT_|__C1__ _________|_personnel changes______________________|_GT_|____|______ _________|________________________________________|____|____|______ 6/19/96__|_Added Non-destructive Testing Inspection_TJH|_RT_|__C1__ _________|_Report/Procedure (Section 9.10)________|_GT_|____|______ _________|________________________________________|____|____|______ 6/19/96__|_Revised Corrective Action log to include_TJH|_RT_|__C1__ _________|_more Job information (Sect. 9.8)_______|_GT_|____|______ _________|________________________________________|____|____|______ 7/24/96__|_Added sections 9.10 to 9.14 to appendix|_TJH|_RT_|__D___ _________|_Added references to new sections in text_GT_|____|______ _________|________________________________________|____|____|______ 11/9/98__|_3.3.3 - Changed location of QA notebook|_TJH|_RT_|__D1__ _________|_from 'office' to 'Inspection Dept.'____|_GT_|____|______ _________|_4.3.2 - Removed reference to blanks____|____|____|______ _________|_for signatures for audits on Inspection|____|____|______ _________|_reports to agree with latest form._____|____|____|______ _________|_Added 5 piece minimum sample for 5 to__|____|____|______ _________|_50 quantity order in sampling plan.____|____|____|______ _________|________________________________________|____|____|______ 9/30/99__|_Changed 2.3.3 to reflect current file__|_TJH|_RT_|__D2__ _________|_of master inspection reports for_______|_GT_|____|______ _________|_copying which replaced old method of __|____|____|______ _________|_hand copying the information onto a ___|____|____|______ _________|_blank form. Added 5.3.3 describing ___|____|____|______ _________|_our Tooling Inventory system.__________|____|____|______ _________|________________________________________|____|____|______ 10/5/99__|_Added 9.17, 6.4.2.2 and 4.3.3__________|TJH_|RT__|__D3__ _________|________________________________________|GT__|____|______ _________|________________________________________|____|____|______ 10/21/99_|_Revised QM 9.4 Internal Quality Audit__|TJH_|RT__|__D4__ _________|________________________________________|GT__|____|______ 12/28/00_|_Organization Chart updated, some ______|TJH_|RT__|__E___ _________|_paragraphs clarified___________________|GT__|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ _________|________________________________________|____|____|______ 9.2 EMPLOYEE AFFADAVIT I hereby affirm that I have read and understand the R.T. Blackhawk Machine Products Employee Handbook and the Quality Manual, and am in agreement with the goals and policies expressed therein. Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ Signed___________________________________Date______________________ 9.4 INTERNAL QUALITY AUDIT REPORT R.T. BLACKHAWK MACHINE PRODUCTS, INC. 1. Last revision date of Quality Manual (see preface).: ___________ 2. List areas where change is needed to meet minimum requirements of Quality Manual : ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ 3. Last calibration date of master jo blocks (restricted for use in calibration of gages only) (5 yrs max).................: ___________ 4. Last calibration date of service jo blocks (intended for less critical daily inspection of parts) (5 yrs max)........: ___________ 6. Flatness of main granite surface plate (.0002 max).: ___________ Date of last resurfacing...........................: ___________ 7. Areas where calibration schedule is behind.........: ___________ Audited by_______________________ Date________________ 9.5 - SPC RUN-TIME CHART 9.6 CORRECTIVE ACTION REPORT Operation(s) performed by:_______________________ Date:____________ Customer :______________________ Part Number :______________________ Shop Order# :______________________ Qty on order:______________________ Qty rejected:______________________ Date :______________________ Defects discovered at:_____________________________________________ Print dimensions or specifications in question: Nature and extent of the defect: Describe the root cause of the problem: Disposition of the parts: Corrective action taken to prevent reoccurence: Corrective action taken by:_____________________ Date_____________ 9.7 QUALITY MANUAL RELEASE LOG DATE ISSUED RELEASED TO BY INI REV LTR ___________________________________________________________________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ | | | _____________|____________________________________|_______|________ 9.8 INSPECTION DEPARTMENT CORRECTIVE ACTION LOG SHEET ORDER QTY DATE JOB COMPANY QTY AFFCTD CONDITION/CORRECTIVE ACTION DISPOSITION ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ | | | | | | | | | | | | | | | | ____________________________________________________________________________ 9.9 SPC INSTRUCTION SHEET The SPC Run Time Chart is used to record measurements for those operations where the volume of parts and the nature of the dimension(s) being held make it applicable. Such charting may be requested by any person involved in the planning or production of the part. To complete an SPC Run Time Chart, place an X in the box that lines up vertically with the number of the reading, and horizontally with the measured value. In this way a graph will begin to develop as parts are checked that will make drifting and tool wear obvious. In addition, when making an offset change or a tool change, mark a letter O or letter T in the box instead of an X. In this way someone studying the chart will be able to see the causes when such changes cause a sudden jump in the reading. When the job is complete, place the chart in the job packet along with the other paperwork, and send it on as usual. The chart may later be used to reduce necessary inspection levels and may be sent along with the inspection report to the customer. Note: SPC software is also available in the office. At any time, a list of readings can be submitted to the Quality Manager, along with the dimension's tolerance limits. The Quality Manager will enter these readings and return a report that predicts what percentage of parts fall outside tolerance limits at the various quality levels. QCM 9.10 NON-DESTRUCTIVE TESTING INSPECTION REPORT R.T. BLACKHAWK MACHINE PRODUCTS, INC. CUSTOMER_______________________ PART NUMBER____________________ PO NUMBER______________________ QUANTITY_______________________ SAMPLE SIZE____________________ APPROVED SUPPLIERS OF NON-DESTRUCTIVE TESTING SOLUTIONS: Crown Industrial Products Co.; Hebron, IL 60034 Dynaflux, Inc.; Cartsville, GA 30120 PROCEDURE: ____ 1. Pre-clean parts with the cleaner that is certified for this application. ____ 2. Dry thoroughly. ____ 3. Spray penetrant on parts and allow to soak 20 minutes. ____ 4. Sray additional cleaner on a rag and wipe off excess penetrant from parts. ____ 5. Shake developer solution thoroughly. ____ 6. Spray developer on parts from 8 to 12 inches away. Do this no more than 10 minutes after step 4. ____ 7. Allow to develop 5 to 15 minutes. Cracks, pores, and faults will now be outlined in red. QUANTITY ACCEPTED:____________ QUANTITY REJECTED:_____________ COMMENTS:______________________________________________________ TEST PERFORMED BY:______________________ DATE:______________ 9.11 - SAMPLE SPC SOFTWARE PRINTOUT: Standard Deviation = 0.00095 Sample size = 24 readings Average = 0.46355 Spread = 0.00320 Two Sigma Limits = 0.46546 / 0.46165 (+/- 0.00191) Three Sigma Limits = 0.46641 / 0.46070 (+/- 0.00286) Four Sigma Limits = 0.46736 / 0.45974 (+/- 0.00381) READING SAMPLE ------- ------ 0.46350 - - - - - - 1 0.46450 - - - - - - 2 0.46450 - - - - - - 3 0.46220 - - - - - - 4 0.46370 - - - - - - 5 0.46380 - - - - - - 6 0.46410 - - - - - - 7 0.46430 - - - - - - 8 0.46450 - - - - - - 9 0.46360 - - - - - - 10 0.46410 - - - - - - 11 0.46220 - - - - - - 12 0.46180 - - - - - - 13 0.46400 - - - - - - 14 0.46240 - - - - - - 15 0.46500 - - - - - - 16 0.46400 - - - - - - 17 0.46450 - - - - - - 18 0.46320 - - - - - - 19 0.46200 - - - - - - 20 0.46320 - - - - - - 21 0.46350 - - - - - - 22 0.46470 - - - - - - 23 0.46200 - - - - - - 24 QCM 9.12 B L A C K H A W K M A C H I N E P R O D U C T S STEEL INVENTORY CONTROL LOG DATE RECV'D TYPE SHAPE SIZE ________________________________________________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ : : : ___________:____________:____________:__________________________________________ QCM-9.13 INSPECTION REPORT AUDIT LOG DATE AUDITED BY NOTES ______________________________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ | | | | _______|______________|_________________________________________ QCM 9.14 - FINAL INSPECTION SAMPLING PLAN R.T. BLACKHAWK MACHINE PRODUCTS, INC. LOT SIZE SAMPLE SIZE FURTHER INSPECTION REQ ______________________________________________________ 5-50 5 1 REJECT 51-100 10 1 REJECT 101-150 15 1 REJECT 150-200 20 1 REJECT 200-300 30 1 REJECT 301 & OVER 32 WITH SPC 1 REJECT OR SPC RESULTS BASE SAMPLE SIZE ON 10 PCS MINIMUM OR 10 PERCENT, WHICHEVER IS MORE, OR ON ABOVE SAMPLING PLAN. 9.15 GAGE CALIBRATION SCHEDULE CHECKLIST 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 JAN Pin sets ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ 0-.25 |XXXX|XXXX|XXXX|XXXX|____|XXXX|XXXX|XXXX|XXXX|____| .250-.500 |____|XXXX|XXXX|XXXX|XXXX|____|XXXX|XXXX|XXXX|XXXX| .2505-.5005 |XXXX|____|XXXX|XXXX|XXXX|XXXX|____|XXXX|XXXX|XXXX| FEB Plug gages ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ 0"-.500" |____|____|____|____|____|____|____|____|____|____| .500"-1" |____|____|____|____|____|____|____|____|____|____| 1"+ |____|____|____|____|____|____|____|____|____|____| MAR Thread plug gages ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ <=.375 |____|____|____|____|____|____|____|____|____|____| +.375 |____|____|____|____|____|____|____|____|____|____| APR Mics and calipers ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ 0"-11" Mics |____|____|____|____|____|____|____|____|____|____| 12"-18" Mics |____|____|____|____|____|____|____|____|____|____| 6" caliper |____|____|____|____|____|____|____|____|____|____| 40" Caliper |____|____|____|____|____|____|____|____|____|____| ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ MAY Ring gages |____|____|____|____|____|____|____|____|____|____| ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ JUN Thread ring gages |____|____|____|____|____|____|____|____|____|____| ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ JUL Personal gages |____|____|____|____|____|____|____|____|____|____| ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ AUG Indicators |____|____|____|____|____|____|____|____|____|____| SEP Equipment ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ Gear checker |____|____|____|____|____|____|____|____|____|____| Digital height |____|____|____|____|____|____|____|____|____|____| 40" height gage|____|____|____|____|____|____|____|____|____|____| Hardness chkr |____|____|____|____|____|____|____|____|____|____| Optical comp. |____|____|____|____|____|____|____|____|____|____| Profilometer |____|____|____|____|____|____|____|____|____|____| OCT Standards ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ Master blocks |____|XXXX|XXXX|XXXX|XXXX|____|XXXX|XXXX|XXXX|XXXX| Working blocks |XXXX|____|XXXX|XXXX|XXXX|XXXX|____|XXXX|XXXX|XXXX| 0-17" Mic rods |XXXX|XXXX|____|XXXX|XXXX|XXXX|XXXX|____|XXXX|XXXX| 0-6" Micmaster |XXXX|XXXX|XXXX|____|XXXX|XXXX|XXXX|XXXX|____|XXXX| ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ NOV Bore gages |____|____|____|____|____|____|____|____|____|____| Surface plates |____|____|____|____|____|____|____|____|____|____| QM 9.4 Audit |____|____|____|____|____|____|____|____|____|____| ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ DEC Sin Bars |____|____|____|____|____|____|____|____|____|____| V-Blocks |____|____|____|____|____|____|____|____|____|____| Riser blocks |____|____|____|____|____|____|____|____|____|____| Master gage blocks are to be calibrated by an outside source traceable to NISI standards once every five years. All other gages are to be calibrated against master blocks. QCM 9.16 - SAMPLE GEAR & THREAD SOFTWARE PRINTOUTS GearCutter External F1=Help F3=About F4=Print F7=Default ESC=Exit Number of Teeth.................GIVEN: 25.000000 Pitch diameter..................GIVEN:í 3.125000 BASIC Helix angle.....................GIVEN:ø 5.200000 5ø 12' 0" SPECS Diametral pitch: Normal..............: 8.033061 Transverse..........: 8.000000 Pressure angle: Normal.........GIVEN:ø 2.000000 2ø 0' 0" Transverse..........:ø 2.008258 2ø 0' 30" _______Normal metric module (25.4/NDP)......: 3.161933 Circular pitch: Normal..............: 0.391083 AT Transverse..........: 0.392699 PITCH Arc tooth thkns: Normal STD.....GIVEN: 0.195541 DIA (basic) Transverse........F7: 0.196350 Backlash........................GIVEN: 0.000000 _______Chordal tooth thickness..............: 0.195416 Lead.................................: 107.875912 OTHER Base circle diameter.................:í 3.123081 _______Standard outside diameter............:í 3.373971 SPAN Number of teeth in span.........GIVEN: 2.000000 _______Measurement over teeth in span.......: 0.586312 Diameter of pins/balls..........GIVEN:í 0.215111 PINS Over 1 pin to gear centerline........: 1.725350 Over 2 balls equidistant from end....: 3.444316 _______Over 3 pins in two parallel planes...: 3.450701 GearCutter Threads F1=Help F3=About F4=Print F7=Default ESC=Exit ------- Number of threads/starts........GIVEN: 2.000000 Pitch diameter..................GIVEN:í 1.750000 Threads per inch................GIVEN: 4.000000 WORM Linear pitch.........................: 0.250000 OR Lead.................................: 0.500000 THREAD Lead angle...........................:ø 5.196508 5ø 11' 47" DATA Diametral pitch: Axial...............: 12.566371 Normal..............: 12.618233 Standard OD for a worm...............: 1.908501 Pressure angle: Normal.........GIVEN:ø 14.500000 14ø 30' 0" Axial...............: 14.557305 14ø 33' 26" Base circle diameter.................:í 0.578430 _______Axial backlash (worms)..........GIVEN: 0.000000 Pin Diameter....................GIVEN:í 0.136000 PIN Over (1) pin to center...............: 0.973846 DIM'S Over (2) or (3) pins (Even)..........: 1.947693 QCM 9.17 - SAMPLE INTERNAL KEYWAY SOFTWARE PRINTOUT This program calculates the depth of a keyway as measured across the bore. Diameter of bore: 3.5 Width of keyway : .375 Depth of keyway : .1875 OD of hub (optional): 5.005 Measurement = 3.6774 allow +.010 in most cases Hub wall thickness = 0.5751 allow - .010 in most cases QCM 9.18 Dear customer, We have recently completed PO 00-000-000 for XXX of P/N XXXX part name. In a continuing effort to improve our service and gain feedback from our customers, we would sincerely appreciate your response to the following questions. On a scale of 1-5 (1=poor, 2=fair, 3=average, 4=good, 5=excellent) please rate the following if applicable: Were you treated in a professional and courteous manner? _____ Did you receive your quote back in a timely manner? _____ Did you receive your completed PO by the required date? _____ Did the parts ordered meet all print specifications? _____ Did you receive an inspection report with parts? _____ Were the parts in satisfactory condition? _____ Were the parts packaged appropriately for type of shipping?_____ Were the charges commensurate with the work involved? _____ Will you use our services in the future? Yes___No___Maybe___ Will you recommend us to others? Yes___No___Maybe___ Comments, Special Needs of Referrals: ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ Thank you for your participation. Please return the completed questionnaire in the enclosed stamped envelope. Sincerely, R.T. Blackhawk Machine Products, Inc. _______________________________ Russell F. Tiritilli Owner/President