Vosky Precision Machining Corp.
70-B Air Park Drive, Ronkonkoma, NY 11779
Tel: (631) 737-3200 Fax: (631) 737-3240
Quality Control Manual
ISSUED: January 21, 2005
Revision. G (12/3/2003)
Vosky Precision Machining Corp.
70-B Air Park Drive, Ronkonkoma, NY 11779
Tel: (631) 737-3200 Fax: (631) 737-3240
Date:________________
This Manual has been reviewed and inspected by the following personnel and has been found
to be in compliance with current procedures performed at Vosky Precision Machining Corp.
This Manual is subject to Customer approval. Any procedures not within customer parameters
shall be overridden by Customer requirements, pending review by Vosky Management.
________________________________
M. Voskinarian - PRESIDENT
________________________________
J. Flock - GENERAL MANAGER
Vosky Precision Machining Corp.
QC Manual – Revision G
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Quality Control Manual Revision Record
Revision Level
Author
Approved
Date
Section Affected and Reason for Revision
A
B
C
D
E
F
G
H
J.F.
Warning: No part of this document shall be reproduced in any form without the written consent of
Vosky Precision Machining Corp. All inquiries regarding this manual shall be directed to the
General Manager, who is responsible for its administration.
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TABLE OF CONTENTS
Sect.
Description
COVER
APPROVAL SHEET
QUALITY CONTROL MANUAL REVISION RECORD
TABLE OF CONTENTS
COMPANY PROFILE AND MISSION STATEMENT
QUALITY POLICY STATEMENT
QUALITY MANUAL AND DOCUMENTATION CONTROL
Page
1
2
3
4
7
8
9
1
SCOPE
10
2
RESPONSIBILITY FOR QUALITY SYSTEM
2.1 - ORGANIZATION
2.2 - RESOURCES
2.3 - MANAGEMENT REPRESENTATIVE
2.4 - MANAGEMENT REVIEW
10
10
10
11
11
3
QUALITY MANAGEMENT SYSTEM
3.1 – GENERAL
3.2 – PROCEDURES
3.3 – QUALITY PLANNING
12
12
12
12
4
CONTRACT REVIEW
4.1 – GENERAL
4.2 – REVIEW
4.3 – RESPONSIBILITES
4.4 – REPEAT OR MULTLINE ORDERS
4.5 – AMENDMENTS TO CONTRACTS
4.6 – RECORDS
13
13
13
13
15
15
15
5
DESIGN CONTROL
15
6
DOCUMENT AND DATA CONTROL
6.1 – GENERAL
6.2 – DOCUMENT AND DATA APPROVAL AND ISSUE
6.3 – DOCUMENT AND DATA CHANGES
15
15
17
17
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TABLE OF CONTENTS
7
PURCHASING
7.1 – GENERAL
7.2 – EVALUATION OF SUPPLIERS
7.3 – PURCASHING DATA
7.4 – VERIFICATION OF PURCHASED PRODUCT
7.5 – VERIFICATION AT SUPPLIER’S PREMISES
17
17
17
18
18
18
8
CONTROL OF CUSTOMER SUPPLIED PRODUCT
8.1 – GENERAL
8.2 – DAMAGED CUSTOMER FURNISHED MATERIAL
18
18
19
9
PRODUCT IDENTIFICATION AND TRACEABILITY
9.1 – GENERAL
9.2 – IDENTIFICATION
9.3 – TRACEABILITY
19
19
19
19
10
PROCESS CONTROLS
10.1 – GENERAL
10.2 – MANUFACTURED PRODUCT
20
20
20
11
INSPECTION AND TESTING
11.1 – GENERAL
11.2 – RECEIVING INSPECTION AND TESTING
11.3 – IN-PROCESS INSPECTION AND TESTING
11.4 – FINAL INSPECTION
11.5 – INSPECTION AND TESTING RECORDS
21
21
21
22
22
22
12
CONTROL OF MEASURING AND TESTING EQUIPMENT
12.1 – GENERAL
12.2 – CONTROL PROCEDURE
12.3 – ADEQUACY OF MEASURING STANDARDS
12.4 – ENVIRONMENTAL CONTROLS
12.5 – INTERVALS OF CALIBRATION
12.6 – CALIBRATION PROCEDURES
12.7 – ADEQUACY OF CALIBRATION SYSTEM
12.8 – CALIBRATION SOURCES
12.9 – RECORDS
12.10 – CALIBRATION STATUS
12.11 – CONTROL OF SUB-CONTRACTOR CALIBRATION
12.12 – STORAGE AND HANDLING
23
23
23
24
24
25
25
26
26
27
27
28
28
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TABLE OF CONTENTS
13
INSPECTION AND TEST STATUS
13.1 – GENERAL
13.2 – USE OF INSPECTION STAMPS
13.3 – INSPECTION STAMP ISSUE AND CONTROL
28
28
29
29
14
CONTROL OF NONCONFORMING PRODUCT
14.1 – GENERAL
14.2 – REVIEW AND DISPOSITION OF NONCONFORMING PRODUCT
29
29
29
15
CORRECTIVE AND PREVENTIVE ACTION
15.1 – GENERAL
15.2 – CORRECTIVE ACTION
15.3 – PREVENTIVE ACTION
30
30
30
31
16
HANDLING, STORAGE, PACKAGING, PRESERVATION AND DELIVERY
16.1 – GENERAL
16.2 – HANDLING
16.3 – STORAGE
16.4 – PACKAGING
16.5 – PRESERVATION
16.6 – DELIVERY
32
32
32
32
32
32
32
17
CONTROL OF QUALITY CONTROL RECORDS
17.1 – GENERAL
17.2 – RECORD STORAGE
33
33
33
18
INTERNAL QUALITY AUDITS
33
19
TRAINING
33
20
SERVICING
34
21
STATISTICAL TECHNIQUES
34
APPENDIX A
MANUFACTURING PLAN
INSPECTION REPORT
DISCREPANT MATERIAL REPORT
INSTRUMENT CALIBRATION RECORD
ORGANIZATIONAL CHART
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37
38
39
40
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Vosky Precision Machining Corp.
COMPANY PROFILE AND MISSION STATEMENT
VOSKY PRECISION MACHINING is a full service machine shop, providing top quality parts
and service to our customers for over twenty years. Our company provides a wide range of services
to our customers in the commercial, military, aerospace, architectural and industrial fields that
require the best in quality and delivery on a consistent basis.
Vosky Precision uses the latest in computer-controlled, state of the art precision lathe and
milling machines, set up and operated by some of the finest, most versatile and well-trained
technicians in the business. Along with a top-notch Quality Control Department and CAD-CAM
programming system, all our resources work together to make Vosky Precision one of the most
capable small machine shops in the region.
Vosky Precision is a family owned business, established in 1980, and currently employs 22-30
people in our 12,000 square foot, temperature controlled shop. As a family-owned enterprise, we
have held onto some of the business principles that seem to have been forgotten these days. We offer
a more personal, service oriented touch when dealing with our customers, thus we have acquired a
reputation for customer service and quality. Our dedication to quality and service has been the
principle that has guided us through our evolution from a one-man shop to today’s thriving, growing
business. The premises that we occupy is a 24,000 square foot building, owned by our company.
Within two years, we shall be expanding our operations to encompass all of this space, in order to
increase our capabilities.
Vosky Precision Machining Corp. has implemented the AS9100 Quality Standard. We use
internal audits to provide feedback to management as to the effectiveness of the Quality Management
System and to continually make improvements in our system. We are in the process of obtaining AS9100 Quality System Certification and will be certified by the end of calendar year 2004.
Our Mission: “To provide all of our customers, from the biggest to the smallest, with the best quality,
the best service, and on-time delivery, every time, every day, and to do it all at a competitive price. In
addition, we will strive to continually improve the quality of our workforce, delivery times, processes
and customer service.”
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Vosky Precision Machining Corp.
QUALITY POLICY STATEMENT
VOSKY PRECISION MACHINING specializes in providing full service machine shop
services in accordance with military, prime contractor, aerospace and commercial
specifications, standards and requirements.Vosky Precision’s objective is to provide complete,
“start to finish” services to ensure complete control and adherence to requirements. We will
provide our customers with optimum quality, reliable performance, on time delivery and fair
pricing. Our goal is to meet all of these requirements, continually improving on all aspects of
our job, by focusing resources on identifying, preventing and eliminating any deficiencies.
To achieve these objectives, our company is focused on implementing and maintaining our
Quality Control Management System, which is based on the AS-9100 Quality System. The
successful implementation and operation of this system depends on the cooperation and
involvement of all personnel at every level. Our continued success and growth is only insured
by the dedication of our staff to customer satisfaction. Adherence to the manual and system
contained herein is the best way that we can achieve this satisfaction. We will work with our
Suppliers to develop relationships with them that will expand our quality and delivery
capabilities.
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Vosky Precision Machining Corp.
QUALITY MANUAL AND DOCUMENTATION CONTROL
The General Manager is responsible for the administration, control, review and distribution of
the Quality Control Manual and for the procedures contained within.
Revisions are identified by consecutive letters A, B, C, …, AA, AB, etc. The revision level is to be
indicated on each page. The front page of the manual is the cover page, followed by the approval
page. Next is the revision page, which shall list the issue revision, author and approval of each
revision, the date of revision, and reason for such. Only those revisions approved in writing by either
the President or General Manager shall be considered official.
Controlled copies of the Quality Control Manual will be maintained in the General Manager’s office,
the Quality Control Department, and the online computer version. A copy of this manual will be
made available to the customer’s representative upon request, but shall not be considered a
controlled copy. This manual is not to be released to the general public.
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1.0 SCOPE
1.1 This manual establishes the requirements of VOSKY PRECISION MACHINING CORP.,
inspection and process control systems. These requirements pertain to the inspections and tests as
well as the documentation necessary to substantiate product conformance as required by contract.
This manual has been prepared in accordance with and outlines the quality control system
maintained by VOSKY PRECISION MACHINING CORP. The requirements of this manual pertain to
and cover all parts and materials supplied by VOSKY PRECISION MACHINING CORP., whether
machined in house or purchased from a vendor, or a combination of the two. The aim of this manual
and the quality system is to ensure that products produced by VOSKY PRECISION MACHINING
CORP. are of the desired quality and that all customer and specification requirements are met.
The quality system is based on the applicable requirements of the MIL-I-45208A Inspection System
and the ANSI/NCSL Z540-1-1994 Calibration Standard and the ISO-9002 Quality System. Unless
otherwise specified, all standards referred to are the latest revisions.
2.0 MANAGEMENT RESPONSIBILITY FOR QUALITY SYSTEM
2.1 ORGANIZATION
2.1.1 RESPONSIBILITY AND AUTHORITY
The organization chart shown on page 36 shows the interrelation of positions within the
company, and the paths of responsibility and authority in relation to quality. The responsibility,
authority and interrelationship of every person who does work relating to product quality is
defined in “Job Descriptions and Requirements”, on file in the Personnel Department.
All personnel may, in their absence, delegate their responsibilities and authority to others as
specified in their job description. All personnel have the authority to stop work being performed
that is non-conforming. This policy gives our personnel the freedom and authority to:
A) Initiate action to prevent the occurrence of any nonconformities relating to the product,
process, or quality system
B) Identify and record any product, process or quality system problems
C) Initiate, recommend, or provide solutions through proper channels
D) Verify and evaluate the implementation of solutions
E) Control further manufacture, processing, delivery or installation of nonconforming
products until the deficiency or unsatisfactory condition has been corrected
2.2 RESOURCES
2.2.1 VOSKY PRECISION MACHINING CORP. management has identified resource
requirements for management of, manufacture of, and verification of all work done by the
company. Adequate resources and trained personnel are provided.
2.2.2 Company management believes in “self-inspection “ of work by operators as well as quality
control department inspection, therefore, all personnel are trained to carry out all inspection
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techniques required (when possible) Approved sub-contractors and their resources may be used
for specialized verification tests when necessary.
2.2.3 Internal Quality Audits are performed by representatives appointed by the company
president or general manager. These representatives are to be independent of the department or
function being audited.
2.2.4 Adequacy of resources and personnel are formally reviewed each year as part of
management review.
2.3 MANAGEMENT REPRESENTATIVE
2.3.1 The General Manager of VOSKY PRECISION MACHINING CORP. has appointed the Quality
Control Manager as the company’s “Management Representative”. The Quality Control manager is
responsible for and has the authority to:
A) Insure that the requirements specified in this manual are implemented and maintained
B) Report on the performance of the quality system to management. A minimum of one annual
review shall be performed and submitted to management identifying areas for improvement
to be acted upon during management review.
C) Co-ordinate with various departments or vendors on matters affecting quality or related to
the company’s quality system
2.3.2 The Quality Control Manager reports directly to the General Manager, or in his absence, to
the President of the company.
2.3.3 The Quality Control Manager has full authority to stop, reject, and resolve any work or
services not conforming to either contract requirements or the Quality System requirements.
2.4 MANAGEMENT REVIEW
2.4.1 The management of VOSKY PRECISION shall meet at least once per year to ensure that the
Quality Management System continues to be suitable and effective in satisfying stated company
policy and objectives, as well as customer expectations and needs and the requirements of the
MIL-I-45208A Inspection System and the ANSI/NCSL Z540-1-1994 Calibration Standard and the
ISO-9002 Quality System.
2.4.2 The review shall be carried out in a meeting chaired by the President or General Manager,
and attended by the Quality Control Manager, Shop Leadmen, Sales Manager, and anyone else
deemed necessary by the Management Representative.
2.4.3 Management shall use all available information, such as internal and external quality audits,
customer complaints and/or comments, discrepancy reports, corrective and preventive actions,
employee reviews and so on, to improve the system
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2.4.4 The results of these reviews are to be documented and maintained by the Quality Control
Manager. The Quality Control Manager will also work in concert with personnel concerned
during the implementation of any actions taken as a result of these reviews.
2.4.5 Any action taken as a result of these reviews which requires modification of this manual
must be documented in this manual within ten days of implementation.
3.0 QUALITY MANAGEMENT SYSTEM
3.1 GENERAL
3.1.1 This Quality Control Manual documents VOSKY PRECISION MACHINING CORP. policies
regarding the handling, inspection, management and routing of jobs according to ISO9002
standards. It shall be the responsibility of the VOSKY Quality Control Department to maintain
this system and all associated data.
The quality control system shall include data from the following, but not limited to:
• Certifications
• Incoming inspection. (Receiving inspection)
• First article inspection reports.
• Final inspection reports.
• Discrepant material reports
• Manufacturing plans
3.2 PROCEDURES
3.2.1 Detailed procedures for support and maintenance of the Vosky Precision Quality Control
System are contained within this manual. Second Tier documents are used as tools through which
methods of operation are implemented. These describe, in detail, methods by which a particular
activity is performed. Vosky Management and/or Quality Control prepares documented
procedures and work instructions consistent with the requirements of this manual and ISO9002.
3.3 QUALITY PLANNING
3.3.1 In order to meet the quality requirements for products, Vosky performs quality planning
activities. These activities are documented in this manual in a format suitable for Vosky’s method
of operations and include the following:
A) Preparation and review of documents such as drawings, parts lists, standards and
purchase orders
B) Identification and acquisition of personnel and equipment necessary to
manufacture products to desired specifications.
C) Generating of Manufacturing Plans containing detailed, sequential instructions
necessary to manufacture the part in question.
D) The design, manufacture and use of tooling necessary to either manufacture or
inspect parts.
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E) Identification of key characteristics and appropriate verification methods
F) Preparation of Inspection and First Article Reports
G) Clarification of any questions regarding contracts or standards of acceptability
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4.0 CONTRACT REVIEW
4.1 GENERAL
To insure the quality, accuracy and timely completion of our contracts, VOSKY PRECISION
MACHINING has developed procedures documented in this manual for the review of contractual
requirements for all orders, including amendments.
4.2 REVIEW
All quotations, purchase orders, and contract acknowledgements shall be reviewed by
management prior to submission to a customer or vendor. The review is to insure that:
A) The contract is accurate and to determine if all contract requirements are
adequately defined and understood.
B) An order is received in writing before work is started manufacturing.
C) The company has the resources and capability to meet contract requirements.
4.3 RESPONSIBILITIES
4.3.1 MANAGEMENT RESPONSIBILITIES IN CONTRACT REVIEW
VOSKY PRECISION MACHINING CORP. will be responsible for meeting all terms
and deliveries required on a Purchase Order, or of notifying the customer if this is not possible
for one reason or another. Upon receipt of a customer purchase order management shall
review customer’s Purchase Order accuracy of all terms and conditions. Management will, at
this time, assign a Control Number, usually the Part Number, by which that contract shall be
known at VOSKY. VOSKY management shall assign this number and assemble and maintain a
file complete with all drawings, revisions, part lists, specifications, and requirements. This is
the master file which will also contain all certifications acquired during the course of the
contract’s life.
Management shall then generate a VOSKY MANUFACTURING PLAN, which shall list
consecutively all steps necessary to make a contract-compliant part. This manufacturing plan
must be checked against the part Blueprint, Parts List, and any applicable Control Drawings,
rather than any internal documents, prior to approval. This manufacturing plan should
include all information required to manufacture the component in question, including but not
limited to information about material required, heat treating, sketches for preliminary
machining operations, sizes required for plating, coating or grinding allowances, any
dedicated fixturing or inspection equipment, and a sequential listing of all outside processing.
The Manufacturing Plan shall also contain reference points requiring inspections and tests,
along with space to note the date a particular operation was finished, the
quantity/length/weight of an item, and room for an inspection stamp to verify that an
operation has been accomplished to specifications. A master copy of the Manufacturing Plan
will accompany each run of a particular part from start to finish. This is the Plan that will have
all pertinent dates and inspection stamps in regards to each operation. A copy of this plan will
be placed in the master file for reference purposes.
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Management shall also make a determination, with reference to contract requirements,
of manufacturing the constituent components or purchasing them from external sources,
(make or buy). Purchased components shall be purchased using VOSKY Purchase Orders,
detailing exactly what is required (including sketches if necessary), including but not limited
to processes and raw materials, certificates of compliance and/or additional tests. All such
details shall be referenced to the assigned VOSKY Control Number.
4.3.2 QUALITY CONTROL RESPONSIBILITIES IN CONTRACT REVIEW
A copy of the contract along with all pertinent drawings, revisions, specifications and
requirements shall be forwarded to the Quality Control Department. Quality Control shall set
up and maintain a control file under the designated control number. Quality Control shall
compare all pertinent copies of Purchase Orders and Manufacturing Plans for accuracy as
related to revisions, drawings, specifications and requirements of the contract before release
for general use. All inaccuracies shall be corrected immediately and any questions regarding
any aspect of the contract should be relayed to the customer at this time. Once the
Manufacturing Plan has been reviewed and OK’ed, the plan can be put into use and material
procured at this point.
Quality Control shall, at this time, before any machining takes place, generate an
INSPECTION REPORT for each component of a customer’s purchase order. The inspection
report should be a form listing, in numeric order, all measurable characteristics of a part, as
well as all part list notes, ADCN or Engineering Order notes, special sizes noted on customer’s
P.O., and any other information that needs to be inspected in order to make an acceptable
product. Alongside each characteristic or note should be a space for recording the measured
characteristic or note observed. Each of these items shall be circled and numbered on a Master
Inspection Print that will be maintained in the Quality Control Department’s file system. The
numbers on the master print shall correspond to the matching numbers on the Inspection
Report. ALL ITEMS on a print must be documented. If an item appears multiple times in a
print, or is noted as typical “x” number of times, then each instance should be listed
alphabetically, such as #1a, #1b, #1c and so on. The applicable numbers on a report shall be
filled in as they are preformed according to the Manufacturing Plan.
The first time that a component is being manufactured by VOSKY, a first article report
report must be made as well as a general one. The first article report will conform to AS9102, a
three part form illustrated in the appendix.
4.3.3 CUSTOMER RESPONSIBILITIES RELATED TO CONTRACTS
The customer is responsible for spelling out in a Purchase Order, all related part and
blueprint numbers and revisions, part list revision levels, pricing, quantities, and delivery
dates required of Vosky Precision Machining for each item in a contract. This purchase order
should also include any special instructions or sizes to be maintained by Vosky during the
manufacture of said components.
The customer is also responsible for flowing down to Vosky, in a timely manner, any
information that affects the manufacture of a part in any way. If a customer requirement
changes in the middle of manufacturing and modification of the component in question is not
possible at this point, then the customer is responsible for purchasing work done to that point
and Vosky shall re-manufacture the part to the new specifications.
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4.4 REPEAT OR MULTIPLE LINE ORDERS
Items that are repeats of old orders or that, due to time or scheduling considerations, must be run
multiple times in order to complete a contract, may use copies of existing Manufacturing Plans and
Inspection Reports for the same items, AS LONG AS NO REVISIONS HAVE BEEN MADE. If any
changes have been made to a part or the manufacturing sequence or method, either because of
manufacturing considerations or Customer revisions, a revised Manufacturing Plan and/or
inspection report must be made, with changes in each noted on the particular form.
4.5 AMENDMENTS TO CONTRACTS
Immediately upon receipt, of any Customer contract changes, a copy shall be compared to the
original order on file, and immediate action taken to assure the use of the appropriate information
used for fabrication and inspection. Should the work have progressed to a point where the changes
are impossible or inappropriate. All work will stop. The appropriate customer purchasing agent shall
be promptly notified.
4.5.1 Any amendment to any contract, coming in to VOSKY or out-going, shall be reviewed in the
same manner as the original. All changes must be clearly noted in the amendment.
4.5.2 Information about amendments and details are promptly communicated to the affected
departments.
4.5.3 Any impact of an amendment that affects price, delivery capabilities, or Vosky’s ability to
manufacture affected component must be communicated to the customer by management before
any additional work proceeds on the order in question.
4.6 RECORDS
Records of contract reviews are documented and maintained. Each contract is stamped and initialed.
The original is kept in the master file in the main office.
5.0 DESIGN CONTROL
Since VOSKY offers only informal design consultation to its customers, and does only internal
design of fixtures and tooling, this element is not applicable to VOSKY.
6.0 DOCUMENT AND DATA CONTROL
6.1 GENERAL
VOSKY’s inspection system shall provide for procedures which will assure that the latest applicable
drawings, specifications and instructions required by the contract, as well as authorized changes
thereto, are used for fabrication, inspection and testing. A complete copy of the contract or customer
order along with a copy of applicable drawings, specifications, and instructions shall be on file in the
VOSKY Quality Control Department in its appropriate VOSKY Job Number file. Manufacturing
Plans, when initiated, shall be compared to the appropriate Job Number file to confirm the correct
usage, of the latest drawing revisions, specifications or instructions. When, First article and Final
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inspection tests are performed, confirmation of correct drawing revisions, specifications or
instructions shall be performed as a regular part of the inspection system.
6.1.1 VOSKY PRECISION MACHINING CORP. has established and documented in this manual
procedures to describe the methods for controlling all documents and data necessary for
maintaining the quality system and ensuring product acceptability.
6.1.2 Documents that are controlled and their method of control include:
A) Inspection and Testing Reports These documents are maintained by the Quality
Control department, with each report filed according to part number. Files shall be
maintained for a minimum of ten years.
B) Manufacturing Plans Manufacturing Plan Number assignment shall be traceable to
each Customer contract number. A copy of Manufacturing Plan is to be filed in the
Quality Control Department for use in In Process Inspection, Final Inspection, and/or
Incoming Inspection. Provision of space shall be provided on the Work Order for
Inspection acceptance or rejection at each manufacturing method or process point.
C) Purchase Order Number assignment shall be traceable to VOSKY Manufacturing
Plan, which in turn shall be traceable to each Customer contract. Purchase Orders shall
provide choice option of the need for Certification of Compliance, (CoC), certifying that
the material ordered conforms to the specifications. Copy of Purchase Order to be filed
in Quality Control Department for use in Incoming Inspection to assure purchased
material meets specification. Copy of Certificate of Compliance referencing specific
purchase order (number) to be filed in Master File for each part. In addition, when a
Purchase Order is generated for outside processing, Purchase Order requirements shall
be reviewed for accuracy by the Quality Control department before the parts go out for
processing.
D) Certifications of Compliance (Source/supplier) on file in VOSKY Job Number file
(front office), traceability provided by Purchase Order, Work order, item identification,
Job Number, contract or customer order number. Additional copy on file in Quality
Control Dept. in respective Job Number file.
E) First Article Inspection Report. Filed in the Quality Control Department; traceability
provided by either Purchase Order or Manufacturing Plan, item identification, Job
Number, then contract or customer order number.
See Appendix A for: VOSKY INSPECTION REPORT
F) Final Inspection Report. Filed in the Quality Control Department; traceability
provided by Work Order, item identification, and Job Number.
See Appendix A for: VOSKY INSPECTION REPORT
G) Discrepant Material Report. Filed in the Quality Control Department; traceability
provided by Purchase Order, Manufacturing Plan, item identification, and Job Number.
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See Appendix A for: VOSKY DISCREPANT MATERIAL REPORT
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6.2 DOCUMENT AND DATA APPROVAL AND ISSUE
6.2.1 Prior to issue, all documents are reviewed for accuracy and adequacy and approved by
authorized personnel.
6.2.2 To prevent the use of invalid and/or obsolete documents, a Document Control Index is
maintained to identify the current revision level of Quality System documents. This index is
maintained by the Quality Control Department and is available for reference to all personnel.
6.2.3 Invalid and/or obsolete documents are promptly removed from all points of issue or use to
prevent their unintended use. Any documents retained for legal and/or knowledge preservation
are to be appropriately identified and kept secure.
6.3 DOCUMENT AND DATA CHANGES
6.3.1 Changes to documents are reviewed and approved in the same manner as the original issues,
by the same personnel responsible for the original, or their designee.
7.0 PURCHASING
7.1 GENERAL
VOSKY PRECISION MACHINING CORP. assumes responsibility for the quality of all materials,
services, and processing purchased from subcontractors. Vosky has implemented and maintains
procedures documented in this manual to select reliable suppliers.
7.2 EVALUATION OF SUPPLIERS
7.2.1 A listing is maintained in the main office of all suppliers who provide products, services,
processing, or support to Vosky.
7.2.2 The evaluation and selection process shall determine a supplier’s ability to meet Vosky’s
quality requirements. The selection process shall include:
A) Evaluation and approval by Management of vendor surveys to determine the
adequacy of said vendor’s Quality Control System.
B) On-site visits by Vosky Management or Quality Personnel may be necessary to
determine a vendor’s ability to fulfill contract requirements.
C) Consideration of already issued Customer approvals shall be a factor in
evaluation of a supplier. A Boeing approved chrome plating house, for instance,
shall be approved by Vosky for chrome plating upon receipt of a completed Quality
survey.
7.2.3 Customer approved supplier listings are consulted when dictated by contract or purchase
order.
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7.2.4 Completed Quality Surveys shall be maintained by the Vosky Quality Control Department
and reviewed on an annual basis.
7.3 PURCHASING DATA
7.3.1 VOSKY PRECISION MACHINING uses PURCHASE ORDERS to communicate all
requirements pertaining to material, technical data, quality and inspection, manufacturing and
shipping, as well as revision levels.
7.3.2 Purchase Orders, attachments, and amendments are reviewed by either Management or the
Quality Control Department for accuracy and to ensure that all requirements are communicated
to the supplier.
7.4 VERIFICATION OF PURCHASED PRODUCT
When a purchased part comes in to Vosky, the Quality Control department shall prepare all
necessary equipment to measure all characteristics being done at this point. Quality control shall
inspect the part and note the dimensions in the proper spot on the Inspection Report.
If a part is found to be non-compliant, a DISCREPANT MATERIAL REPORT shall be generated
and submitted to the vendor. This is the same report as generated for in-house evaluation and follows
the same procedures.
7.5 VERIFICATION AT SUPPLIER’S PREMISES
Purchase Orders for parts requiring on-site inspection at a vendor’s facility shall contain a right of
entry clause, allowing Vosky management or its’ customer’s representatives to enter a vendor’s
facility for the purpose of either inspecting that facility to determine a vendor’s ability to meet
purchase order requirements or to inspect products at the vendors’ facility. Purchase orders shall also
provide a selective choice option should Customer inspection be required for material, prior to
shipment from a subcontractor's or vendor's plant with the following wording:
"Customer inspection is required prior to shipment from your plant. Upon receipt of this order,
promptly notify the Customer representative who normally services your plant so that
appropriate planning for inspection can be accomplished."
See Appendix A for a copy of VOSKY PURCHASE ORDER
8.0 CONTROL OF CUSTOMER SUPPLIED PRODUCT
8.1 GENERAL
Vosky has established and maintains procedures for the examination and control of all incoming
product, whether material is furnished by the Customer, or purchased by VOSKY,
VOSKY procedures shall be as follows;
• Examination upon receipt, consistent with practicability, to detect if
damage in transit occurred.
• Inspection for completeness and proper type.
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• Periodic inspection and precautions to assure adequate storage
conditions and to guard against damage from handling and deterioration
during storage.
• Functional testing, either prior to or after installation, or both, as
required by contract to determine satisfactory operation.
• Identification and protection from improper use or disposition
• Verification of quantity.
8.2 DAMAGED CUSTOMER FURNISHED MATERIAL
VOSKY shall report to the Customer representative any Customer furnished material found
damaged, malfunctioning or otherwise unsuitable for use. In the event of damage or malfunction
during installation, the contractor shall determine and record probable cause and necessity for
withholding material from use. Verification by Vosky does not absolve Customer of the responsibility
to provide acceptable product.
9.0 PRODUCT IDENTIFICATION AND TRACEABILITY
9.1 GENERAL
VOSKY PRECISION MACHINING CORP.
has established and maintains procedures
documented in this manual for the identification and traceability of each part during all stages of
manufacture, storage and shipping.
9.2 IDENTIFICATION
9.2.1 WORK IN PROCESS
Work in process is accompanied by a VOSKY MANUFACTURING PLAN, which is traceable
to the Customer contract or purchase order. The manufacturing plan provides the drawing
number and revision levels to which parts are being manufactured. All certifications and test
results are stored in the main part file and recorded on VOSKY’s Certificate of Compliance.
9.2.2 FINISHED PARTS
Finished parts are identified by part marking according to drawing specifications. (i.e.: Bag
and Tag, Electrochemical etch, engrave, etc…) in addition to package marking which provides
traceability to its origin.
9.3 TRACEABILITY
9.3.1 Traceability methods are used only if required by standards or customer contract.
9.3.2 The extent of traceability shall be agreed upon by Vosky’s representative and the customer
and documented before starting work.
9.3.3 All serialized parts are controlled by noting serial numbers on Vosky’s Manufacturing
Plan and on all certifications issued by vendors.
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10.0 PROCESS CONTROLS
10.1 GENERAL
VOSKY PRECISION MACHINING CORP. has implemented and documents in this manual the
means by which all operations performed at Vosky are controlled. Special process control
procedures, such as Statistical Process Control, shall be an integral part of the VOSKY inspection
system when such inspections are a part of the specification or the contract or customer order. All
processes required by contract or customer order shall be included in the VOSKY Manufacturing
Plan so that they are included within the normal inspection systems. Those parts or processes
required from a subcontractor or vendor shall be cited on a VOSKY Purchase Order so that they may
be included within VOSKY’s normal Incoming inspection systems.
10.2 MANUFACTURING PROCESSES
10.2.1 Management describes, in a Vosky Manufacturing Plan, the sequence of all operations
necessary to make a conforming part.
10.2.2 Manufacturing shall coordinate with Management and Quality Control to provide fixtures,
gauges, and specific process control information.
10.2.3 Manufacturing is responsible for machine setup and part conformity to specifications.
10.2.4 Quality Control is responsible to inspect the first piece of any manufacturing operation and
to provide the manufacturing department with all necessary equipment to maintain part
conformity. In addition, Quality Control will conduct and document by means of an inspection
stamp in the appropriate place on the Manufacturing Plan, in-process inspections of ongoing
operations.
10.2.5 Upon completion of each operation, the Operator/Technician responsible notifies the
Quality Control Department, which will verify and document by means of an inspection stamp in
the appropriate spot on the Manufacturing Plan, that the operation has been completed to
specification.
10.2.6 Manufacturing processes are monitored by various means including Coordinate Measuring
Machine readings, Statistical Process Control, mechanical and visual evaluation, auditing, and lot
sampling.
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11.0 INSPECTION AND TESTING
11.1 GENERAL
11.1.1 Vosky has established procedures for the inspection and testing of products to ensure that
they meet requirements. These procedures are documented on Manufacturing Plans and
Inspection Reports for each applicable part or detail. AS9102 First Article Reports document
methods by which these tests are performed.
11.1.2 VOSKY shall maintain adequate records of all inspections and tests. The records shall
indicate the nature and number of observations made, the number and type of deficiencies found,
the quantities approved and/or rejected, the nature of corrective action taken, if necessary, and
the disposition of nonconforming parts, as appropriate. These records shall remain on file for a
period of not less than ten years.
11.1.3 Inspections and tests are performed using standard inspection methods and calibrated
instruments capable of the necessary accuracy.
11.1.4 Authorized Inspector Stamps document the acceptance of parts.
11.1.5 Nonconforming parts are tagged and segregated from acceptable parts.
11.2 RECEIVING INSPECTION AND TESTING
11.2.1 All incoming products are inspected or otherwise verified as conforming to specifications
before being released for use or for further work.
11.2.2 To ensure that incoming raw material conforms to specifications, Vosky requires all
purchased materials to be accompanied by written and signed certification from the supplier and
chemical analysis ascertaining that the material supplied is in accordance with the required
specifications. These certifications must be reviewed by Management or Quality Control and
review is documented by use of an approved Inspection Stamp at the bottom of said certification.
11.2.3 Parts purchased from a vendor in a machined state will be treated as if machined at Vosky
and inspected as detailed in sections 7.4 and 10.2.4 to 10.2.6. Manufacturing plans and Inspection
reports shall be generated for these parts as if they are being manufactured in house. Note that
any parts manufactured by vendors that are on probation due to past rejects or deficiencies in
their Quality System shall be inspected 100% for all characteristics. Parts purchased from a vendor
in good standing may be inspected using lot sampling methods, except for Key Characteristics,
which must be inspected 100%.
11.2.4 Products that are needed urgently may be used prior to passing Incoming Inspection with
the approval of the General Manager, Quality Control Manager or one of their designees. This is a
temporary action used only to expedite delivery and does not absolve Vosky of the responsibility
to ensure part quality. The customer must be notified of this and parts must be tagged to reflect
this status until received and approved by the customer.
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11.3 IN-PROCESS INSPECTION AND TESTING
11.3.1 In-process inspections and tests are performed at appropriate intervals during the
manufacturing process and as specified in the Manufacturing Plan and Inspection Reports.
Manufacturing Plans have places for inspection stamps to document when in-process inspections
have been performed by the Quality Control Department.
11.3.2 Product conformance to specifications is established by a combination of Quality Control
oversight and constant monitoring by manufacturing personnel. As noted in section 2.2.2, Vosky
Management believes in operators monitoring their own work. This enables us to detect a
discrepancy immediately and to minimize scrap parts.
11.3.3 No product is released for use or further processing until all of the required inspection
procedures have been performed and documented, except under the conditions outlined in
section 11.2.4, under incoming inspection. All clauses remain in effect when a part is
manufactured in house.
11.4 FINAL INSPECTION
11.4.1 No product is released to the customer until all manufacturing, inspection, and testing
procedures have been performed as per the Manufacturing Plan. All tests must be documented by
means of a Quality approval stamp at their appropriate place in the Manufacturing Plan.
11.4.2 The Manufacturing Plan, First Article Report and Inspection Reports will be used in
conjunction with each other to ensure that all quality requirements and tests have been
satisfactorily completed.
11.4.3 The Quality Control Department is responsible for ensuring that all Quality requirements of
a contract are fulfilled prior to shipment of a product to a customer. These requirements include,
but are not limited to:
A) Dimensional conformity
B) A review and verification of required documentation
C) Verification of marking, storage, packaging, and shipping requirements.
11.5 INSPECTION AND TEST RECORDS
11.5.1 All inspection and test records for all products are maintained for a minimum of ten years
by the Quality Control Department (40 years for flight safety parts and critical parts).
11.5.2 These records show clearly whether the product has passed or failed the tests according to
defined criteria.
11.5.3 These records, by means of Inspection Stamps, identify the personnel responsible for product
acceptance and release.
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12.0 CONTROL OF MEASURING AND TEST EQUIPMENT
12.1 GENERAL
12.1.1 VOSKY PRECISION MACHINING CORP. has established and documents in this manual
detailed instructions for the use, calibration, maintenance, shipping and storage of all measuring
and test equipment used to ensure product acceptability. This system is in accordance with the
ANSI/NCSL-Z-540-1-1994 calibration standard.
12.1.2 VOSKY shall provide and maintain gages and other measuring and testing devices
necessary to assure that supplies conform to the technical requirements. In order to assure
continued accuracy, these devices shall be calibrated at established intervals against certified
standards, which have known valid relationships to national standards. If production tooling such
as jigs, fixtures, templates, and patterns are used as a media of inspection, such devices shall be
proved for accuracy at established intervals. Calibration of inspection equipment shall be in
accordance with ANSI/NCSL-Z-540-1-1994.
12.1.3 When required, VOSKY’s measuring and test equipment shall be made available for use by
the Customer's representative to determine conformance of product with contract requirements.
In addition, if conditions warrant, Vosky personnel shall be made available for operation of such
devices and for verification of their accuracy and condition.
In the event of a conflict of
equipment use, VOSKY Quality Control Department shall generate a plan or schedule that
provides opportunity for customer use and VOSKY use, without inhibiting the flow of production
or processing of Customer contracts.
12.1.4 Inspection, measuring and test equipment shall be used in a manner that ensures
measurement uncertainty is known and is consistent with the required measurement capability.
12.2 CONTROL PROCEDURE
12.2.1 Suitable measuring and test equipment capable of necessary accuracy and precision are
selected after identifying the measurements to be made and the accuracy requirements.
12.2.2 VOSKY shall provide and maintain all necessary measuring and testing tools and
equipment required to assure compliance with technical Quality Control requirements. The
VOSKY Quality Control Department shall be responsible for actual quality assurance through the
following:
•
•
•
•
•
•
•
Calibration.
Adequacy of measuring standards.
Environmental controls.
Intervals of calibration.
Calibration procedures.
Out-of-tolerance conditions.
Adequacy of calibration system.
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•
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Calibration source.
Records.
Calibration status.
Control of Subcontractor's calibration
Storage and handling.
Amendments and revisions
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Should an out-of-tolerance condition be discovered during calibration, and the tool or instrument
is currently being used on an in process work order, immediate corrective action must be taken. The
procedures outlined in the tool’s calibration sheet shall be followed.
See Appendix “A” for a copy of VOSKY CALIBRATION SHEET
12.3 ADEQUACY OF MEASURING STANDARDS.
At frequent prescribed intervals, the VOSKY Quality Control Department shall sub-contract the
measurement and test of the following described equipment to a measuring laboratory with accuracy
standards traceable to the National Institute of Standards and Technology herein known as NIST.
(Formerly National Bureau of Standards; NBS), who will perform for VOSKY the calibration,
documentation and certification of the following standards tools and/or devices:
• Restricted use measuring blocks (commonly known as Jo- Blocks)
• Master ring gages
• Coordinate measuring machine
• Granite surface plate
Restricted use Jo-Block sets and Master Sunnen ring gages shall be set aside for the exclusive use of
the Quality Control Department as master calibration reference.
Working Set Jo-Blocks shall be used for day to day confirmation and calibration of all other company
owned measuring equipment and employee owned measuring equipment.
Wherever practicable, VOSKY Quality Control shall calibrate all working tools, instruments and
measuring devices to a minimum of a 4 to 1 ratio to reflect a minimum acceptable area of un-certainty
of 25%.
Ex. If a specified tolerance is .0002"., the device used must be calibrated to .00005" at minimum
12.4 ENVIRONMENTAL CONTROLS
The VOSKY inspection work area shall be at ambient room temperature and humidity. The area shall
be kept neat, clean and free of chips and dust.
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12.5 INTERVALS OF CALIBRATION
12.5.1 The VOSKY Quality Control Department shall be responsible for the maintenance and
calibration intervals of the following types of measuring equipment, tools, instruments and
devices at the following intervals:
Every 6 Months:
• Working Jo-Blocks
• Sunnen Gage master setting micrometer
• Sunnen Gage master setting rings
• Dial indicator micrometers
• Outside micrometers*
• Inside micrometers*
• Electronic outside micrometers*
• Vernier dial calipers*
• Vernier electronic calipers*
• Height gage*
• Dial indicators
• All other measuring instruments, tools and devices, Company and
employee owned are to be considered only as reference instruments and
should be used only upon approval from the Quality Control Department
* To be checked (calibrated) before each use
12.5.2 VOSKY Quality Control shall establish and maintain records for calibration of all measuring
instruments, tools and devices, company owned and employee owned, and shall determine the
schedule of calibration. Users and owners (employee owned) of measuring tools and instruments,
shall be notified one week prior to the actual calibration interval. Measuring tools and instruments
must be submitted to Quality Control on their due date. If not, Quality Control must impound
them. All measuring tools, instruments and devices shall contain unique marks or pressure
sensitive labels indicating calibration status. At the time of calibration interval or at any time
prior, should the tool or instrument prove to be incapable of calibration, it shall be so marked or
labeled, and shall not be used for measurement at all.
12.6 CALIBRATION PROCEDURES
12.6.1 VOSKY Quality Control shall establish and maintain a calibration procedure file for each
and every type of measuring tool, instrument or device in use at VOSKY. At minimum, the file
should contain the following:
• Manufacturer's procedures, if available.
• The required parameters, range, and accuracy of the measurement standard.
• The acceptable tolerance of each instrument characteristic being calibrated.
• Calibration procedures providing instructions to enable calibration by VOSKY
Quality Control personnel, to adequately calibrate each instrument characteristic or
measurement parameter of concern and the equipment that should be used.
• State the collective accuracy ratio (minimum) between the uncertainty of the
calibration equipment and the tolerance of the characteristic being calibrated.
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• Instruction for the placement of the proper calibration status seal, labels or wax.
12.6.2 OUT-OF-TOLERANCE CONDITIONS
Should anyone within the VOSKY quality system, discover that any measuring tool,
instrument, device or equipment is calibrated as an out of tolerance condition, immediate action
must be taken. The VOSKY Quality Control Department and the current user of the tool or
instrument must be notified immediately.
If the tool or instrument is currently in use on an in-process work order, and the
out-of-tolerance condition is significant, immediate corrective action must be taken. A significant
out-of-tolerance condition is one that has less than a 4 to 1 calibration to tolerance ratio, as related
to the minimum uncertainty area indicated in Section 12.3.
12.7 ADEQUACY OF THE CALIBRATION SYSTEM
The VOSKY Quality Control Department shall periodically, but randomly audit, the quality of the
VOSKY calibration system, including all related calibration records, in order to assure the integrity of
the VOSKY calibration system and it's components as described in section 12.2. The results and data
of these audits shall be recorded in a VOSKY Calibration System Audit Report on file in the Quality
Control Department.
12.8 CALIBRATION SOURCES
Measuring tools, instruments, equipment and devices shall be calibrated by the VOSKY Quality
Control Department or an external qualified calibration facility using measuring standards whose
calibration is traceable. All measurement standards used in the VOSKY calibration system shall be
supported by certificates, reports or data sheets attesting to the description or identification of the
item:
• The calibration source
• Date of calibration
• Calibration assigned value
• Statement of uncertainty and environmental or other conditions
under which the calibration results were obtained
All certificates and reports shall be on file in the VOSKY Quality Control Department, and shall
contain the following information:
• Identification or serial number of the measurement standard or measuring tool,
instrument or equipment to which the report or certificate pertains.
• Identification of the calibration source and report number.
• Date of calibration.
• Calibration assigned value(s) with statement of uncertainties.
• A statement attesting to the fact that the measurement standards used in
obtaining the results are traceable, if the calibrating laboratory is other than the
NIST or DoD laboratory.
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The VOSKY Quality Control Department is responsible for assuring that calibration sources, other
than the NIST or DoD laboratories, are capable of performing these services to the satisfaction of the
requirements of ANSI/NCSL-Z540-1-1994.
12.9 RECORDS
VOSKY Quality Control Department shall establish a record system that shall assure full control of
its calibration system. These records shall document the established schedules and procedures that
are used to maintain the accuracy of all measuring tools, instruments and/or equipment and
measurement standards. At minimum they should provide for the following:
• An individual record of calibration for each item.
• Calibration interval.
• Date of calibration.
• Identification of calibration source.
• Calibration procedure used.
• Calibration results.
• Calibration corrective action taken.
• Certification with report number.
• Any pertinent occurrences not related to periodic calibration such as
operational failures, erratic behavior, etc..
VOSKY shall retain these records for a minimum period of two years. Each item shall bear a
current pressure sensitive label indicating its calibration status, per Section 12.10
12.10 CALIBRATION STATUS
Measuring tools, instruments, equipment and measuring standards shall be labeled to indicate
calibration status. At minimum the label shall identify the specific date calibrated and the specific
calibration due date. Where impractical, such as Jo-Blocks, the label shall be affixed to the instrument
case or container. Tamper-resistant seals, labels and/or waxes shall be affixed to operator accessible
controls or adjustments on measuring tools, instruments, equipment and measuring standards which,
if moved, will affect the calibration. Should it be discovered that the seals, labels or waxes have been
broken or moved, immediate action must be taken. The measuring tool, instrument, and equipment
or measuring standard must be considered as out-of-tolerance or not calibrated, and, if in current use,
all current work previously calibrated as out-of-tolerance. VOSKY Quality Control shall be
immediately informed, and VOSKY Quality Control procedures 12.6.2 explicitly followed. The
VOSKY Quality Control Department shall maintain a record of any such occurrences of broken or
moved seals, labels or waxes of either company owned or employee owned measuring tools,
instruments, equipment or measuring standards.
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12.11 CONTROL OF SUB-CONTRACTOR CALIBRATION
VOSKY recognizes that it has the sole responsibility to verify that its sub-contractors, vendors, or
suppliers are in compliance with ANSI/NCSL-Z540-1-1994 completely or to the extent necessary to
assure compliance with applicable contractual requirements. This verification shall be suitable to the
requirements and may range from traceable certifications to complete audits. The VOSKY Quality
Control Department shall maintain a file containing the results of such audits and shall make them
available for Customer review when requested.
12.12 STORAGE AND HANDLING
The VOSKY Quality Control Department shall be responsible for handling, storing and
transportation of all measuring tools, instruments, equipment and measuring standards in a manner,
which shall not adversely affect the calibration or condition of the equipment. Some of these
conditions may be vibration, shock, temperature variances, humidity and dust. The following factors
shall apply;
• All equipment shall be appropriately protected prior to and during
transportation.
• All handling of equipment during transportation or use shall follow
manufacturer's recommendations and good commercial practice.
• Storage areas for equipment shall provide acceptable conditions of
temperature, humidity, and other pertinent factors to preclude
deterioration.
• The VOSKY Quality Control Department shall maintain a file
documenting incidents of improper handling, storage or transportation
and their adverse effect on measuring tools, instruments, equipment and
measuring standards and the appropriate corrective action taken.
13.0 INSPECTION AND TEST STATUS
13.1 GENERAL
13.1.1 VOSKY PRECISION MACHINING CORP has established and maintains in this manual
procedures or ensuring that products are positively identified regarding the conformance or nonconformance with regard to inspection and tests performed.
13.1.2 Inspection and test status of products is identified by the use of Authorized Stamps,
markings, tags and notes in the appropriate places on the Manufacturing Plans, Inspection
Reports and parts themselves
13.1.3 The Manufacturing Plan that accompanies all parts through the manufacturing process has
defined areas for Inspection Stamps. These are maintained to ensure that only parts that have
passed all applicable inspections and tests are released for use or further processing.
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13.1.4 Non-conforming parts shall be clearly tagged, identified , and segregated as per section 14.0
of this manual until disposition.
13.2 USE OF INSPECTION STAMPS
13.2.1 Inspection Stamps, used to indicate approval status of parts through the manufacturing
process, are applied to Manufacturing Plans and Inspection as required by approved personnel
only.
13.3 INSPECTION STAMPS ISSUE AND CONTROL
13.3.1 VOSKY PRECISION MACHINING CORP. has established and maintains in this manual a
procedure for the issuance and maintenance of Inspection Stamps to approved and qualified
personnel.
13.3.2 The General Manager is responsible for the issuing of Inspection Stamps to Quality Control
personnel.
13.3.3 A list is maintained in the General Managers office detailing who is authorized to use a
particular stamp. All stamps must say “Vosky” on them as well as have a number unique to the
person authorized to use that stamp number.
13.3.4 The stamp is surrendered when the user is no longer assigned to the position for which the
stamp was issued. The stamp will not be re-issued for a period of at least one year.
14.0 CONTROL OF NONCONFORMING PRODUCT
14.1 GENERAL
14.1.1 VOSKY has established and maintains in this manual an effective and positive system for
controlling nonconforming material, including procedures for the identification, segregation,
presentation and disposition of reworked or repaired supplies.
14.1.2 Repair of nonconforming supplies shall be in accordance with documented procedures
acceptable to the Customer.
14.1.3 The acceptance of nonconforming supplies is the prerogative of and shall be as prescribed
by the Customer.
14.1.4 All nonconforming supplies shall be positively identified to prevent use, shipment and
intermingling with conforming supplies. Holding areas, mutually agreeable to the contractor and
the Customer representative, shall be provided by VOSKY.
14.2 REVIEW AND DISPOSITION OF NONCONFORMING PRODUCT
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14.2.1 Parts that are found to be non-conforming to specifications, whether manufactured inhouse or purchased, are identified on a Discrepant Material Report (DMR) and segregated from
compliant parts and parts awaiting inspection to prevent their use and issue.
14.2.2 DMR’s are used as a tool to communicate to that a part is not acceptable. When a part is
found to be non-compliant, the DMR is generated and, in the case of a purchased part,
Management is notified of the condition and contacts the vendor. If a part has been manufactured
in-house and is found to be non-conforming to specifications, manufacturing shall be immediately
notified and work on the part shall cease until corrective action can be effected. A copy of the
DMR shall accompany the parts and a copy shall be placed in a master DMR list in the Quality
Control Department.
14.2.3 Parts are then tagged and placed in Vosky’s bonded area pending disposition.
14.2.4 Parts that can be repaired or reworked to conformance to specifications are returned to
manufacturing with specific instructions. Upon completion of rework, parts are to be re-inspected
in the original manner.
14.2.5 Parts that cannot be repaired or reworked to drawing specifications, but may still be usable,
are submitted to the customer for evaluation and disposition. If a part is determined by the
customer to be usable or rework able, then a new Inspection Report is generated reflecting the
changed requirements and the part is inspected to the new specifications. Product deemed not
acceptable, repairable or reworkable shall be disposed of in a manner agreed upon by Vosky and
the Customer.
14.2.6 Parts that are not usable but can be used for set-up on subsequent operations must be
tagged or otherwise visibly marked so as not to be inadvertently mixed in with acceptable parts.
15.0 CORRECTIVE AND PREVENTIVE ACTION
15.1 GENERAL
15.1.1 VOSKY PRECISION MACHINING CORP. has established and maintains in this manual a
procedure for eliminating nonconformances relating to process or the Quality Management
system. Corrective and preventive action is taken to eliminate the causes of actual or potential
nonconformities. The level or degree of corrective or preventive action taken depends on the
magnitude of the problem and is commensurate with the risks encountered.
15.1.2 Any changes to documented procedures resulting from corrective or preventive action shall
be documented in the appropriate manufacturing plan and listed as revisions.
15.2 CORRECTIVE ACTION
15.2.1 Vosky shall take prompt action to correct assignable conditions, which have resulted or
could result in the production of supplies and services that do not conform to:
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(1) the quality assurance provisions of the item specification,
(2) inspections and tests required by the contract, and
(3) other inspections and tests required to substantiate product conformance.
15.2.2 In the event, during an operator or In Process inspection test, a nonconforming part or
process is discovered, work shall be stopped immediately. The cause of the nonconformance shall
be corrected, and 100% inspection test screening performed until ensuing inspection tests indicate
that lot sampling can be continued. A Discrepant Material report shall be generated, listing the
discrepancy, cause of such, corrective action taken, and follow up. This report shall accompany
the Manufacturing Plan during the run.
15.2.3 Corrective Action procedures ensure that:
A) Customer complaints and reports of product nonconformities are handled
promptly and effectively.
B) Nonconformities relating to product, process, or Quality System are investigated
to determine the cause and that results are recorded on Discrepant Material Reports.
C) Corrective action is determined to eliminate the cause of nonconformities.
D) Corrective action is taken and is effective.
15.2.4 In the event that a nonconforming condition is discovered that may affect parts previously
shipped, Quality Control will notify Management, which will notify the customer of the possible
problem. A record of all correspondence will be retained for further reference.
15.3 PREVENTIVE ACTION
15.3.1 The procedures for preventive action ensure that information is utilized to detect, analyze,
and eliminate potential causes of nonconformance.
15.3.2 Customer complaints and returns are analyzed to prevent further reoccurrence of rejects.
Any modification of the processes used in manufacturing are noted in the appropriate
Manufacturing Plan.
15.3.3 The relevant information taken and/or suggested to prevent nonconformities are to be
reviewed by Management.
15.3.4 Corrective and preventive action data is included in the Management review of the Quality
System.
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16.0 HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY
16.1 GENERAL
VOSKY PRECISION MACHINING CORP. has established and documents in this manual
procedures to ensure the integrity of parts and material throughout the manufacturing process.
16.2 HANDLING
Parts must be handled with care at all times through the manufacturing process. Any inadvertent
banging, bumping together, dropping, or other mishandling can result in damaged parts and should
be avoided at all costs. Responsibility for proper handling of a product is assigned to the department
in which the work is currently being performed. When required, special handling instructions are
provided on the Manufacturing Plan.
16.3 STORAGE
16.3.1 Designated storage areas are provided to prevent misuse, misappropriation of, or damage
to materials.
16.3.2 Shipping is responsible for control of production material to prevent loss, damage or
substitution.
16.3.3 Quality Control is responsible for the storage and control of nonconforming materials while
awaiting disposition. A bonded, locked, limited access area is provided for this activity.
16.4 PACKAGING
16.4.1 Packaging and protection is provided to prevent damage during manufacture, processing,
storage, handling, and shipping.
16.4.2 Special instructions regarding the packaging of parts are included on Manufacturing Plans
when necessary.
16.5 PRESERVATION
16.5.1 Shipping is responsible for ensuring that finished products are properly protected to
prevent degradation, corrosion, or damage prior to storage or shipping.
16.5.2 Special instructions regarding preservation are provided on Manufacturing Plans when
necessary.
16.6 DELIVERY
Shipping is responsible for ensuring that parts are properly packed and labeled to prevent damage
or loss during transit. Shipping methods shall be in accordance with customer purchase orders.
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17.0 CONTROL OF QUALITY CONTROL RECORDS
17.1 GENERAL
VOSKY PRECISION MACHINING CORP. has established and documents in this manual procedures
for the control and preservation of Quality Control Department records. Quality records are
maintained to demonstrate the effective operation of the Quality Management System. Records
maintained include: Part Inspection Reports, Discrepant Material Reports, Audit Records, Instrument
Calibration and Inspection Reports, Personnel training certificates, and sub-contractor approval and
Quality audits.
17.2 RECORD STORAGE
Quality Control is responsible for the storage of all records pertaining to part quality, tests, and the
Quality System.
17.2.1 Records are maintained for all instrument and testing equipment calibration in the
inspection department.
17.2.2 Inspection Reports and Discrepant Material Reports are to be retained for a period of not
less than ten years. Reports pertaining to Flight Safety or Fracture Critical parts must be retained
for forty years.
17.2.3 When required by customer, quality records are provided for review.
17.2.4 At the end of the retention period, records may be disposed of under the supervision of the
Quality Control manager.
18.0 INTERNAL QUALITY AUDITS
18.1 Vosky Management shall, at periodic intervals not to exceed one year, conduct audits of the
Quality Control System to ensure the continued reliability and effectiveness of the System. The audits
shall be conducted under the guidelines in section 2.4 of this manual.
19.0 TRAINING
VOSKY PRECISION MACHINING CORP. has identified training needs and provides instruction to
all its personnel in all areas. The individual department head or supervisor is responsible for
ensuring that personnel performing various tasks are adequately instructed and have proper
equipment to perform the assignment.
Additional training is provided on an as-needed basis to ensure personnel’s ability to complete
work.
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20.0 SERVICING
Where servicing is required as part of a specified contract or customer purchase order, Vosky will
establish and maintain procedures for the servicing of products in accordance with contract
specifications.
21.0 STATISTICAL TECHNIQUES
21.1 GENERAL
Where statistical techniques are required as part of a specified contract or customer purchase
order, Vosky will establish and maintain procedures for the measuring and testing of products in
accordance with contract specifications.
21.2 STATISTICAL PROCESS CONTROL
21.2.1 Due to the smaller quantities of parts of parts generally run at Vosky, SPC does not usually
lend itself to our applications. However, when required by contract or customer Purchase Order,
this technique is used to evaluate the control of key characteristics.
21.2.2 Manufacturing uses SPC data to evaluate process capability and responds to out-of-control
conditions.
21.2.3 Quality Control uses SPC data to assist in determining part acceptability, when practical.
21.3 SAMPLING INSPECTION
21.3.1 The use of sampling inspection techniques is done under the direction of the Quality
Control Manager and with the approval of the General Manager.
21.3.2 Sampling inspection is performed in accordance with ANSI ASQC Z1.4 or customer
specification.
21.3.3 Sampling inspection is done only when it adequately monitors product quality.
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Vosky Precision Machining Corp.
Manufacturing Plan
Customer:
Part#:
B/P Rev.:
Description:
Material:
Model:
H/T:
P/L Rev.:
M/P Rev.
Other Outside Processes:
Revision Notes:
Applicable Documents:
10
MATERIAL
Date Started:
Start Qty:
Set-Up Time:
Date Completed:
Finish Qty.
Cycle Time:
In Process Insp.:
Final Insp.:
Date Started:
Start Qty:
Set-Up Time:
Date Completed:
Finish Qty.
Cycle Time:
Operators:
Machine:
First Piece Insp.:
Comments:
20
SAW
Operators:
Machine:
First Piece Insp.:
In Process Insp.:
Final Insp.:
Comments:
30
CNC LATHE
Date Started:
Start Qty:
Set-Up Time:
Date Completed:
Finish Qty.
Cycle Time:
In Process Insp.:
Final Insp.:
Operators:
Machine:
First Piece Insp.:
Comments:
40
CNC LATHE
Date Started:
Start Qty:
Set-Up Time:
Date Completed:
Finish Qty.
Cycle Time:
In Process Insp.:
Final Insp.:
Start Qty:
Set-Up Time:
Operators:
First Piece Insp.:
Machine:
Comments:
Date Started:
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Date Completed:
Finish Qty.
Cycle Time:
In Process Insp.:
Final Insp.:
Date Started:
Start Qty:
Set-Up Time:
Date Completed:
Finish Qty.
Cycle Time:
Operators:
Machine:
First Piece Insp.:
Comments:
60
HONING
Operators:
Machine:
First Piece Insp.:
In Process Insp.:
Final Insp.:
Comments:
70
SHIPPING
Date Started:
Start Qty:
Set-Up Time:
Date Completed:
Finish Qty.
Cycle Time:
In Process Insp.:
Final Insp.:
Operators:
Machine:
First Piece Insp.:
Comments:
NOTES:
o
Methodized By:
James Flock
Approved By:
Mourad Voskinarian
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Vosky Precision Machining Corp.
INSPECTION REPORT
FIRST ARTICLE
PART NUMBER:
PART NAME:
DWG. REV:
SERIAL NUMBERS:
FINAL PIECE
P/L REV:
INSP.
N/A
ORIGINAL
QTY.
SPLIT
QTY.
SPLIT AT
OP. #:
INSP.
STAMP
DATE:
REMARKS:
#
DRAWING DIMENSION
ZONE
VIEW
SHT.
STAMP
ACTUAL DIMENSION
REMARKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
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Vosky Precision Machining Corp.
DMR#:
70-B Air Park Drive, Ronkonkoma, NY 11779
Tel: (631) 737-3200 Fax: (631) 737-3240
DISCREPANT MATERIAL REPORT
Part #:
Job #:
Last Op.#: Completed
DISPOSITION
SCRAP
MRB
RWK
BY:
Part Name:
Qty. Rec’d
DATE
Initiator
Qty. Rejected:
REWORK PERFORMED
OPERATOR
DATE:
Qty. Accepted:
REINSPECTED
INSPECTOR
DATE
QTY. ACC.
S/N:
FINDING / DESCRIPTION OF DISCREPANCY
Dwg. Item #:
Zone:
View:
Sheet:
Mfg. Supervisor (Lead Man)
Operator’s Name
Department Responsible
Requirement (Should Be):
Actual Dimension(s)
Machine
CAUSE AND CORRECTIVE ACTION
1. Immediate Correction:
2. Root Cause:
3. Root Cause Correction
4. Corrective Action Verification Plan
5.0 Follow-Up
Date
CA Effective
Name
General Notes:
STAMP
Vosky Precision Machining Corp.
INSTRUMENT CALIBRATION RECORD
INST. NAME
S/N:
MFG. NAME:
DATE:
MODEL #:
CALIBRATION INTERVAL:
CAL. SOURCE:
STD. USED:
PROCEDURE:
CALIBRATION RECORD
DATE
t
P/F
INSP.
NEXT CAL.
DATE
P/F
INSP.
NEXT CAL.
Vosky Precision Machining Corp.
ORGANIZATIONAL CHART
PRESIDENT – Mourad Voskinarian
Plant Manager – James Flock
Quality Assurance
John Sardone – John McFadden
Lead Man
Milling Dept.
Felipe Molina
Lead Man
Turning Operations
Andrew Voskinarian
Lead Man
Other Operations
Operators
Milling Operations
Som Thongkaseth
Darren Pymento
Operators
Turning Operations
Jorge Perez
Omer Ogrunc
Phil Rizzi
Operators
Other Operations
Angel Flores
Raul Flores
Ramiro Suarez
Farid Zeidan
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