Professional Documents
Culture Documents
Policy: The Company shall develop, implement, and maintain product realization processes
under controlled conditions which produce products that conform to requirements.
Purpose: To delineate the processes used to manufacture, inspect, and package product for
customer use.
Scope: This procedure applies to all personnel involved in the handling and production of
Company products and their components.
Responsibilities:
Manufacturing (production) personnel are responsible for producing the Company's end
product(s) in a manner that ensures quality and meets statutory/regulatory and
customer requirements.
Quality Control is responsible for monitoring and measuring all manufacturing (product
realization) processes, to ensure Company products conform to requirements.
Foreign object detection (FOD) – Discovering a foreign object (object that does not
belong) in a part, component, product, etc. Requirement of AS9100 – clause 7.5.1(i).
May be done at any stage of production, using various detection methods/tools (e.g., x-
ray, ultrasound).
Product realization – Act of bringing a product into existence; or, making a product.
Product realization is often synonymous with the terms "manufacturing" and
"production".
Procedure:
2.3 If material packages (containers) must be broken to issue the correct quantity, the material handler
shall place the correct quantity into an appropriate container and clearly label the container
with the material name, quantity, purchase order number, and work order number.
If the appropriate quantity of a material is not in the location indicated on the pick
list, the material handler shall attempt to find additional locations for the item on the
Company inventory system and, if found, note the quantity and actual location on the pick
list.
If the item cannot be located in the plant, the material handler shall contact the
Production Supervisor immediately to determine if the kit should be held in storage until
complete and/or the work order should be rescheduled.
2.4 The material handler shall deliver the completed kit to Production with a copy of the completed pick
list.
2.5 Using the original pick list, Production shall enter all material issues from the actual locations on the
computer system. If location discrepancies were noted during kitting, Production shall notify
Material Control.
3.0 Production
3.1 The Production Supervisor shall assign the work order for the first operation on the Router (routing
sheet).
3.2 The Operator shall move parts, subassemblies, etc., issued on the work order to the work area.
3.3 The Operator shall follow the operating instructions on the Router. The Router shall indicate or
reference the appropriate production documentation.
If the operating instructions call for operator inspection, inspection instructions must be
included and an operator checklist should be provided by QA, based on product
requirements. See AS1150-1 INSPECTION/ TESTING CHECKLIST for guidance.
If the instructions call for Quality Assurance to conduct an inspection, the operator shall
forward the part(s) with inspection instructions to Quality Assurance (see section 3.0).
3.4 When the operation is complete, the operator shall complete the Router and forward the product
and work order packet to the next operation on the Router.
4.0 Inspection and Testing
4.1 Quality Assurance shall inspect Company products in accordance with requirements, to verify the
quality and conformity of parts and gauge the effectiveness of the design, development, and
production processes.
4.2 The QA Manager shall fill out AS1150-1 INSPECTION/TESTING CHECKLIST for the part to be
inspected, based on inspection requirements, key characteristics, etc. (see AS1050 CUSTOMER
AND PRODUCT REQUIREMENTS), and assign the inspection.
The QA Manager should include a detailed description/explanation of the inspection (see
section 4 of AS1150-1) and attach relevant inspection records, etc., as needed.
Depending on the nature, composition, and complexity of some items – and possibly due to
customer or other requirements – they will require inspection for the presence of foreign
Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions
objects (Foreign Object Detection, or FOD). If FOD is required, this must be included on the
Inspection/Testing Checklist (see section 3, AS1150-1).
4.3 The inspector shall inspect the item (part, component, etc.) for conformance to all requirements
stated on the AS1150-1, checking the box in the "I" (inspected) column after each requirement.
If the inspector tests for conformance, the "T" (tested) column must be checked.
4.4 If the item fails to meet a requirement, the inspector shall indicate in the "Comments" section which
of the listed requirements was not met (referencing the requirement number on the form) and
include an explanation.
4.5 The inspector/tester shall sign and date the AS1150-1, indicating whether the part passed or failed
inspection/tests, and submit the checklist to the QA Manager.
4.6 The QA Manager shall review the checklist with Production, to determine whether to continue with
production.
4.7 If the product, part, component, etc., fails the inspection/test, the QA Manager shall dispose of the
item in accordance with AS1230 – CONTROL OF NONCONFORMING PRODUCT.
5.0 Packaging and Labeling
5.1 The packaging operator shall apply required labels to product packaging.
5.2 The operator shall record serial number sequence on the Router, if applicable.
5.3 The operator shall package finished products according to work instructions for the product.
5.4 The operator shall apply box labels to the packaged product in accordance with work
instructions and stage the product for release in the appropriate area.
5.5 If the product is a component to be used in a subsequent operation, the operator shall place the
product in an appropriate container and attach a tag, indicating the component name/ID and
work order number on the tag. Include a shop router, as needed.
6.0 Final VERIFICATION
QA or an individual designated by QA shall verify that the product, as packaged, conforms to
requirements
BMPCOE is a partnership among the Office of Naval Research's BMP Program, the Department
of Commerce, and the University of Maryland. Its objective is to empower defense and
commercial customers to operate at a higher level of efficiency and effectiveness.
A. Quality Procedures
AS1000 DOCUMENT CONTROL
AS1010 QUALITY RECORDS
AS1140 CONTROL OF PRODUCTION PROCESSES
AS1160 IDENTIFICATION AND TRACEABILITY
AS1170 CUSTOMER PROPERTY
AS1180 CONTROL OF MONITORING AND MEASURING DEVICES
Records/Forms:
Production schedule
Parts list(s)
Pick list
Shortage report
Work orders and routers
Bizmanualz Sample from the As 9100 Rev C Aerospace Policies and Procedures Manual includes
an example policy, procedure, a list of topics, forms and job descriptions
Inspection sheets/reports
Operating procedures; operator checklist(s)
AS1150-1 INSPECTION/TESTING CHECKLIST
Test results report
Production measurement data
Revision History
1. CUSTOMER REQUIREMENTS I T
a.
b.
c.
d.
2. REGULATORY REQUIREMENTS I T
a.
b.
c.
d.
3. OTHER REQUIREMENTS I T
a. Foreign Object Detection
b.
c.
d.
4. INSPECTION (attach narrative, spreadsheets, charts, etc., as needed)
a. Nature of inspection; technique(s) – describe
b. Inspection conditions
c. Observations/results
5. TESTING (attach information sheets, charts, etc., as needed)
a. Location
b. Restate/specify test requirements
c. Nature, type of testing (lab, simulator, in-flight, nondestructive, etc.); tools, techniques used
d. Test conditions
e. Observations/results
COMMENTS (attach additional sheets, if needed)