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Quality Manual

This manual is the property of Dill Air Controls Products. It may not be reproduced in whole or in part or otherwise disclosed without prior consent from the Quality Assurance Manager.

Level I Cover

QUALITY MANUAL Procedure No. QM-TC Revision Level M

TITLE: QM-TC TABLE OF CONTENTS Revision Date 1/7/11 Page No. 1 of 1

Document Title / Revision Level ISO / TS specification QM-TC Table of Contents / Rev M QM-QP Quality Policy / June 2006 QM-A Quality Management System Scope / Rev H QM-C Dill Air Controls Products Process Flow / (January, 2008) QM-B Quality Management Procedures QP-05-01 Control of Documents 4.2.3 QP-16-01 Control of Records 4.2.4 QP-18-01 Training 6.2.2.2 QP-17-01 Internal Quality Audits 8.2.2 QP-13-01 Control of Non-Conforming Product 8.3 QP-14-01 Corrective Action 8.5.2 QP-14-03 Preventive Action 8.5.3 QM-D Dill Air Controls Products Organizational Chart / (January 2011) Basic New for Air Controls Division

A QM-01 Rev level was “Basic” 4/8/04 L. Schlesinger B QM-A, QM-B,QM-01 Rev level was “A”, All other Rev levels were “Basic” 7/6/05 R. Buhr C QM-01 was rev. B 1/6/06 R. Buhr D QM-B, QM-01, QM-02, QM-06, QM-09, QM-15 updated at review 2/27/06 R. Buhr E Totally revised for TS 16949 6/21/06 R. Buhr F Scope revised for exclusion of service provision. 7/6/06 R. Buhr G Organizational Chart updated 8/07 R. Buhr H Organization Chart Up-dated 5/08 R. Buhr I Organization Chart Up-dated 10/08 R. Buhr J Scope updated to ISO 9001:2008 6/09 R. Buhr K Organization Chart Up-dated 12/09 R. Buhr L Organization Chart Up-dated 6/10 R. Buhr M Organization Chart Up-dated 1/11 R. Buhr

“Destroy Previous Revision Level”

Dill Air Controls Products, LLC

“Quality Policy”

“It is the policy of Dill Air Controls Products to

meet or exceed Internal and External Customer

Expectations by providing superior Products and

Services. We do this by focusing on Customer-led

Quality Objectives and continually improving

The Quality Management System.”

QM-QP June 2006

Air

Controls

Products

QUALITY MANUAL Section QM-A Revision Level H

TITLE: QM-A QUALITY MANAGEMENT SYSTEM SCOPE Revision Date 6/15/09 Page No. 1 of 2

Dill Air Controls Products, LLC (Dill), headquartered in Oxford, North Carolina, has established a quality management system that satisfies the needs of its customers and assures continuous improvement. The quality management system covers the design, manufacturing, verification and delivery of our products and complies with internationally recognized quality system standard ISO/TS 16949:2002 with registration to ISO 9001:2008. The Quality System supports Dill with design, manufacturing & sales responsibility located in Oxford, NC serving both OEM and Aftermarket agents for air control products. A Quality Manual has been prepared which describes the quality system for Dill. The manual is a source of reference for Quality System Procedures, which define responsibilities concerned with the operation and monitoring of the quality system, and assists in the training and education of new staff in matters relating to quality. Dill does not have service agreements with customers and does not provide service centers, special tools or measuring equipment, or offer training of service personnel. Section 7.5.1.8 of TS16949 to be excluded from the quality system. The Quality Manual provides customers an understanding of Dill's commitment to quality and confidence in the capabilities of the company to produce a quality product. The Quality Manual and Quality System Procedures are electronically maintained by the Quality Assurance Department. Controlled copies are issued upon request. This Quality Manual is hereby formally authorized and approved by the undersigned. Name: Position: Date: _____________ General Manager _______ Brian Rigney _____________ Operations Manager _______ Tony Monfrado _____________ Engineering Manager _______ Larry Schlesinger _____________ Sales and Marketing Manager _______ Brian Rigney (interim) _____________ Sales _______ Joe Hebert _____________ Quality Manager _______ Richard Buhr _____________ Controller _______

QUALITY MANUAL Section QM-A Revision Level H

TITLE: QM-A QUALITY MANAGEMENT SYSTEM SCOPE Revision Date 6/15/09 Page No. 2 of 2

Kathleen Myers (ELECTRONIC USERS: Signatures on file in Quality Department) Basic New for Air Controls Division A Corrected document numbers in Level II per DNV finding – 9/16/02 B Eaton Air Controls Division changed to Dill Air Controls Products 7/6/05 C Roxboro, NC changed to Oxford, NC for new location of business 2/27/06 D Totally revised for TS 16949 6/7/06 E Changed approvals for all staff 6/21/06 F Added exclusion of servicing provisions. 7/6/06 G Revised for change in General Manager 6/23/08 H Revised to new ISO 9001:2008 standard 6/15/09 “Destroy Previous Revision Level”

Monday, January 28, 2008

Page 1

DILL ACP PROCESS FLOW

MARKET ANALYSISQMS-P-001

CONTRACT REVIEW

QMS-P-003

PRODUCT DEVELOPMENT

QMS-P-002

ORDER ENTRYQMS-P-004

CUSTOMER SURVEYS

CUSTOMER REQUEST FOR

QUOTE

CUSTOMER NEED

/ APPROVALS

CUSTOMER ORDER

QUANTITY NEED DELIVERY NEED

STRATEGY &PLANNING

FORECAST ADVERTISING

DETERMINE CAPACITY &

TRAININGQP-18-01

DETERMINE AND ORDER TOOLING

AND GAGING

DEVELOP BILLS AND ROUTINGS

DEVELOP AND POST COSTING

DEVELOP AQP

MAKE /TEST PROTOTYPE / PILOT PARTS

IT SUPPORT

LAYOUT / PPAP

QUALIFY SUPPLIERS

ORDER PARTS, MATERIALS AND

PRODUCTION SERVICES

SUPPLIERS

SCHEDULE ORDER

SPECIFICATIONS AND DRAWINGS

QP-05-01QP-16-01

RELEASE ORDER WITH

SPECIFICATIONS

REQUISITION PARTS /

MATERIALS

B

C

D

A

F

G

G

A

SETUP

SETUP APPROVAL

INSPECT PRODUCTQP-13-01

PACKAGE AND LABEL PRODUCT

STORE PRODUCT

PRODUCE PRODUCTQMS-P-006

RECEIVE RAW MATERIAL AND

PARTSQMS-P-005

INSPECT RAW MATERIALS AND

PARTS

STORE RAW MATERIAL AND

PARTS

PICK REQUISITIONS

SUPPLIERS

RECEIVE INVOICES

PAY INVOICES

PICK ORDER

INSPECT ORDERQP-13-01

PACK AND LABEL ORDER

SHIP ORDERQMS-P-007

INVOICE ORDER

QMS-P-007

EVALUATE PERFORMANCE

QMS-P-008

CUSTOMER PAYMENT

COLLECT PAYMENT

SCHEDULE LABOR

HR SUPPORT

CUSTOMER SURVEY

SUPPLIERS

Monday, January 28, 2008

Page 2

DILL ACP PROCESS FLOW

B C

D

CUSTOMER

GRADE SUPPLIERS(SUPPLIERQUALITYMANUAL)

F

G

IT SUPPORT

G

FACILITIES AND TOOLING SUPPORT

G

LAYERED PROCESS

AUDITS

E

EINTERNAL

AUDITSQP-17-01

CORRECTIVE ACTIONSQP-14-01

PREVENTIVE ACTIONSQP-14-03

H

H

QUALITY PROCEDURE Procedure No. QP-05-01 Revision Level F

TITLE: QP-05-01 DOCUMENT CONTROL Revision Date 6/30/08 Page No. 1 of 4

1. PURPOSE The purpose of this procedure is to define the control methods for the quality system documentation, when required, and assign responsibility for establishment, review, authorization, issue, distribution, and revisions of controlled documents. 2. APPLICATION This table represents an overview of the quality system documentation. For specific document contents see Quality System Documentation Procedure. Additional documents requiring control are covered within individual work instructions and control is defined within that work instruction document. Section 6.0 of this procedure applies to all categories of controlled quality system documents Dill Air Controls Products

DOCUMENT CONTROL TABLE DOC LEVEL

DOCUMENT CATEGORY

DOCUMENT TYPE

APPROVAL AUTHORITY

ISSUING FUNCTION

I

Quality Manual

Quality Manual

Operation Staff

Quality Assurance

II

Quality Procedures

Quality Procedures

Applicable department manager or designee

Quality Assurance

III

Work Instructions

Work instructions for manufacturing operations Work instructions for administrative operations

See document control work instructions. Applicable department manager or designee

See document control work instructions. Applicable department manager or designee

III

External Standards

Drawings Material Quality Industrial Government Other

Publisher Government

Product Engineering, Quality Assurance

III

Product Drawings and Specifications

Product Drawings Product Specifications

Prod. Engineering See applicable specification work instructions

Prod. Engineering Prod. Engineering

III

Quality Planning Documents

Control Plan Process Flow Chart P.F.M.E.A. Characteristic Matrix D.F.M.E.A.

See document control work instructions. Prod. Engineering

See document control work instructions. Prod. Engineering

III

Customer Drawings and Specifications

Customer Drawings and Specifications

Customer

Prod. Engineering

Other

Business Planning Documents

Customer Specific Requirements

Others

Division Strategic Business Plan

Customer Published Manuals

As defined by Internal Quality System documentation

Strategic Planning &

Market Development Mgr.

Customer


Marketing

Quality Assurance




3. RESPONSIBILITIES The functions responsible for approving and issuing quality system documentation are shown in the Document Control table. 4. REFERENCE DOCUMENTS a) TS-WI-7.3.6.3-01 - Production Part Approval Work Process Work Instruction 5. DEFINITIONS PFMEA: Process Failure Modes & Effects Analysis DFMEA: Design Failure Modes & Effects Analysis 6. PROCEDURE

6.1. General

6.1.1. Anyone in DILL ACP can request the issue of a new document or the revision of an existing one. The person submits a draft of the proposed document to the appropriate approval authority.

6.1.2. Currently released documents referenced by customer specifications and drawings are

available at the manufacturing locations.

6.1.3. The designated reviewing functions have access to pertinent background information to facilitate the review.

6.1.4. The review, update and re-approval of documents to be performed as required and

verified by approval and date of ECR.

6.2. Document Approval

6.2.1. The issuing function ensures the document draft is reviewed and approved for adequacy, prior to issue, by the approval authority listed in the table. Document revisions are reviewed and approved by the same function(s) that approved the initial release unless specifically designated otherwise. This document revision review/approval may be in the form of a ballot process or other methods specified by the appropriate issuing function in their work instruction. Administrative changes to the Quality Documents may be made and approved by the appropriate approval authority. An administrative change is defined as a change where intent is not affected and may include, but is not limited to: changes in grammar, correction of spelling errors, adding reference document notations, and/or minor wording changes that do not affect intent as determined by the appropriate approval authority, (the flow chart process is not applicable for changes of this nature).

6.2.2. Documents being circulated for approval are appropriately identified to prevent

unintended use.

6.2.3. Handwritten revisions to released documents must be signed and dated by the applicable approval authority and, if permanently adopted, must be replaced with formally changed documents as soon as reasonable time permits.

6.2.4. Temporary work instructions other than released documents must be controlled and

signed by the approving authority.



6.2.5. The following flow chart graphically illustrates the process for creation, revision and approval of quality system documents.

Procedure Flow Chart

Control DocumentIdentified

(Add, Delete, Modify)

DocumentProposal Made

Submit for Review

DocumentReview Accepted

/ Rejected

Reject

Accept

Submit forApproval

Accept

DocumentApproval

Accepted /Rejected

See ApprovalAuthority In

Document ControlTable

Identify ControlMethod & Update

System

See IssuingFunction In


Notification



Formal TrainingRequired?

Yes

No



Implement Document Revision

1. Issue Req'd Copies2. Gather & Destroy

ObsoleteDocuments

Train & Record(per 4.18)

Reject / Modify

Modify

See ApprovalAuthority In


Scrap





6.3. Document Release and Distribution

ature of the change shall be identified in the document or the appropriate attachments.

roval submissions are required in accordance with the Production Part Approval Process.

ccording to their system. These documents are available at the manufacturing location(s).

k Instructions are uncontrolled, as they are electronically controlled in the computer system.

6.3.5. Controlled documents are identified by individual Manufacturing Orders.

6.3.6. The issuing function is responsible for maintaining an effective control method which:

removed from the point of

6.3.6.3. ensures issued documents are readily identifiable and legible to the end user.

6.4. Obsolete and Historical Documents

e issuing function in accordance with the Control & Retention of Records Work Instruction.

Basic

6.3.1. The issuing function shall ensure released documents are identified with a title or number,

date of revision and/or revision level and a means of showing formal release appropriate to the document. Where practicable, the n

6.3.2. All customer standards/specifications and changes are reviewed, distributed, and

implemented in a timely manner, appropriate to the type of document. The date a change is implemented into production is recorded and maintained. Changes in these specifications are reviewed by Quality Assurance to determine whether customer production part app

6.3.3. Customer documents are identified by the customer a

6.3.4. Hard copies of the Quality Manual, Quality Procedures, Quality Work instructions, and

Manufacturing Wor

6.3.6.1. identifies the current revision status 6.3.6.2. ensures that any obsolete/invalid documents are promptly

issue or use, or otherwise assured against unintended use

6.4.1. Obsolete documents that are retained for preservation of knowledge or legal reasons are

identified accordingly by th

New for Air Controls Division A Corrected document numbers in Level II per DNV finding – 9/16/02 B Modified for Dill Air Controls Products 11/4/05 C Reviewed and revised for TS 16949 6/27/06 D Revised 6.1.4 for clarification of document approval and up-dated document control table

10/15/07 L. Watts E Up-Dated Reference Documents -1/24/08 F Up-dated Section 6.3.4 and 6.3.5 6/30/08 L. Watts


QUALITY PROCEDURE Procedure No. QP-16-01

Revision Level D TITLE: QP-16-01 QUALITY RECORDS Revision Date 1/28/08

Page No. 1 of 2

1. PURPOSE The purpose of this procedure is to provide a system and instructions for identification, storage, protection, retrieval, retention time and disposition and disposal of quality records that are retained in support of the quality system. 2. APPLICATION This procedure applies to all records that demonstrate the effective implementation of the quality system at Dill Air Controls Products. Specific quality records from Dill Air Controls subcontractors are included. This procedure provides a list of affected records. Records can be in the form of any type of media. 3. RESPONSIBILITIES The departments/functions listed in the Record Retention Table are responsible for compliance to this procedure for each respective record. The control and maintenance of the Record Retention Table is the responsibility of the Quality Manager at Dill Air Controls. 4. REFERENCE DOCUMENTS

4.1. TS-WI-4.2-01 – Record Retention Table 5. PROCEDURE

5.1. Scope

5.1.1. Quality records are listed in the Record Retention Table. The records are maintained and are available for customer evaluation except in the case of confidentiality. Governmental or customer requirements may supersede these requirements.

5.2. Identification

5.2.1. Records are identifiable to the product, person, or events to which they pertain. Records

are legible, dated and identify who established the record. Records are collected, and filed in logical groupings relating to the activity to facilitate their retrieval/access. Where records contain confidential information they are marked to indicate their confidential nature.

5.3. Storage/Maintenance

5.3.1. Records are stored in dry, organized environments. Record containers are labeled as to

their contents. To insure retrievability/access, records and other quality documents are not to be stored in locations that would inhibit required access. When electronic media is used, back up methods are employed to prevent loss.

QUALITY PROCEDURE Procedure No. QP-16-01

Revision Level D TITLE: QP-16-01 QUALITY RECORDS Revision Date 1/28/08

Page No. 2 of 2

5.3.2. Records and/or storage containers are identified to ensure the following:

5.3.2.1. Name of record or area to which the record applies, e.g. "Inspection Check List" 5.3.2.2. Dates to which the records apply 5.3.2.3. Disposal and/or retention date

6. Record

6.1. Quality records are maintained for the minimum required time as set forth in the Record Retention Table. The disposal method is determined by the Management Representative or issuing authority and may include recycling for hard copies.

Basic New for Air Controls Division A Corrected document numbers in Level II per DNV finding – 9/16/02 B Modified for Dill Air Controls Products - 11/04/05 C Reviewed and Revised for TS 16949 -6/21/06 D Up-dated Reference Documents – 1/28/08


QUALITY PROCEDURE Procedure No. QP-18-01 Revision Level E

TITLE: QP-18-01 TRAINING Revision Date 1/28/08 Page No. 1 of 2

1. PURPOSE The purpose of this procedure is to provide a system and instructions for determining training needs, providing training and assessing training effectiveness. 2. APPLICATION At Dill Air Controls Products, training is viewed as a strategic issue affecting all personnel, including contract and agency personnel. 3. RESPONSIBILITIES The Staff is responsible for compliance to this procedure. 4. REFERENCE DOCUMENTS

4.1. TS-WI-4.2-01 – Control & Retention of Records Work Instruction 4.2. TS-WI-5.6-01 - Management Review Work Instruction

5. PROCEDURE

5.1. General

5.1.1. Personnel (including temporary and contract employees) performing specific tasks are qualified through appropriate education, training, and/or experience as required by the qualification requirements.

5.2. Qualifications of Personnel

5.2.1. Qualification requirements are developed for specific tasks by the area supervisor. The

Supervisor must approve the qualification requirements.

5.2.2. Personnel performing specific tasks while in training must meet the following conditions:

5.2.2.1. The employee has completed the job orientation. 5.2.2.2. At least one qualified employee in the immediate area has been assigned to answer

questions, and provide any needed assistance.

5.2.3. Personnel move from "in training" status to qualified when they meet the qualification requirements. The supervisor and/or designated trainer must signoff that the appropriate training has been successfully completed and meets the required training and experience defined by the qualification requirements.

5.2.4. Personnel meeting the qualification requirements are deemed qualified as of the

implementation date of this procedure.

5.2.5. Employees not meeting the qualifications are considered "in training” and adhere to the conditions mentioned above.

QUALITY PROCEDURE Procedure No. QP-18-01 Revision Level E

TITLE: QP-18-01 TRAINING Revision Date 1/28/08 Page No. 2 of 2

5.3. Training Needs

5.3.1. The facilities training needs are assessed annually by supervisors, departmental managers and area representatives through a minimum of one or more of the following:

5.3.1.1. A review of qualification requirements and/or annual surveys 5.3.1.2. A review of plant goals and objectives 5.3.1.3. A review of Government regulations 5.3.1.4. A review of our customer's future expectations

5.4. Training Programs

5.4.1. The employee orientation training familiarizes employees with issues such as working

hours, benefits, safety, and a general explanation of the quality system.

5.4.2. Training programs (provided both internally and externally) are tracked by the Training function.

5.4.3. Employee meetings are held regularly to communicate the relevance and importance of

their activities and how they contribute to the achievement of quality objectives and business success.

5.5. Training Effectiveness

5.5.1. Training effectiveness is evaluated periodically through various methods as applicable.

Examples may include:

5.5.1.1. Periodic surveys - evaluations of task performance 5.5.1.2. Pre-testing and post testing on selected courses 5.5.1.3. Meeting plant goals - business performance

5.6. Information on effectiveness is documented and used in the development of subsequent training

plans. 6. RECORDS

6.1. A training record is established and maintained for each employee to show evidence of qualification.

6.2. Training records are maintained in accordance with the Quality Records Procedure.

Basic New for Air Controls Division A Corrected document numbers in Level II per DNV finding – 9/16/02 B Modified for Dill Air Controls Products-11/4/05 R. Buhr C Revised per CRN 10181 -2/24/06 T. Monfrado D Reviewed and revised per TS 16949 -6/27/06 E Added 5.4.3 1/28/08 L. Watts


QUALITY PROCEDURE Procedure No. QP-17-01 Revision Level D TITLE: QP-17-01 INTERNAL QUALITY AUDITS Revision Date 1/28/08

Page No. 1 of 2

1. PURPOSE The purpose of this procedure is to define a system and provide instructions for planning and conducting internal quality audits to determine whether quality activities and associated results comply with planned arrangements and to determine the effectiveness of the quality system. 2. APPLICATION This procedure applies to all activities within the quality system. 3. RESPONSIBILITIES The Quality Assurance function is responsible for managing the internal audit process. Audited departments/functions are responsible for developing and implementing corrective actions to address noncompliances found. 4. REFERENCE DOCUMENTS

4.1. TS-WI-8.5-02 - Corrective Actions Work Instruction 4.2. TS-WI-4.2-01 – Control & Retention of Records Work Instruction 4.3. TS-WI-5.6-01 - Management Review Work Instruction 4.4. QMS-P-006 – Produce Product Process Flow

5. PROCEDURE

5.1. Planning

5.1.1. The Quality Assurance function is responsible for planning and scheduling the internal audits. A complete audit of all quality system elements including all active shifts is conducted at least once a year. The audits are completed in accordance with a documented schedule which is based on the status and importance of the activity, taking into account an increased frequency when internal and external nonconformances, customer complaints or past audit results reveal compliance concerns.

5.2. Audit Team

5.2.1. The Quality Assurance function assigns qualified personnel to carry out internal audits.

Assigned auditors are independent of those having direct responsibility for the audited activity. Auditors sourced from outside the organization must meet these requirements.

5.2.2. The evidence of auditor qualifications is retained according to the Quality Records

Procedure.

5.3. Preparation for Audit

5.3.1. Audit checklists are developed taking into consideration the customer audit requirements, the quality manual and referenced procedures, the noncompliance reports and corrective action files and, as appropriate, specifically prepared questions.

QUALITY PROCEDURE Procedure No. QP-17-01 Revision Level D TITLE: QP-17-01 INTERNAL QUALITY AUDITS Revision Date 1/28/08

Page No. 2 of 2

5.4. Conducting the Audit

5.4.1. The manager(s) responsible for the area being audited is notified in advance. 5.4.2. The auditors use the audit checklist and seek objective evidence demonstrating whether

the audited activities comply with the requirements of the documented quality system. The results of the audit are documented on an audit report and discussed with the responsible function(s).

5.5. Audit Review

5.5.1. The area manager's acknowledgement of review (signature) is required on the audit report.

5.5.2. Management, according to the Management Review Work Instruction reviews internal

audit results.

5.6. Corrective Action and Follow-Up

5.6.1. When noncompliances are identified and documented, the area manager is responsible for investigation of the problem(s) noted as a noncompliance, and taking timely corrective action according to the Corrective Action Work Instruction.

5.6.2. Following implementation, or at the next scheduled audit, an auditor follows up to

determine if the corrective action has been implemented and if it is effective. Objective evidence is reviewed and recorded in the audit results. If more work is needed to implement the action, a new follow-up date is agreed upon and documented.

6. RECORDS

6.1. The audit reports and corrective actions are documented and maintained according to the Control & Retention of Records Work Instruction.

Basic New for Air Controls Division A Corrected document numbers in Level II per DNV finding – 9/16/02 B Modified for Dill Air Controls Products- 11/4/05 C Reviewed for TS 16949 – 6/21/06 D Up-Dated Reference Documents -1/24/08 “Destroy Previous Revision Level”

QUALITY PROCEDURE Procedure No. QP-13-01 Revision Level D

TITLE: QP-13-01 CONTROL OF Revision Date 1/28/08 NONCONFORMING PRODUCT Page No. 1 of 3

1. PURPOSE The purpose of this procedure is to provide a system and instructions for identification, documentation, evaluation, segregation, and disposition of suspect and confirmed nonconforming products and materials to prevent unintended use or installation into an assembly. 2. APPLICATION Any Non-conforming or Suspect Product or Material, which does not meet, required specifications. 3. RESPONSIBILITIES It is the responsibility of personnel conducting inspection or testing to identify, document, and segregate non-conforming or suspect material. The material review authority is responsible for evaluation, disposition, and/or notification of non-conforming or suspect material 4. REFERENCE DOCUMENTS

4.1. TS-WI-8.5-02 - Corrective Actions Work Instruction 4.2. TS-WI-7.3.6.3-01 - Production Part Approval Work Instruction 4.3. TS-WI-4.2-01 – Control & Retention of Records Work Instruction 4.4. TS-WI-7.5.3-01 - Product Identification Work Instruction 4.5. TS-WI-7.5.3-02 – Product Traceability Work Instruction 4.6. QMS-P-006 – Produce Product Process Flow

5. PROCEDURE

5.1. Identification and Documentation

5.1.1. Personnel who conduct inspection or testing are responsible for visually identifying non-conforming and suspect products in the course of their activities.

5.1.2. When nonconforming or suspect product is identified, it is visually labeled as

nonconforming and it is segregated (when practical) to prevent unintended use. The nonconforming product is identified according to the Product Identification and Traceability Work Instructions. The material review authority is notified.

5.1.3. Information to Management - When products and/or processes become noncompliant to

requirements Quality Assurance function is notified. The Quality Assurance Function will evaluate the nonconformance and promptly notify the facility management as appropriate based on the severity of the nonconformance and those affected. When non-conforming product is detected after delivery or use has started, all suspect product and components will be contained for evaluation. Dill will notify the customer to the effects or potential effects of the non-conformity.

5.1.4. Where containment areas exist, they are visually marked with a placard or other visible

indicator.



5.2. Nonconformity Review and Disposition

5.2.1. The material review authority will manage the review and disposition of nonconforming products in the following manner:

5.2.1.1. Reworked to meet the specified requirements, 5.2.1.2. Accepted as-is, with or without repair (providing customer approval is obtained where

required by contract), 5.2.1.3. Accept as-is, providing customer requirements are met, 5.2.1.4. Re-grade (use in an alternative application in which it meets customer requirements), 5.2.1.5. Scrapped

5.2.2. The disposition and corrective actions are completed according to the Corrective Action

Work Instruction.

5.2.3. These dispositions are approved by the Quality Assurance function and are documented in the Control Plan and/or appropriate control document.

5.2.4. Once disposition is determined the material review authority identifies the product

according to the Product Identification and Traceability Work Instruction.

5.3. Reworked and Repaired Product

5.3.1. Documented work instructions at the workstation are utilized in the reclamation of product according to the Control Plan and/or appropriate control document using appropriately trained personnel. The system assures that no rework or repair can be visible on the exterior of the product supplied for non-original equipment service applications without prior approval of the customer service parts organization.

5.3.2. When required by contract, the customer is notified by Sales, Quality Assurance, or

Product Engineering for concurrence to accept nonconforming product or the proposed repairs that would affect the product quality.

5.3.3. The facility staff establishes a rework reduction plan. Data on nonconforming material that

is subject to rework is compiled and analyzed. Priorities are determined and action plans developed in conjunction with any ongoing corrective/preventive actions. Progress toward the plan is tracked through trend and/or Pareto charts.

5.4. Re-inspection

5.4.1. Repaired or reworked products are inspected according to the Control Plan and/or

appropriate control document to verify that they comply with specified requirements.

5.5. Customer Engineering Approval - Product Authorization

5.5.1. In accordance with customer requirements, prior written approval is obtained through Sales, Quality Assurance, or Product Engineering whenever the product or process is different from that currently approved per the Production Part Approval Work Instruction. This applies equally to products or services purchased from subcontractors. Dill Air Controls Products Sales and/or Quality Assurance resolve any issues and concur with the requests of a subcontractor before submission to a customer. If authorization expires, Sales, Quality



Assurance, or Product Engineering requests written customer approval before subsequent shipment of product. Materials shipped under an authorization are identified with the authorization description clearly visible on each shipping container.

6. RECORDS

6.1. Records of nonconforming product will be maintained in accordance with the Quality Records Work Instruction.

6.2. Records of product or process changes, including expiration date and/or quantity authorized are

maintained according to the Quality Records Work Instruction. Basic New for Air Controls Division A Corrected document numbers in Level II per DNV finding – 9/16/02 B Modified for Dill Air Controls Products -11/4/05 C Reviewed and revised for TS 16949- 6/27/06 D Up-dated Reference Material – 1/28/08



TITLE: QP-14-01 CORRECTIVE ACTION Revision Date 1/28/08 Page No. 1 of 3

1. PURPOSE The purpose of this procedure is to provide for a system and instructions for initiating, carrying out, and verifying the effectiveness of corrective actions. 2. APPLICATION This procedure applies to correcting nonconformities related to materials, components, subassemblies, finished products, packaging, production processes, and the quality system. 3. RESPONSIBILITIES All functions are responsible for the effective deployment and maintenance of corrective actions. 4. REFERENCE DOCUMENTS

4.1. TS-WI-8.3-01 - Control of Nonconforming Product and MRB Work Instruction 4.2. TS-WI-4.2-02 - Document Control Work Instruction 4.3. TS-WI-7.1-01 – Engineering Change Control Work Instruction 4.4. TS-WI-4.2-01 – Control & Retention of Records Work Instruction 4.5. TS-WI-5.6-01 - Management Review Work Instruction 4.6. QMS-P-006 – Produce Product Process Flow

5. PROCESS

5.1. Corrective Action Requests for Subcontractors

5.1.1. When nonconforming purchased parts, materials or services incorporated in the finish product are found they are documented according to the Control of Nonconforming Product & MRB Work Instruction.

5.1.2. Subcontractors are required to respond to Quality Assurance for the nonconforming

product with corrective action. Depending upon the degree of the problem, the Quality Assurance function may assign an approach to be taken.

5.2. Corrective Actions on In-House Nonconformities

5.2.1. Corrective actions for in-house nonconformities are performed using a disciplined structured problem solving method. Depending upon the scope of the problem and whether or not the cause is known, two formats may be used.

5.2.1.1. If the cause is known, a three-step approach may be used:

5.2.1.1.1. Define Problem 5.2.1.1.2. Implement Permanent Actions 5.2.1.1.3. Verify Effectiveness of Permanent Actions



5.2.1.2. If the cause is not known, an eight-step approach is used: 5.2.1.2.1. Form Team 5.2.1.2.2. Define Problem 5.2.1.2.3. Implement Containment Action 5.2.1.2.4. Define/Verify Root Cause 5.2.1.2.5. Choose/Verify Permanent Actions 5.2.1.2.6. Implement/Validate Permanent Actions 5.2.1.2.7. Prevent Recurrence 5.2.1.2.8. Congratulate Team

5.2.2. Mistake Proofing

5.2.2.1. Prior to the closing/completion of a corrective action mistake proofing methodology is

considered and implemented where appropriate.

5.3. Corrective Actions on External Nonconformities

5.3.1. Quality Assurance ensures that corrective actions on external nonconformities are addressed in a manner and format compliant with any customer specific requirements.

5.4. Returned Product Test/Analysis

5.4.1. Parts returned from the customer's manufacturing plants, engineering facilities, service

parts centers, and dealerships are analyzed and, as appropriate, actions are taken.

5.5. Effectiveness of Corrective Actions

5.5.1. The Quality Assurance function verifies the effectiveness of corrective actions taken.

5.6. Corrective Action Impact

5.6.1. Prior to the closing/completion of a corrective action similar products and processes are evaluated to determine if the resulting corrective actions and controls can be used to reduce the potential for producing nonconforming material. This also includes sharing corrective action information with other facilities using similar products and processes.

5.7. Process and Document Changes

5.7.1. Corrective actions involving process changes are handled in accordance with the

Engineering Change Control Work Instruction. Changes to documents are implemented and recorded according to the Document Control Work Instruction.

5.8. Review

5.8.1. Review of corrective actions and effective implementation is conducted according to the

Management Review Work Instruction.



6.0 RECORDS

6.1 Corrective action records and returned product analyses are maintained in accordance with the Control & Retention of Records Work Instruction.

Basic New for Air Controls Division A Corrected document numbers in Level II per DNV finding – 9/16/02 B Updated for Dill Air Controls Products- 11/4/05 C Reviewed for TS 16949 – 6/21/06 D Up-Dated Reference Documents -1/24/08 “Destroy Previous Revision Level”


TITLE: QP-14-03 PREVENTIVE ACTION Revision Date 1/28/08 Page No. 1 of 2

1. PURPOSE The purpose of this procedure is to provide a system and instructions for developing, implementing and verifying the effectiveness of preventive actions. 2. APPLICATION This procedure applies to preventing nonconformities related to materials, components and subassemblies incorporated into and including finished products, production processes, and the quality system. 3. RESPONSIBILITIES The facility management group is responsible for developing preventive action plans and complying with this procedure. 4. REFERENCE DOCUMENTS

4.1. TS-WI-7.1-01 – Engineering Change Control Work Instruction 4.2. TS-WI-4.2-02 - Document Control Work Instruction 4.3. TS-WI-5.6-01 - Management Review Work Instruction 4.4. TS-WI-4.2-01 – Control & Retention of Records Work Instruction 4.5. QMS-P-006 – Produce Product Process Flow

5. PROCEDURE

5.1. Development of Action Plan

5.1.1. Reviews by the facility management staff, using one or more of the following, result in documented preventive action plans:

5.1.1.1. Failure Modes and Effects Analysis review, specifically analyzing Special

Characteristics or characteristics with high RPN's 5.1.1.2. Customer complaints and visit reports 5.1.1.3. Process capability data, prioritizing Special Characteristics 5.1.1.4. Internal audit concerns 5.1.1.5. Audit/Test rejection rates, prioritizing Special Characteristics 5.1.1.6. Scrap and rework 5.1.1.7. Management Review

5.2. Mistake Proofing

5.2.1. Preventive actions will be performed using a multi-disciplined structured problem solving method considering mistake-proofing methodology, which will be implemented where appropriate.

5.3. Process and Document Changes


TITLE: QP-14-03 PREVENTIVE ACTION Revision Date 1/28/08 Page No. 2 of 2

5.4. When preventive actions involve process changes, they are handled in accordance with the Engineering Change Control Work Instruction. Changes to documents will be implemented and recorded according to the Document Control Work Instruction.

5.5. Review

5.5.1. Review of preventive action plans and effective implementation is conducted according to the Management Review Work Instruction.

6. RECORDS

6.1 Records of preventive actions will be kept and maintained in accordance with the Control & Retention of Records Work Instruction.

Basic New for Air Controls Division A Corrected document numbers in Level II per DNV finding – 9/16/02 B Modified for Dill Air Controls Products- 11/4/05 C Reviewed for TS 16949 – 6/21/06 D Up-Dated Reference Documents -1/24/08


1

Brian RigneyGeneral Manager

ManagementRepresentative

Anthony MonfradoOperations Manager

Joseph HebertMgr – Automotive

And Industrial Sales

Brian Rigney (acting)Manager – Sales &

Marketing

Kathleen MyersController

Naomi DennyOffice Manager

and HR Specialist

Scott DonkersDanny Bova

Aftermarket Sales

(Mary Davis, Phyllis Newman, Lori Joyner, Karen Kleber)

Customer Service &Inside Sales

David MathewsFacility, Safety, Health

& EnvironmentalMargaret McAllister

Material Planner

Dennis BerryShipping Supervisor

& PlannerGary Gravitte

Tooling & Maintenance

Milton JeffriesMickey GlascockMFG Engineers

(Ben Clay &Phyllis Sanford)

Shift Supervisors

Larry SchlesingerManager - Product

Engineering

Melvin CashDean ThomasMiguel Cavas

Ren KangEngineering

Robert BradsherLead Man

Rick SimmonsIT Generalist

OPENMaterials Manager

Richard BuhrQuality Manager

Leon WattsSarah Hebert

Quality Engineer

Mike NewtonSupplier Development

Engineer

Barbara TuckDeanna Whittley

Purchasing

Dual Reporting Relationships

Richard Buhr – Brian Rigney

B Tuck– Kathleen Myers

D. Berry – Brian Rigney

Designated – Customer Representatives

January 2011

Quality Manual - Dill Air Controls Quality Policy.pdf · Quality Manual This manual is the ... QM-C...

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