Supplier Quality Manual - Valcor Engineering Corporation€¦ · SUPPLIER QUALITY MANUAL SQM-001...

Uncontrolled when printed. Verify document revision online at www.Valcor.com

Valcor Engineering Corporation

SUPPLIER QUALITY MANUAL

SQM-001 August 20, 2014

Valcor Engineering Corporation®

2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487

Supplier Quality Manual

Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®.

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Copyright © 2014, Valcor Engineering Corporation®. Sheet 3 of 39 Uncontrolled when printed. Verify document revision online at www.Valcor.com

Contents 1.0 Supplier Quality Visual Model ........................................................................................................... 4

2.0 Valcor’s Quality Policy ....................................................................................................................... 5

3.0 Introduction ...................................................................................................................................... 5

3.1 Precedence of documents ............................................................................................................ 5

3.2 Certificate of Conformance and Analysis ...................................................................................... 6

3.3 Record Retention .......................................................................................................................... 6

3.4 Flow-Down to Sub-Tier Suppliers .................................................................................................. 6

3.5 Foreign Object Damage (FOD) Prevention .................................................................................... 6

3.6 Right of Access .............................................................................................................................. 7

3.7 Export Control ............................................................................................................................... 7

4.0 Supplier Approval Process ................................................................................................................ 8

5.0 Supplier Audit Process .................................................................................................................... 10

6.0 Change Request .............................................................................................................................. 12

7.0 Non-Conformances ......................................................................................................................... 13

7.1 Supplier Deviation Flow Chart .................................................................................................... 13

7.2 Supplier Quality Escape Flow Chart ............................................................................................ 15

8.0 Supplier Corrective Action .............................................................................................................. 17

9.0 Delivery Requirements .................................................................................................................... 19

9.1 Packaging .................................................................................................................................... 19

9.2 Foreign Object Damage (FOD) .................................................................................................... 21

9.3 Labeling ....................................................................................................................................... 21

10.0 Supplier Performance ..................................................................................................................... 22

10.1 Overall Performance Rating ........................................................................................................ 24

11.0 Dock-to-Stock Authority.................................................................................................................. 25

12.0 Valcor Owned Property ................................................................................................................... 26

13.0 Appendix A: Valcor Supplier Quality Survey SF1016A .................................................................... 27

14.0 Appendix B: Deviation/Change Request SF1019A .......................................................................... 32

15.0 Appendix C: Material Rejection Report SF-104/R.03/12 ................................................................ 34

16.0 Appendix D: Corrective Action Request/Report SF1018A .............................................................. 36





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1.0 Supplier Quality Visual Model

Supplier Managment

Supplier Collaboration

Supplier Information

Certificate Management

Risk Assesmnet

ScoreCard

Reference Documents

Valcor Documents and Specifications

Warranty and Cost Recovery

SCAR

Change Request

Certificate of Analysis/

Conformance

ESTITRACK

Real-time data driven Decisions

Supplier Improvement

Dock-to-Stock

Reduce Risk

Customer Satisfaction

Engineering

Purchasing

Quality Inspection Data

Supplier Related Customer Complaints

Budget Time Cost

Potential Supplier

Performance Audit/ 3rd Party Audit

Deviation Request

Quality AssuranceInformation

Management





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2.0 Valcor’s Quality Policy

Achieve total customer satisfaction by continuously improving all work processes to satisfy our internal and external customers

3.0 Introduction Valcor’s mission is to provide innovative, high quality, reliable fluid control components and systems to

customers in response to their specialty requirements. This supplier quality manual is based on

prevention and continuous improvement rather than defect detection. Valcor expects their suppliers to

aspire to zero defects, zero failures, and zero losses.

Valcor encourages all suppliers of components, materials, or services to institute a Quality Management

System that follows: AS9100 Quality Management System Requirements for Aviation, Space & Defense

Organizations and/or ISO 9001:2008 International Industry Quality Standards. The Nuclear division may

impose additional nuclear specific requirements depending on the nature of work. Valcor may choose to

conduct on-site assessment(s) to determine the supplier’s ability to meet Valcor’s requirements.

3.1 Precedence of documents In the case of a conflict and between the requirements, the precedence of documents is as follows;

1. Purchase order

2. Terms and Conditions

3. Part Drawing

4. Supplier Quality Manual

3.2 Applicable Forms The following forms are referenced within this manual and are available from

http://www.valcor.com/customer-product-support/suppliers/

Form Number Form Title

SF1016A Valcor Supplier Quality Survey

SF1019A Deviation/ Change Request

SF1018A Supplier Corrective Action Request

http://www.valcor.com/customer-product-support/suppliers/





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3.3 Certificate of Conformance and Analysis All suppliers shall provide a Certificate of Conformance, Physical or Chemical Analysis, or Calibration,

when applicable. Each shipment must be certified by an authorized representative with their signature,

title, and date. The supplier shall verify and confirm compliance with the drawing, specification, and/or

any special processes as described on the Purchase Order. Without this documentation, Valcor cannot

receive the parts, and both the payment and parts will be placed on hold until resolution in

documentation can be provided.

The following information is required on the Certificate of Conformance at a minimum:

Supplier Name, address and contact information and manufacturer’s name (if different from

Supplier)

Purchase Order Number

Valcor part number, revision, lot, and quantity

Specification Number including revisions and amendments

Additional information may be required for parts returned for rework

Identify when parts have been reworked

Return Purchase Order Number

Non-conformance Deviation Number

3.4 Record Retention Valcor shall identify supplier records requirements on the purchase order, drawing notes, or

procurement specifications. The delivered product’s records shall be maintained for a minimum of

fifteen (15) years at the supplier, unless otherwise specified. Upon request, the supplier shall provide

copies to Valcor.

3.5 Flow-Down to Sub-Tier Suppliers Suppliers shall flow down applicable requirements noted on Valcor’s Purchase Order and Terms and

Conditions to all sub-tier suppliers.

3.6 Foreign Object Damage (FOD) Prevention When applicable, noted on Valcor’s purchase order, the supplier shall establish, document, and maintain

a program to control and prevent FOD during manufacturing, assembly, test, inspection, and any sub-

tier supplier operations. This program can follow NAS412 or be an otherwise approved control by

Valcor. The supplier shall maintain work areas and inspect for foreign objects/materials to reduce the

risk of FOD incidents.





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3.7 Right of Access Suppliers shall allow Valcor, customers and regulatory agencies reasonable access to the applicable

areas of all facilities involved in fulfilling the purchase order requirements and to all applicable

documentations. Valcor has the right to conduct surveys, audits, inspections, and surveillance of

Supplier’s facilities and sub-tier suppliers with prior coordination to determine capability.

When required, source and/or government inspection will be noted on the purchase order. The supplier

shall ensure the product is not released until source and/or government inspection is completed.

3.8 Export and Import Compliance The products, technical data and services produced and/or provided by Valcor Engineering Corporation

may be subject to the provisions of the Export Administration Act of 1979 (50 USC 2401-2420), the

Export Administration Regulations promulgated there under (15 CFR 730-774), and the International

Traffic in Arms Regulations (22 CFR 120-130). These statutes and regulations impose restrictions on

import, export, re-export and transfer to third countries of certain categories of hardware, data,

technical services and information, and that licenses from the U. S. Department of State and/or the U. S.

Department of Commerce may be required before such hardware, data, technical services and

information can be provided/disclosed hereunder, and that such licenses may impose further

restrictions on use and further disclosure of such data, technical services and information.

Disclosure of data, technical services and information to foreign persons, as defined at ITAR 120.16, and

at EAR 734.2(b), is subject to the above regulations regardless if the export occurs in the U.S. or

abroad. Violation of these export laws are subject to severe criminal penalties.





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4.0 Supplier Approval Process This process applies to all new potential Valcor suppliers and defines Valcor’s criteria of selection and

assessment.

Flowchart

Send survey to Supplier

Review if Supplier requirements were met per

survey

Supplier Approved?

Determine if an Audit is needed?

Approve Supplier

Potential Supplier?

Perform Audit

Supplier approved per

audit?

Supplier to fill out Survey

Supplier Agrees to an Audit?

YES

Disqualify Supplier

YES

Supplier to return survey and other

required documents

Request for Supplier Corrective Action

Supplier to return corrective Action

Work with Supplier?

NO YESYES

YES NO

NO

NO

Supplier

Purchasing

Quality Assurance

Review Supplier CA

Accept CA?

YES

NO

NO





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Supplier Approval Process

Responsibility

All potential suppliers are required to fill out a quality survey (SF1016A) to collect general information about the company and its products or services. This form will be used to indicate the standards of a potential supplier and will be performed as a self evaluation survey.

Potential suppliers will be evaluated on their ability to provide a quality product based on the Supplier Quality Survey Form and the Supplier’s quality system certifications.

Valcor recognizes all third –party certifications that are compliant to ISO-9001, AS9100, NADCAP, and/or ISO 17025 accreditations which an onsite audit may be waived. The supplier quality survey form and attached certifications will be assessed by Valcor’s Quality department and will reserve the right to conduct an onsite audit when deemed necessary. Suppliers that meet all requirements will be placed on the Approved Supplier List.





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5.0 Supplier Audit Process The purpose of this procedure is to establish a process to evaluate the supplier’s quality system, control

of process and product quality, and the maintenance of product compliance.

Audit Flow Chart

NO

Audit is required

Schedule Audit and send the Audit agenda to the

Supplier

Supplier Agrees to an Audit?

YES

Perform Audit

Supplier to Review Audit Report and send a response when applicable

Request for Supplier Corrective

Action

NO

Review Audit Report Response

Accept Supplier Response?

NODisqualify Supplier

NOSend Feedback to

the supplier

Review Supplier CA

Supplier to return corrective Action

Determine if a follow-up audit is

neededNO

YES

Accept CA?

YES

Update Supplier List

YES

YES

Supplier

Quality Assurance

Purchasing

Send Audit Report to Supplier

YES





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Supplier Audit Process

Procedure

Valcor may conduct an audit at the supplier to make a physical evaluation of the supplier’s quality system. Audits performed at the supplier will be completed by the appointed lead auditor.

Non-conformities observed during Audit

Upon detection of a nonconformance, the auditor’s first concern will be to determine if any work in process is affected and will verbally notify the supplier. The supplier will immediately need to stop work on that item. In all cases of a non-conformance a quality audit report will be sent to the supplier for the purpose of initiating a corrective action plan. The report shall be submitted within a specific time period not exceeding 30 days.

Follow-up audit

A follow up audit at the supplier, when directed by Quality Assurance, will be performed to assure effective action has been taken to correct the significant condition.





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6.0 Change Request When required, the supplier shall not change the plans, drawings, designs, product definition, processes

or specifications associated with the parts referenced on the Purchase Order. If a change is needed, the

supplier and sub-supplier must receive prior written approval from Valcor.

Configuration Control Flow Chart

Change Request is initiated

Review Change Request

Approve Change Request

YES

Make appropriate changes and update PO

NOUpdate Request

database

Supplier

MRB Review

NO

Repeat Request

YES Purchasing

Communicate Y/N to supplier

Procedure

The supplier submits a Change Request form (SF1019A) and includes a complete description of the

proposed change to Valcor’s Purchasing Department. Based on the change request, it will be evaluated

by engineering, purchasing, and/or quality assurance. Once the Change Request is dispositioned, Valcor

will inform the Supplier.





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7.0 Non-Conformances A non-conformance exists when a discrepancy is found in packaging, documentation, and/or quality

(defects in form, fit, or function) to the part or P.O. requirements.

Non-conformances will be identified:

At supplier prior to shipping – Supplier Deviation Flow Chart – Section 7.1

At Valcor – Quality Escape Flow Chart – Section 7.2

7.1 Supplier Deviation Flow Chart

Detect a quality deviation

Issue and forward the Deviation

Request to Valcor

Approve deviation request?

Parts need to be replaced

Receive Deviation Form

Supplier

Purchasing

MRB Review

Notify Supplierof rejection

YES

Notify Supplier of approval

Send Rejected Deviation Report to the Supplier

Annotate Deviation # on

CofC

Send parts and a copy of an approved

deviation to Valcor

NO

Receive parts into inspection

Recieving

Corrective Action

Required

Quality Assurance

Send Corrective Action Request

to SupplierFollow section

8.0

YES

NO





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Non-Conformance: Supplier Deviation

Procedure

The supplier shall initiate and submit a formal Deviation/Change Request (SF1019A) to Valcor for

disposition (approval or rejection) of the non-conforming parts or process. The deviation form shall be

completed per the following:

Supplier and Part Information

Current Requirement: Fully describe the current part or process requirements and

specifications.

Request for Deviation: Fully describe the requested deviation from the current part or process

requirements and specification

Reason for Request: Describe the reason for the deviation.

And forwarded to Valcor’s Purchasing Department (use email unless not available, otherwise send as

facsimile). The Supplier shall provide any test and inspection data to support their request for approval

of the deviation. Purchasing will coordinate the disposition within Valcor and return a response to the

supplier within 72 hours.

Deviation Approval

If the deviation request is approved, Purchasing will inform the supplier of the disposition. The Supplier

is required to indicate the approved deviation number on their Certificate of Compliance/Conformance

and include an approved copy of the deviation with the parts. When all paperwork has been completed

and approved, the product may then be shipped. The parts or materials shipped under an approved

deviation request shall be tagged with the deviation number.

Deviation Rejection

In the case that the deviation request is rejected, Purchasing will notify the supplier and return the

rejected deviation form. The discrepant material and/or parts may not be shipped to Valcor. The

supplier will then need to replace the parts to fully meet the Purchase Order specifications.

Corrective Action

Valcor may issue a Supplier Corrective Action based on deviation request. Suppliers must follow

Corrective Action steps as identified in Section 8.0.





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7.2 Supplier Quality Escape Flow Chart

Material Rejection Report (MRR) initiated and

reviewed

Quality Assurance

Use as is

Return compliant parts to Valcor

Supplier

Rework in house

MRB Review

Non-conformance detected

Scrap, Rework, or Replace

Containment of affected items

Communicate and send reports to

Supplier

Is a Corrective Action Required

NO

YES

Send Corrective Action Request to

SupplierFollow Section 8.0





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Non-Conformance: Supplier Quality Escape

Procedure

The discrepancies will be documented on a Material Rejection Report (MRR). The MRR will be evaluated

by Valcor’s Material Review Board (MRB) personnel who will determine the disposition of the discrepant

parts and a copy will be sent to the Supplier. The supplier may contest the quality escape with objective

evidence.

Valcor will disposition the supplier’s parts per the following:

Return to Supplier

Use as is

Rework in house

When returned, the supplier must have a method to distinguish on paper and clearly identify if each

shipped part has been:

reworked

replaced

left unchanged

If requested on the PO or drawing, the Supplier shall make Valcor aware of any processes that are outside of the regular production procedures or controlled work conditions in critical processes (forging, casting heat-treating, welding, stamping, and any other special processes). Corrective Action

Valcor may issue a Supplier Corrective Action based on a quality escape. Suppliers must follow

Corrective Action steps as identified in Section 8.0.

Charges to Supplier

Valcor, at their discretion, may choose to rework or sort any non-conforming parts to prevent

interruption of the production line. Valcor reserves the right to charge the supplier for all costs

associated with the quality escape.





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8.0 Supplier Corrective Action This process is to outline the Supplier’s submission of a Corrective Action report.

Corrective Action Flow Chart

Develop a Corrective Action Plan

Send Corrective Action to Valcor

Identify Corrective Action is needed

Send Correction Action Request to

the Supplier

Contain defective hardware

Review CA Plans

Determine Root Cause

Approve CA?

Audit Required?

YESComplete Audit at

Supplier

NO

CAR effectiveness review

Close Corrective Action

Quality Assurance

Supplier

MRB Review

Communicate with Supplier

NO

Effective? NOYESCloseout CAR

Verify findings on CA have been

adressedYES





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Supplier Corrective Action

Procedure

A Supplier Corrective Action Request/Report (SF1018A) may be required when a nonconformance is

identified. Containment must be completed within 72 hours and the corrective action plan must be

submitted within 30 calendar days of the initial request.

Upon Supplier notification that a Corrective Action Request plan is approved, the supplier is expected to

complete all planned actions within 60 calendar days unless otherwise agreed to by Valcor. Valcor and

the supplier will verify and ensure that all findings on the Corrective Action have been addressed;

however they do not need to be closed at the same time. The effectiveness review due date will be

determined as appropriate and will conclude if the achieved results were met. A supplier corrective

action request form will stay open until the verification and effectiveness review have been validated by

Valcor.

An extension may be granted, only if the supplier made an initiative and periodic updates were provided

to Valcor. When there is no communication made between the supplier and Valcor, the request will be

denied and the supplier’s scorecard will be affected.

A repeated nonconformance is an indication of poor root cause analysis and/or corrective action. If such

a case arises, Valcor will pose rigid containment requirements based of the severity of the

nonconformance and re-assign a second corrective action request. Due to the risk it may present to

Valcor or its customers, an onsite supplier audit may be required.

If the Supplier does not know how to complete the corrective action request, it is the responsibility of

the Supplier to contact Valcor’s Supplier Quality Department for assistance.





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9.0 Delivery Requirements The Supplier will inform Valcor of any delay in delivering the product and provide a new date. If the

Supplier ships non-conforming (quality escape) parts and materials to Valcor, the Supplier will be

responsible for the return expenses.

9.1 Packaging Suppliers are responsible to ensure that parts meet same quality conditions as they were manufactured.

All supplier packaged shipments shall follow good commercial practice, unless otherwise stated on the

purchase order and/or drawings.

Piece part Cell Packaging Acceptable Bulk Packaging

- Sub- assemblies - Critical parts* - Tubes (non-raw material) - Seats - Seal discs - Machined threaded parts - Bodies - Filters - Other parts will be noted on PO

- Washers - Nuts - Screws - Springs and Helicoils - O’Rings

*All items that have a 16 Ra surface finish or lower (defined on the drawing) are considered as “critical

parts”.

The shipping container and parts requirements are, but not limited to:

package each item separately to ensure adequate protection from physical contact with

other parts

packaging must be strong enough for the weight of the part for it to remain intact

parts are cushioned against impact from each other

parts are secured to prevent movement during shipment

package to provide enough clearance from the item and the external packaging

o To prevent product damage against shock and vibration there should be

cushioning placed away from the walls of the box.

Machined castings, forging parts, and other parts subject to corrosion shall be packaged with anti-corrosive packaging such as capping, VCI anti-rust wrapping/bagging, plugging, covering, or any other suitable methods to prevent against cosmetic and functional damage of the part.

Additional special packaging requirements will be identified on the Purchase Order or drawing.





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Packaging Requirements Examples

Acceptable Packaging Suggestions

Unacceptable Packaging- will be written up on a non-conformance

-Parts packaged in single tubes to protect ends (size can vary). -Cushioned from each other to prevent shock, vibration, and damage

-Parts are able to move freely -Not protected from each other -Not enough clearance from external packaging

-Sub-assembly/valves protected and adequately cushioned from the external walls -Inlet/outlet ports capped and plugged

-Sub-assembly/ valves not protected from each other. -Threaded inlet/outlet ports not protected

-Parts wrapped in anti-corrosive bags

Rust

-Parts not wrapped and subject to corrosion

Further examples go to www.Valcor.com and click the “Supplier” link.

http://www.valcor.com/





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9.2 Foreign Object Damage (FOD) As defined on the purchase order, all parts with openings, internal and external threads shall be

protected from foreign object damage. Packaging materials that generate particles, fibers, or other

debris are not acceptable.

Any form of “free flow or loose fill” material (such as peanuts, popcorn, or similar) regardless of material

type is not acceptable as this will create a FOD hazard.

Example of Packaging a FOD prone item:

Packaging Requirements

9.3 Labeling Parts and material must be identified by the supplier with an identification label on each box, crate, or

container shipped to Valcor. When shipping a product, the Purchase order number must be referenced

on the UPS, FedEx, or other carrier shipping label.

An identification label at minimum should have the following information:

Purchase Order

Supplier name

Box X of Y (example “Box 2 of 3” if it is the second box of a total of 3).

Example: Threaded part with caps and plastic bag





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10.0 Supplier Performance Supplier performance will be monitored on a monthly basis through the purchasing and quality

departments and will be available quarterly to the supplier. The data will show comparative results and

will provide the strengths and weaknesses amongst individual suppliers.

The measurement for supplier performance will be evaluated on the following criteria; quality and

delivery.

Main Categories

Category Total Points Sub-category Weight

Quality 100

# Quality Escapes 60%

# Deviations 20%

Past due Corrective Actions 10%

Accuracy of Paperwork/Documentation 10%

Delivery 100 % On time Delivery 100%

Sub-Categories

Main Category : Quality Total Weight : 100%

Sub-category Weight Points Evaluation Basis

# Quality Escapes 60%

100 0 quality escapes

0-99

Measures a supplier's quality impact at Valcor to meet agreed specifications .6 x (total lots -# quality escapes/ total lots ))x 100

# Deviations 20%

100 0 deviations

0-99

Measures a supplier's quality impact prior shipping to Valcor to meet agreed specifications. .2 x (total lots - # deviations/ total lots ))x 100

On time Corrective Actions 10%

100 0 late Corrective Actions

0-99

Measure the responsiveness of a corrective action .1 x (On time Corrective Actions/ Total Corrective Actions) x 100

Accuracy of Paperwork/Documentation

10% 0-100

Measures errors that appear on the C of C (qty received PO #, part number, revision, and/or missing special processes) .1 x (# accurate documents/ total lots received) x 100





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Main Category : Delivery Total Weight : 100%

Sub-category Weight Points Evaluation Basis

% On time Delivery 100% 0-100 Measures the agreed delivery date on the PO (on-time shipments/ total shipments received) x 100

Separate consideration will be given for low volume suppliers. Adjustments will be made as applicable to

the performance categories and their weights to reflect the different purchase order requirements.





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10.1 Overall Performance Rating Valcor’s supplier rating system measures the performance of current suppliers and rates them based on

a supplier scale.

Performance Rating

Supplier Classification Description

95 - 100% Preferred Meets all Valcor requirements in quality, cost, and delivery.

85 - 94% Acceptable Meets minimum Valcor requirements.

75 - 84% Restricted Does not meet Valcor minimum requirements.

Required written corrective action.

Management approval to bid new work

0 - 74% Unacceptable

On Probation unless documented evaluation justifies continued use.

No new business and the existing business will be phased out.

Corrective Action Plan needs to be implemented and “Acceptable” status within 60 days.





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11.0 Dock-to-Stock (DTS) The DTS program exempts a supplier’s parts from routine incoming inspection at Valcor. Suppliers that

produce high quality parts and have an effective quality system can be considered a candidate for the

Dock-to-Stock program.

To become a DTS candidate, the supplier must achieve:

A performance level of 100% lot acceptance based on the most recent 12 months or 10 most

recent lots

98% or better piece count acceptance

An approved on-site surveillance (if appropriate) to assure that product quality will be

maintained

No open or late corrective actions for the part number (or family of parts)

Demonstrate certification and/or compliance to AS9100, ISO9000, or equivalent

The supplier’s part will continue to be put through a random inspection frequency determined by

Valcor.

Note: This program does NOT apply to Valcor Nuclear products.

Advantage of DTS:

Certified “Dock-to-Stock” suppliers will be considered ahead of non-DTS for additional business

Non-compliant part

If a deviation to the blueprint is found at the supplier’s facility follow Section 7.1 (Supplier Deviation).

However, when a nonconformance is identified at Valcor, the supplier’s part may be removed from

Dock-to-Stock authority, and will follow Section 7.2 (Supplier Quality Escape). In addition, suppliers

failing to maintain an overall score of 95% rating two consecutive quarters may be put on probation. A

supplier on probation may only be returned to the Dock-to-stock program when 10 consecutive lots

have been accepted without rejection or when the quarterly performance rating meets the 98%

requirement in two consecutive quarters.





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12.0 Valcor Owned Property The supplier, at their facilities, is responsible for the maintenance and protection of Valcor owned

property. The supplier is required to establish control methods that will help prevent property loss,

damage, or mishandling.

Valcor owned products can consist of the following but not limited to:

Re-usable packaging containers

Tooling

Gages

Inspection gages damaged or not sent to Valcor with the product will be considered as late, and result in

an on time delivery score reduction.

To protect Valcor’s investment, the supplier is responsible for the following furnished items:

Raw material

Partially process components

Sub-assemblies

The supplier needs to notify Valcor immediately of a nonconformance, and if needed, a corrective action

will be requested. Liability for the occurrence, per case, shall be determined and discussed with the

supplier.





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13.0 Appendix A: Valcor Supplier Quality Survey SF1016A

VALCOR SUPPLIER QUALITY SURVEY FORM

2 LAWRENCE ROAD ▪ SPRINGFIELD, NJ 07081 TELEPHONE: 973-467-8400 ▪ FAX: 973-467-9391 Page 1 of 4

Valcor Supplier Quality Survey Form Revision Date: 21 November 2013

Form # SF1016A

GENERAL INFORMATION Supplier’s Name

Street Address

City

State Zip Phone Fax Website

Major Product/Process

CHECK APPLICABLE BOXES For VALCOR use Only

Approved Disapproved Conditional

Approved By:__________________Date_________

SURVEY TYPE: Self Evaluation On-Site Evaluation 3rd Party

SURVEY CLASSIFICATION: Distributer Processor Manufacturer Other _________________________

KEY SUPPLIER MANAGEMENT PERSONNEL # OF EMPLOYEES President/ Owner

Quality Mgr. Name Total Personnel

Manufacturing Engineering

Sales/Service

Production Quality Assurance Quality Control Inspection

Engineering

Other BUILDING/FACILITIES Type: Corporation Partnership Individual

Square Footage

To whom does the Quality Organization report to?

Established since

Is a current organization chart available?

YES NO

% of Manufacturing Capacity Utilized

Is security clearance required? YES NO

NAME OF MAJOR CUSTOMERS: THREE (3) MINIMUM CUSTOMER NAME APPROVAL DATE CUSTOMER NAME APPROVAL DATE

QUALITY PROGRAM Do you have a written quality manual?

YES NO

If yes, Title of Q.A. Manual_____________________________ Rev____________ Date _________________

Does your quality program meet the following (check all those applicable) For suppliers ISO-9001, AS9100, NADCAP, and/or 17025 accredited: complete the above section only, and sign the last page. Include a copy of your certificates and your Quality Assurance Manual.

MIL-Q-9858A MIL-I-45208A MIL-STD-45662

AS9001 ISO-9001 NQA-1

10CFR50, Appendix B ANSI N45.2 ISO 17025

NADCAP A2LA

If none of the above are applicable, describe the Quality Management System:




Form # SF1016A

SPECIAL PROCESS For each special process performed in-house and at sub-tier suppliers, list the processes and governing specifications and standards (AWS D17.1, J-STD-001, AMS2700, etc.). Attach supporting evidence that substantiates process approval.

Process Specification(s) Standard(s) Expiration Date Welding

Soldering

Plating

Painting

Surface

Finishing

Other

SUPPLIER SELF EVALUATION QUESTIONNAIRE 1.0 MANUFACTURING CONTROL & INSPECTION YES NO N/A

A. Is there a definite training program for inspectors & other personnel whose job function affects product quality?

On job training, Classroom

B. Are inspections documented and do records provide evidence of the following: Lot quantity, Level of inspection, result of inspection

C. Are incoming parts/material inspected to verify compliance to PO requirements?

D. Are end products inspected/tested before delivery to customer?

E. Does the program provide provision of material traceability where applicable?

F. Do you use Statistical Process Control (SPC) to control major processes?

G. Is sampling inspection utilized? Based on what plan? _________________________________________________________

H. Does the program address retention time of inspection records? __________months/years.

I. Is software, when used in the manufacture and inspection of product, controlled?

2.0 CALIBRATION CONTROL YES NO N/A

A. Is there a gauge calibration system?

B. Do you allow the use of personal gauges?

C. Are procedures in effect which describe the method and frequency of calibration?

D. Is measuring and test equipment marked to indicate calibration status and when next calibration is due?

E. Is adequate measuring equipment available to inspection for verifying conformance of supplies/materials?




Form # SF1016A

F. Is there an evaluation recall and notification procedure of hardware inspected by a gauge later found to be out of tolerance?

3.0 PROCUREMENT/ MATERIAL CONTROL YES NO N/A

A. Are procurement sources controlled to assure that all procured material meets all imposed requirements?

B. Is a list of approved sources maintained and periodically reviewed for status?

C. Are certifications/test reports of purchased material required?

4.0 EVALUATION OF SUBCONTRACTORS YES NO N/A

A. Are the records of acceptable subcontractors such as an “Approved Supplier List” or other such document?

B. Is there confirmation that the quality system controls are effective at the subcontractors?

5.0 DOCUMENT CONTROL POLICY YES NO N/A

A. Has a process been established to control all documents, data, and engineering drawing that relate to the purchase order, including to the extent applicable, external standards, and customer drawings?

B. Is there a system for identification/ retrieval/ removal of obsolete documents from all points of issue or use?

C. Are all inspection records being kept and maintained?

6.0 NON-CONFOROMANCE AND CORRECTIVE ACTION YES NO N/A

A. Is control established to prevent nonconforming material from inadvertent use?

B. Does the Material Review Board consist of both Engineering and Quality Personnel?

C. Is corrective action obtained on significant or repetitive non-conformance?

D. Is customer authorization obtained before delivering items that deviate from contractual requirements?

E. Do you perform Internal Audits?

7.0 PACKAGING/SHIPPING/STORAGE YES NO N/A

A. Are procedures written controlling the preservation, packaging, and shipping processes?

B. Do you maintain in-house or subcontracted packaging facility to meet special customer requirements?

C. Is material with life, age or other limitations controlled and identifiable to the limitation and remaining usefulness?

8.0 HOUSEKEEPING/SAFTEY YES NO N/A

A. Do you enforce 6S?

B. Are facilities equipped with automatic sprinkler system?

C. Does facility have well marked and well located fire protection equipment?




Form # SF1016A

9.0 DO YOU HAVE A GOVERNMENT INSEPCTOR? YES NO N/A

Resident

Itinerant: Agency Name _________________

SELF-EVALUATION SURVEY PARTICIPANTS

I certify the above Self-Evaluation Survey has been completed in accordance with our Quality Assurance procedures and is accurate and correct.

Surveys without a supplier signature will not be accepted.

Filled Out By: ____________________________________ Date: ___________________ (Print Name) Signature: ____________________________________





SQM-001 Revision -


14.0 Appendix B: Deviation/Change Request SF1019A

DEVIATION/CHANGE REQUEST FORM

Form # SF1019 Rev. A

DCR #

SUPPLIER INFORMATION PART INFORMATION

Date: Part Number:

Supplier Name: Part Description:

Supplier Code: Revision Level: Quantity:

Contact: Phone #: PO Number:

DESCRIPTION

1st

Time

Repeat, DCR#______________

Product Related

Process Related

Current Requirement:

DEVIATION REQUEST

Request for Deviation:

Reason for Request:

CHANGE REQUEST

Request for Change:

Reason for Request:

Acknowledgment (Departments to sign when needed) Date Approve/Disapprove Comments

Purchasing: YES NO

Engineering: YES NO

Manufacturing: YES NO

Quality Assurance: YES NO

VALCOR DISPOSITION

Drawing/Spec Change Required? YES NO If Yes, ECO# __________________

Corrective Action Required? YES NO If Yes, CAR# __________________

Final Disposition and Comments:

Supplier Note: If deviation is approved, a copy of this form shall be included inside the shipping container with each affected

shipment.





SQM-001 Revision -


15.0 Appendix C: Material Rejection Report SF-104/R.03/12





SQM-001 Revision -


16.0 Appendix D: Corrective Action Request/Report SF1018A

CAR Number 4

Supplier Corrective Action Request

Date Defined / /

Status Open

Part NumberInventory Number

Defined by 1111 TEST USER CustomerSupplier

P.O NoNonconformance

Serial No

Operation No 0

WorkcenterDepartmentStandard

1. Problem Description

Date Completed: / / Status:Responsible:

What, Where, and When? Include evidence observed.

2. Team MembersEstablish a team of people with product/process knowledge.


Define and execute actions to isolate discrepant and/or potentially discrepant materials/parts until corrections have been implemented and verified. Define the action(s) taken to eliminate the existing situation at each manufacturing phase (ex. Shipped, Raw Material, Finished Goods, WIP, etc.).

3. Containment Actions / Reinspection Findings

08/11/2014 08:40:30 AM Page 1Valcor Engineering Corporation

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SF1018A stamp

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Coverup

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Coverup

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CAR Number 4


Date Defined / /

Status Open




Serial No

Operation No 0



Determine and verify what caused the defect to be produced. Support with evidence by using root cause analysis (Recommended Tools: 8D, 5 Whys, Fishbone, Flowchart, etc.)

4. Root Cause(s)

5. Select / Verify Corrective Actions


Describe all planned and completed actions which address the root cause and prevent recurrence of the non-conformance.


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Supplier Managment

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SF1018A stamp

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Coverup

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Coverup

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CAR Number 4


Date Defined / /

Status Open




Serial No

Operation No 0


6. Implement Corrective Actions


Provide objective evidence (photos, training records, work instructions, ECOs, and etc.) to verify that all findings have been addressed.

7. Verification

8. Congratulate Team


Determine and provide objective evidence that a change has occurred and that the product and process achieved desired results.


Preventative Actions: Determine and implement actions to prevent the recurrence of this root cause and all similar problems.


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QA managment

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SF1018A stamp

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Coverup

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Coverup

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Valcor Logo

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