LAHAV Division
QUALITY ENGINEERING
INSTRUCTION
TITLE: QUALITY ASSURANCE
INSTRUCTION NO: 056/15
CHAPTER: INSPECTION
REPLACING PROCEDURES NO: _
APPLICABLE TO: THE LAHAV DIVISION
EFFECTIVE DATE: 01.07.2015
SUBJECT: F-16 Manufacturing Plan Guidelines for critical part
F-16 Manufacturing Plan Guidelines for critical part
Below are general guidelines to be used in preparation of manufacturing plans for LM Aero – Fort
Worth F-16 parts. This is not intended to be a complete list nor does it establish firm requirements. It
is recommended that suppliers responsible for critical part planning review these guidelines before
submitting plans for review. Additionally, suppliers should add to these guidelines based on LM Aero
– Fort Worth’s review of the planning they submit to avoid repeating errors and to facilitate the
approval cycle.
1. The plan should show the Part Number and Drawing Revision Level.
2. The plan should also show the Plan Revision Level and Date. Update the plan rev level and date
with each submittal through the review/approval process. The plan rev number or letter is needed
for manufacturing plan review/approval and for reference in the Certificate of compliance.
3. Mark Plan: “FRACTURE CRITICAL”, “MAINTENANCE CRITICAL”
Plans for Durability Critical parts need not be submitted.
4. Note the criticality as shown on the face of drawing, e.g. THIS PART IS FRACTURE CRITICAL
TRACEABLE. MANUFACTURE, PROCESS, INSPECT, IDENTIFY, SERIALIZE AND PROVIDE
TRACEABILITY.
5.
Include a statement: CHANGES TO THIS PLAN REQUIRE PRIOR REVIEW AND APPROVAL
BY LM AERO – FORT WORTH F-16 M&PE. Alternatively, CHANGES TO CONTROLLED
OPERATIONS REQUIRE PRIOR REVIEW AND APPROVAL BY LM AERO – FORT WORTH
M&PE.
6. Identify the raw material used. Include material spec, alloy, temper, condition, grade, and size,
as applicable. Show the actual material to be used. This should agree with the material and
thickness shown in the engineering unless a material substitution per 16PR092S has been
selected. If a substitution has been authorized by a Variance, reference the Variance number and
approval date.
7. Verify that the information provided on the material certificate meets the requirements of the
material spec.
8.
For serialized, traceable parts, note the material supplier and heat lot or parent plate number on
the traveler. For multiple parts / serial numbers being processed with a single traveler, make sure
they are each from the same heat lot. If more than one heat lot is used to make parts, use
additional travelers. The intent is to assure that each serial number can be traced to the heat lot.
Inspection operations should VERIFY SERIAL NUMBER. Manufacturing operations should
MAINTAIN SERIAL NUMBER.
DISTRIBUTION: _
Editor:
D. RAFAELOV
Approved:
Y. YOSSINGER
PRINT DATE:
06.07.2015
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OF: 3
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LAHAV Division
EFFECTIVE DATE: 01.07.2015
9.
QUALITY ENGINEERING
INSTRUCTION
INSTRUCTION NO: 056/15
Verify that any required ultrasonic inspection has been done, e.g. VERIFY MATERIAL
MEETS CLASS A ULTRASONIC INSPECTION REQUIREMENTS PER MIL-STD-2154.
10. If a grain direction is marked on the F/D, verify that the part is oriented with grain direction as
shown. Grain directions are not typically controlled for parts made from Ti and steel.
11. Parts should be processed in accordance with applicable spec requirements, e.g. for metal
removal operations, add METAL REMOVAL PER FPS-3017; Or, for final machining or deburr
operations ALL SURFACES PER FPS-3017 TYPE I AND MISMATCH PER FPS-3017 TYPE III.
12. Include any special requirements contained in drawing notes or on the face of drawing, for
example VERIFY 63 MAX SURFACE ROUGHNESS on the specified surface. There may be
additional surface finish requirements in specifications noted on the drawing. The supplier must
be aware of these requirements and may want to include the task to verify the surface finish in
the plan.
13. For serialized, traceable parts: Unique serial numbers must be assigned for each part. These
are not to be re-used if a part is scrapped or if a subsequent order is received. Serial numbers
should not be repeated for a new dash number of a given part number. List serial numbers
individually on the traveler, e.g. XXX1, XXX2, XXX3, XXX4, not XXX1 through XXX4. The plan
should include steps to mark or tag the billet, to maintain the serial number as it proceeds through
the manufacturing sequence, and to verify the serial number at each inspection operation after
each manufacturing operation.
a. When required, the plan should include the requirement to VIBROENGRAVE THE FSCN PER
FPS-3008 CLASS 1A IN THE LOCATION SPECIFIED ON THE B/P. THE MARKING SHALL
INCLUDE:
Manufacturer’s Cage Code Part No.–Dash No. Serial No.
b. If test coupons are processed with the part, they should be given the same serial number.
14. Certain operations require the use of Qualified Sources. Examples of these include chem
milling, anodizing, etching, penetrant inspection, etc. The plan should state that these operations
shall be conducted by a QCS-001 approved source for Process Code XXXX, or the plan should
identify the source, or both. For plans which detail a specific processor for a QCS-001 operation,
apart from titanium heat treat operations, the manufacturing plan operation which lists the specific
processor may be revised to “any QCS-001 approved source for process code XXXX” where
XXXX is the specific process code for the operation. The revised plan does not require review
and approval by Materials and Processes because there is no requirement that the processor be
specifically identified as long as they are QCS-001 approved F-16 Manufacturing Plan
Guidelines
15. Generally, process procedures for QCS-001 processes do not need to be included. They
must be included for more complex processing, such as heat treating or welding. They are not
required for penetrant inspection or finishing. Manufacturing plans for outside machining must be
submitted.
DISTRIBUTION: _
Editor:
D. RAFAELOV
Approved:
Y. YOSSINGER
PRINT DATE:
06.07.2015
PAGE: 2
OF: 3
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LAHAV Division
EFFECTIVE DATE: 01.07.2015
QUALITY ENGINEERING
INSTRUCTION
INSTRUCTION NO: 056/15
16. If parts are to be shipped to an outside processor, the plan should include a step to package and
protect the parts. And, the plan should include a step for the outside processor to package and
protect for returning the parts to the supplier. When parts are to be delivered to LM Aero – Fort
Worth, they should be packaged and protected per PM 5010 and shipped to LM Aero – Fort
Worth.
17. Hardness and/or conductivity testing are required when there is a requirement to verify heat
treat per NDTS-1500. Conductivity should be checked on the raw material or verified that the
information is on the raw material certificate – record min and max readings on the traveler; and
after final machining, prior to finishing – record min and max readings or record specific readings
at checkpoint locations if specified on the drawing. Also note, the difference in conductivity
measurements within a part must not exceed 2.0% IACS. All other accessible pockets must be
conductivity checked, but acceptable readings are not recorded. For serialized parts, record
hardness/conductivity for each serial number.
18. First Article Inspection, recurring dimensional inspection, and CMM should be aligned with the
Quality measurement plan requirements. The plan may include a task to advise the source
inspector 5 days in advance. First article parts require an Engineering First Article Evaluation
(EFAE), except EFAE is not required for Maintenance Critical or Durability Critical parts unless
noted on the drawing. Currently, EFAE for Fracture Critical parts will generally be conducted at
LM Aero – Fort Worth after delivery of the finished part or assembly. For Fracture Critical parts,
the planning should note to include a notification request for EFAE with the delivery paperwork.
DISTRIBUTION: _
Editor:
D. RAFAELOV
Approved:
Y. YOSSINGER
PRINT DATE:
06.07.2015
PAGE: 3
OF: 3
ProceduresLive30056-15_06Jul15