QA022-02
Revision: Initial
May 13, 2013
Page 1 of 21
Seller Quality Requirements
QCS-001 Processing Sources
The latest issue to this document is the version that is available on the Lockheed Martin
Logistics Services Supplier Quality Management website:
http://www.lockheedmartin.com/us/suppliers/bu-info/aeronautics/sustainment-services.html
TABLE OF CONTENTS
SECTION
1.
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15.
TITLE PAGE
General Requirements
Quality System
Access to Facilities
Contract Review and Planning
Selection, Control and Requirements Flow Down to Every Tier
Selection, Control and Contract Flow Down to Quality Control
Specification (QCS)-001 Sources
Seller’s Performance of QCS-001 Processes
QCS-001 Requirements for Seller-Designed items
Calibration
Control and Processing Nonconforming Material and Corrective Action
Material Review Authority
Product Certifications and Acceptance
Changes to Seller’s Operations
Records
Minimum Processing Instructions and/or Planning Requirements
PAGE
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The terms “Item(s)”, “PO”, “Seller”, and “Buyer” as used herein, have the same meaning as the
terms “Work”, “Contract”, “Seller”, and “Lockheed Martin”, respectively.
Questions regarding QA022-02 or the applicability of QA022-02 shall be addressed to Lockheed
Martin’s Supply Chain Management Representative (Buyer) who administers this PO.
Copies of Aerospace Standards (AS/EN documents) from the Society of Automotive Engineers
may be obtained at www.sae.org.
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1) General Requirements
a) The terms “Item(s)”, (including “item(s)” with lower case “i”), “PO”, and “Buyer” as used
herein, have the same meaning as terms “Work”, “Contract”, “Seller”, and Lockheed
Martin, respectively.
b) Seller shall use the QCS-001 Directory to identify both the process sources and the
controlled processes that require Buyer approval, prior to use for Items delivered to
Buyer. * Seller shall have Internet access for obtaining requirements of the “PO”, of
which this document is a part (“PO”).
c) Language - Unless otherwise authorized by Buyer in writing, all records, reports,
specifications, drawings and other documentation shall be in English.
d) Supplier Control - Seller is responsible for ensuring all Items procured from its suppliers
for this PO conform to all requirements of this PO.
e) Seller’s documented quality system shall provide for the review of the PO to ensure that
quality requirements are incorporated into manufacturing planning, and inspection and
test instructions, as applicable, to assure compliance with the PO. Seller shall retain
evidence of such review as defined in Section/paragraph 14(a) of this PO.
f) Seller shall utilize written instructions for all manufacturing, processing and inspection
operations. Instructions shall be in the form of planning, manufacturing operation sheets,
shop orders, travelers or any other identifying document. Such instructions shall identify,
in sufficient detail, the controls and conditions of manufacturing peculiar to the Item
being manufactured, assembled, inspected and tested. Changes to planning instructions
shall be traceable and approved prior to use (refer to Section/paragraph 15).
g) Certified Materials - Seller shall establish controls to prevent the use of non-certified
materials when certified materials are required.
h) Seller shall establish controls to ensure that material subject to age control, shelf life, or
environmental controls are properly identified, monitored and maintained.
i)
Seller shall control drawings, specifications and supplemental instructions and changes
thereto to the extent necessary to ensure that only documents of the revision specified in
the PO are utilized.
j)
Seller shall maintain a system to ensure removal of obsolete documentation from the
manufacturing, inspection and test areas.
k) Notification - Seller shall notify Buyer when:
i)
Seller or Seller’s sub-tiers are found to be non-compliant to Buyer specifications,
ii)
Seller’s sub-tier is disapproved by Seller
iii) Seller or Seller’s sub-tiers are disapproved by a Government Agency,
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Seller Quality Requirements
QCS-001 Processing Sources
iv) Government/Industry Data Exchange Program (GIDEP) Alert is required or received
affecting Buyer Items.
2) Quality System
a) Seller shall maintain a documented Quality System that meets the requirements of the
PO including, without limitation, this QA022-02.
3) Access to Facilities
a) Work under this PO is subject to Buyer's periodic surveillance/audit of Seller's
compliance with Seller’s internal procedures and other documents applicable to this PO.
b) Seller shall provide or obtain for Buyer, Buyer’s Customers and regulatory agency
personnel, access to any and all facilities, including those facilities of Seller’s
subcontractors, where work is being performed or is scheduled to be performed. Buyer
shall have the right to perform in-process inspections, audits or system surveillance at
Seller’s and Seller’s subcontractors’ facilities as part of verification of conformance to the
requirements of this PO. Denial of any such access may result in inactivation of Seller’s
approval. Seller shall include the provisions of this facility access requirement in its Pos
with its subcontractors.
i)
Seller shall provide, at no increase in price, cost or fee to Buyer, Government or
appropriate regulatory agencies, suitable facilities at Seller and Seller’s
Subcontractors’ manufacturing locations for Buyer, Government, and regulatory
agency representatives to perform compliance verification.
ii)
Seller shall provide Buyer’s Field Representative with internet access via one of the
following methods:
(1) Direct Non-Digital telephone line
(2) ISDN line
(3) DSL Line
(4) High-Speed Internet Access via Seller’s Network
iii) Seller shall include the provisions of this paragraph “3” in each purchase order. If
any, with each of its subcontractors where Item processing is being performed or is
scheduled to be performed in connection with the PO, and shall require that this
paragraph “3” is inserted in all subcontracts at every tier, and noting that the term
Buyer refers to Lockheed Martin acting through its Lockheed Martin Aeronautics
Company business unit.
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Seller Quality Requirements
QCS-001 Processing Sources
4) Contract Review and Planning
a) Seller must maintain and control QCS-001 processes through written processing
instructions and/or planning
NOTE: Seller shall ensure that work instructions and/or planning include, as a minimum,
the applicable requirements in section/paragraph 15.
b) Seller shall have a system in place to ensure that all Buyer unique requirements are
translated to operational processing instructions and/or planning.
c) Seller shall review all sub-tier purchase orders to ensure that such sub-tier purchase
orders contain referenced specification(s), revision level(s) and drawing(s)
requirement(s).
d) Seller shall have a documented system to ensure that processing instructions and/or
planning changes are reviewed, at a minimum, by its production, engineering (when
available and/or applicable), and quality organizations.
e) Seller shall clearly define control of processes, training, certification of its personnel,
interpretation of results, and final disposition of parts in documented procedures.
f) Seller shall ensure that its personnel have the required training and experience
commensurate with the requirements necessary for the performance of this PO.
g) Seller shall inspect Items or materials received from Buyer or Items from Buyer’s subtiers for verification of condition, quantity, serialization, when required, and dimensional
data, when required.
h) Seller shall have a documented quality system for controlling and maintaining traceability
of Items processed. The use of correction fluids and/or correction tapes on Seller
documentation for traceable Buyer Items is prohibited.
i)
Prior to performing any QCS-001 controlled process, Seller shall review QCS-001 to
ensure Seller is approved to perform such process.
j)
Seller shall ensure that, for any furnace used for curing, or embrittlement relief, the
furnace/oven chart(s) and/or supporting documentation are identified with process
planning or traveler number, time in, time out, quantity, stamped or signed off as directed
herein by Seller’s operator to assure Item traceability is maintained.
5) Selection, Control and Requirements Flow Down to Every Tier
a) Seller's documented quality system shall include procedures for determining the
capability of sub-tier suppliers prior to issuance by Seller of a purchase order to any
such sub-tier.
b) When Seller performs a Quality System Survey or Evaluation for a sub-tier facility, Seller
shall document the results of each survey or evaluation.
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c) Seller is responsible for ensuring all materials, services and components it procures for
incorporation into Items processed for Buyer conform to all requirements of the PO.
d) Seller shall define and establish a program for determining the need for periodic resurvey or re-evaluation of Seller's sub-tiers to ensure compliance with the PO.
e) Prior to production and award of subcontracts, Seller shall institute a program that will
ensure control of its quality and control of such quality at sub-tiers at all levels for all
Items procured by Seller in support of the PO.
f) Seller shall include the applicable portions of the PO in each of its purchase orders, if
any, with each of its sub-tiers where processing is being performed or is scheduled to be
performed in connection with the PO and require that, where applicable, such portions
are inserted in all subcontracts at every tier.
g) Seller shall include in its purchase orders to its sub-tiers the applicable revision and
amendment level, as applicable, for referenced Buyer specifications and other Buyer
and/or Seller documents.
h) Seller shall include a complete description of Buyer requirements in purchase orders
issued to Seller’s sub-tiers.
i)
Seller shall maintain a documented Receiving Inspection function to ensure material
and/or Items received from Seller’s sub-tiers are inspected to and meet the requirements
of the PO. Verification of Item(s) conformance to drawings, specifications and
requirements of the PO shall be in accordance with inspection plans, including sampling
where applicable, surveys, and certifications of conformance at Seller or Seller’s subtier’s facilities, as appropriate. Seller shall properly physically segregate inspected Items
from Items awaiting inspection.
j)
Seller shall identify and document incoming material as to acceptance or rejection
status. Seller shall ensure that such material is identifiable to the PO and material
certifications.
6) Selection, Control and Contract Flow Down to Quality Control Specification (QCS)-001
Sources
a) Prior to use, for Items delivered to Buyer, Seller shall use QCS-001 to identify the
process sources, processes and specifications requiring Buyer approval. By Buyer
definition, and for Seller’s benefit, a controlled process is an operation performed on an
Item where the operation is not readily conducive to being inspected subsequent to its
conclusion. Controlled processes have verifiable controls inherent to the process, i.e.
heat treat, plating, non-destructive testing, etc.
b) Seller is not required to use approved sources listed in QCS-001 for standard hardware
(nuts, bolts, washers, etc.) ordered to military, federal or industry specifications or
standards (e.g., MS, AN, NAS, etc.) or for metallic raw material (plate, sheet, bar,
extrusion, etc.) purchased from a mill.
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c) Buyer hereby authorizes Seller to use Nadcap approved sources for Industry Standard
processes controlled by QCS-001. Seller shall ensure that a source is currently
approved by Nadcap, prior to a source performing processing on Items. Seller may
access Nadcap approved sources at http://www.pri.sae.org or
http://www.eauditnet.pri.sae.org. Upon request by Buyer, Seller shall provide Buyer with
objective evidence that Seller selected and used a source approved by Nadcap at the
time processing was performed and at the time Item(s) is/are delivered to Buyer. Buyer
does not mandate Seller’s use of Nadcap approved sources and shall not be responsible
for any cost associated with Nadcap accreditation or the use of a Nadcap approved
source or process. Buyer shall have the right to validate any Nadcap approved source or
process using normal survey practices, and shall have the right to disapprove Seller’s
use of any such source in connection with this PO.
d) The list of both Buyer-controlled processes and Buyer-approved sources can be found
at: http://www.lockheedmartin.com/us/aeronautics/materialmanagement.html
i)
Select “Quality Requirements”
ii)
Select “Supplier Quality Management System”
iii) Select “Supplier Quality Management” and follow instructions
e) Seller shall use Buyer-approved sources for Buyer-controlled processes, either Buyer
“Unique” or “Consensus Industry Standard (CIS)” processes, except as noted in “c”
above.
f) Seller shall review the list of Buyer-approved sources for Buyer-controlled processes,
prior to using a process source for a controlled process listed in QCS-001, and select
process sources that are approved by Buyer. Seller shall provide objective evidence of
Seller’s review to Buyer upon request.
g) If Seller performs or directs its sub-tier to perform processes controlled by QCS-001
without Buyer’s prior approval, Buyer shall have the right to disapprove Seller’s quality
system.
h) Seller’s utilization of Buyer-approved sources does not relieve Seller from the obligations
to ensure subcontracted sources are in full compliance with applicable process
specifications and to deliver conforming Items. Upon request by Buyer, Seller shall
provide objective evidence that such compliance was attained and that such conforming
Items were delivered.
i)
Seller shall be responsible for ensuring that Seller or QCS-001 sources have the
appropriate revision level of the process standards/specifications prior to performing
processing in connection with the Items.
j)
Seller shall maintain objective evidence that each Buyer-approved process source
selected by Seller is being monitored to ensure compliance with all applicable process
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specifications. Upon request by Buyer, Seller shall promptly provide Buyer with objective
evidence of such compliance.
k) Seller shall ensure process controls are established and required process control tests
are accomplished at required intervals to ensure continued compliance with process
specifications.
l)
Seller shall ensure all Seller sub-tier purchase orders and/or associated purchase order
documents for Buyer-controlled processes include the following data elements,
statements, or the statement in the Note after “vi)”:
i)
Seller’s unique LM Aero identification number (“vendor code”) and all LM Aero
unique “process codes” for each Buyer-controlled process to be performed,
ii)
a statement with the words, “Processing to be accomplished in performance of this
purchase order is directly related to a Lockheed Martin Logistics Services purchase
order and must be accomplished in accordance with process specification(s) on this
purchase order and Lockheed Martin Logistics Services QA022-2”,
iii) a statement that Seller’s supplier must file and maintain a copy of all purchase
orders containing the above statement and make these available for review by
Buyer, upon request,
iv) a statement that Seller’s supplier must submit a Certificate of Conformance ("CoC”)
with a unique certification number containing the following information:
(1) title and specification number (including revision letter) of the process,
(2) name and address of the process or non-destructive testing (“NDT”) facility,
(3) Seller’s supplier’s unique LM Aero identification number (“vendor or processor
code),
(a) If processor is utilized based on a Nadcap approval, a statement to the effect
“Source utilized based on current Nadcap accreditation” shall be included,
(4) date the CoC was issued,
(5) purchase order part number,
(6) quantity of parts (to include quantity accepted/ rejected),
(7) signature and title of authorized quality agent of Seller, and
(8) fracture durability classification or serialization, when required
v)
a statement to ensure Seller’s sub-tiers suitably wraps, boxes or racks parts to
guard against shipping damage and to apply rust or corrosion protection, and
vi) a statement requiring Seller’s sub-tier to identify specification(s) title, specific
revision level(s) and drawing(s) requirement(s) to be performed by a QCS-001
source.
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QCS-001 Processing Sources
Note: Seller can also use the following statement in lieu of the above statements i) –
vii) to meet the requirements of this paragraph:
Include Seller’s unique LM Aero identification number (vendor code) and a
statement with the words:
“Processing to be accomplished in performance of this purchase order is directly
related to a Lockheed Martin purchase order and must be accomplished in
accordance with process specification(s) on this purchase order and the revision
in effect as of the date of this PO of Lockheed Martin Logistics Services QA02202. All requirements of such QA022-02 paragraph l. i through vii shall be
accomplished.
vii) Seller shall review testing lab Certificate of Conformance to ensure all required
testing has been accomplished and meets all requirements of the applicable
specification. Upon Buyer’s request, Seller shall provide objective evidence of
Seller’s review.
viii) Seller shall submit all requests for additional QCS-001 process approvals in writing
to Buyer.
7) Seller’s Performance of QCS-001 Processes
a) When performing QCS-001 Controlled Processes in Seller’s facility, Seller shall
accomplish QCS-001 processes in accordance with the applicable process
specification(s) and the then current Lockheed Martin Logistics Services QA022-02.
QA022-02 is located at http://www.lockheedmartin.com/us/suppliers/buinfo/aeronautics/sustainment-services.html
8) QCS-001 Requirements for Seller-Designed items
a) Seller has the responsibility and authority to approve and control its own processing
sources, including in-house processes with the following exception:
For those Seller designs invoking Buyer-designed technical specifications that require
LM Aeronautics Materials and Processes Engineering (“M&PE”) qualification or
approval, Seller shall ensure LM Aero M&PE qualifies and/or approves the Seller’s
source prior to use, or Seller may use a source approved in QCS-001.
Seller shall notify and disclose details to Buyer when Seller and/or any of its sub-tiers
are determined non-compliant with Buyer requirements, specifications, are disapproved
by Seller and/or a Government Agency, or when Seller or a Government Agency initiates
a GIDEP Alert related to Seller actions.
b) Seller shall ensure that the assignment of personnel is commensurate with their
respective levels of experience, training and proficiency.
c) Buyer shall have the right to review and maintain surveillance of Seller’s system for
approval and control of Buyer-approved processes, including those performed in-house.
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If Buyer determines Seller’s system has failed to control processing or testing, Buyer
shall have the right to withdraw Seller’s authority to approve and control Buyer-approved
processes listed in QCS-001. In the event of withdrawal of such authority, Buyer shall
have the right to direct Seller, at no increase in price, cost or fee to Buyer, to use Buyerapproved sources listed in QCS-001.
d) Seller design shall include Buyer drawings identified as Source Control Drawings or
Specification Control Drawings for purposes of Paragraph 8.
9) Calibration
Seller shall maintain a documented calibration system for the calibration and maintenance of
tools, jigs, inspection and test equipment. Seller’s calibration system shall be compliant to
prevailing industry requirements in accordance with Seller’s Quality Management System
(“QMS”), including without limitation ISO 17025, ISO10012-1, ANSI Z540.
10) Control and Processing Nonconforming Material and Corrective Action
a) Seller shall implement and maintain a documented quality system that provides for
identification, documentation, segregation and disposition of nonconforming material.
Seller shall ensure effective corrective action is taken (including repetitive
nonconformance(s) dispositioned “Use-As-Is” by Buyer’s or Seller’s Material Review
Board (“MRB”) actions) to prevent, minimize, or eliminate nonconformance(s).
b) Seller’s QMS shall ensure that non-conforming material is not used for production
purposes.
c) Seller shall maintain records of all nonconforming material, dispositions, assignable
causes, corrective actions, and effectiveness of corrective actions for the period
specified in this PO.
d) Seller shall evaluate each nonconformance for its potential to exist in previously
produced or delivered Items. If a nonconformance exists,
e) Seller shall notify Buyer, in writing, within 24 hours for issues impacting flight safety, and,
in writing, within 5 working days for all other issues.
f) Seller shall respond to all Buyer requests for corrective action. When requested by
Buyer, Seller shall provide trend data and findings for Buyer returned Items.
g) Seller shall assess all Buyer identified nonconformance(s), whether or not Item(s)
was/were returned to Seller, and take appropriate actions to ensure causes of
nonconformance are corrected. Seller shall notify Buyer of actions taken to prevent
recurrence by completing Quality Notification (QN).
11) Material Review Authority
a) Material Review Authority for Seller-Designed Items
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i)
Seller has Material Review Authority (“MRA”), except for nonconformance(s) that
affect a parameter controlled by Buyer drawing or specification, where form, fit or
function, interchangeability, service life or reliability is affected. Seller shall submit
dispositions of nonconformance(s), if any, affecting any such parameter(s) to Buyer
for approval.
ii)
Buyer has the right to remove MRA if Seller demonstrates abuse of the MRA
process.
b) Material Review Authority for Buyer-Designed Items:
i)
Seller disposition authority is limited to scrapping of Items, eliminating the
nonconformance by rework to engineering, or returning to Seller. On Items of Buyer
design, Seller shall document nonconformances for submittal to Buyer’s Material
Review Board (“MRB”) for dispositions as required by this PO. Seller’s continued
processing, prior to Buyer’s MRB disposition, of any Buyer-designed Items
containing a nonconformance prior to Buyer’s MRB disposition will be at Seller’s
risk.
ii)
If Buyer has delegated MRA to Seller on Buyer-designed Items, Seller shall exercise
such MRA except for nonconformances of a parameter that affects form, fit,
function, interchangeability, service life or reliability.
iii) Seller shall submit requests for MRA on Buyer-designed Items in writing to Buyer.
c) Material Review Board Submittals
i)
Seller’s request for Buyer MRB disposition of Seller or Buyer-designed Items shall
be submitted to the Buyer.
ii)
Seller shall not incorporate any nonconformance(s) into any Item, process,
procedure or data that affects a parameter controlled by Buyer drawing or
specification or affects form, fit or function, interchangeability, service life or
reliability unless and until Seller has received prior written approval from Buyer to do
so.
iii) Buyer and Buyer’s customers shall each have the right to refuse to accept any
nonconformance(s). When Government Source Inspection is a requirement of this
PO, and Buyer’s customer has delegated MRA to Seller’s cognizant Government
source representative, Seller shall submit material review dispositions to Seller’s
local Government representative for concurrence.
iv) Prior to delivering Items that have Buyer MRB dispositions, Seller shall ensure that
root cause analysis and corrective action plans for all discrepancies have been
completed. Seller shall submit corrective action plans to the Buyer or Buyer’s
Representative with final acceptance paperwork.
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12) Product Certifications and Acceptance
a) Seller’s documented quality system shall provide a means for maintaining accurate
indication of inspection status, at all times while in the possession of Seller and during
shipment to Buyer, for Items to be delivered to Buyer.
i)
Seller shall use inspection stamps of a design distinctively different from inspection
stamps used by Buyer and Buyer’s Customers.
ii)
Seller’s documented quality system shall provide a method for the control and
issuance of inspection stamps and for the prevention of unauthorized use of such
stamps. If indication of inspection status is accomplished using signatures or initials,
Seller shall have a documented procedure addressing how signatures or initials are
distinguished and/or controlled. The use of signatures or initials are prohibited for
Non-Destructive Testing Inspectors. Upon request by Buyer, Seller’s procedure
shall be available for review.
b) Certificate of Conformance
i)
Seller shall prepare a Certificate of Conformance (“CoC”) asserting that the Items
contained within this shipment are in total compliance with the requirements of this
PO. Items provided under this PO must meet all applicable requirements. Any
exceptions shall be annotated in the delivery package. A copy of the CoC shall be
included with Seller’s product shipper.
ii)
Seller’s CoC prepared for each shipment shall include the following data
elements/information:
(1) title and specification number (including revision letter) of the process
(2) name and address of the process or NDT facility
(3) Buyer’s assigned processor number
(4) date the CoC was issued
(5) purchase order part number
(6) quantity of parts (to include quantity accepted/ rejected)
(7) signature and title of authorized quality agent of seller, and
(8) fracture durability classification or serialization when required
iii) When QCS-001 controlled processes are performed by Seller or Seller’s sub-tier(s),
Seller shall provide Buyer, at time of Buyer’s acceptance, objective evidence that
Seller or such sub-tier(s) used is/are approved by Buyer on date of acceptance by
Buyer, regardless of when processing was performed. If Seller and/or sub-tier(s)
used were approved at the time processing was performed but subsequently is/are
not approved at time of Buyer’s acceptance, Seller shall contact Buyer for Item(s)
disposition.
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iv) When Buyer’s customer requires source inspection, Seller shall obtain objective
evidence of Buyer’s customer representative’s inspection by signature and title or by
stamp on any shipping documents required by the PO.
c) Buyer Inspection at Source Requirements
i)
The point of acceptance is indicated on each PO issued. Seller is responsible for
ensuring all requirements of this PO have been met. Buyer shall have the right to
conduct surveillance and/or audits at any time, without increase in price, cost or fee
to Buyer.
(1) Items designated “Buyer Accept at Source” shall be subject to final acceptance
by Buyer’s PQAR at Seller’s facility prior to shipment.
(2) Items designated “Buyer and Government Accept at Source” shall be subject to
acceptance by Buyer’s PQAR and the assigned Government Representative at
Seller’s facility prior to shipment.
(3) Items designated “Seller at Source” shall be subject to acceptance by Seller’s
quality assurance representative prior to shipping. Should Seller’s performance
result in a change to the point of acceptance to “Buyer at Source”, Seller shall
be subject to costs associated with the added task.
(4) Items designated “Purchase Order Administrator/User” are not subject to
acceptance by PQAR.
ii)
When this PO calls for “Buyer Accept” or “Buyer and Government Accept at Source”
Seller, not less than five (5) days after receipt of this PO, shall notify the Buyer’s
PQAR who normally services Seller's facility, unless Seller has received written
Buyer authorization to accept Items and/or processing on behalf of Buyer. The
notification shall include PO number, date of scheduled shipment and any special
security clearance required to perform Buyer activities. If Seller does not know
Buyer PQAR assigned to this facility, Seller may request this information from
Buyer.
iii) When this PO calls for “Buyer Accept at Source”, Seller shall notify Buyer’s PQAR
not less than 48 hours prior to Items being ready for shipment, unless Seller has
received written Buyer authorization to accept Items and/or processing on behalf of
Buyer.
iv) Seller shall not claim entitlement to an increase in the PO price, cost, or fee based
upon an assertion that “Buyer Accept” or “Buyer and Government Accept at Source”
imposes additional cost(s) or task(s) on Seller.
v)
Work under this PO is subject to Buyer's periodic surveillance/audit of Seller's
compliance with Seller’s internal procedures and other documents applicable to this
PO.
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13) Changes to Seller’s Operations
a) Quality System Changes - Seller shall notify Buyer, in writing, of any adverse change in
its quality system status resulting in the loss of 3rd Party registrar’s certification status, or
any action taken by Seller’s customer, the Government, Federal Aviation Administration
(FAA) or Civil Aviation Agency (CAA). Seller shall also notify Buyer upon any sale,
relocation or transfer of Seller’s manufacturing operations or upon any change in the
quality organization, process or procedures that could affect conformity verification of
Items. Notification by Seller shall be made within 30 days of such changes.
b) Seller shall notify Buyer within 48 hours of any changes in Nadcap accreditation and/or
NDT Level II or III personnel, and all other personnel changes within five (5) normal work
days.
14) Records
a) Seller shall maintain complete records of all manufacturing, process capability (if
applicable), inspection and test, including copy of CoC. Seller shall make records
available to Buyer, upon request, for at least three (3) years after completion of this PO
and for longer periods as may be specified elsewhere in this PO. Upon request, Seller
shall forward specific records to Buyer at no additional cost, price, or fee to Buyer. For at
least seven (7) years after completion of this PO, Seller shall maintain and provide to
Buyer upon request, records of all QCS-001 process control tests performed by Seller,
and inspection records of processed Items.
b) Seller shall maintain special processing activity data on each Buyer-approved process
performed for Buyer, including processes performed by Seller on Buyer Items, or any
QCS-001 Source utilized, and Seller shall compile a quarterly Usage Report of this
activity data and submit it to Buyer at http://elli.lmtas.lmco.com/qads/QCS001Menu.asp.
Seller shall also include in this Usage Report all special processing activity
accomplished which may have been subcontracted by Seller’s sub-tier manufacturing
sources. Fax and e-mail submittals are prohibited, and will not be accepted by Buyer.
Seller shall submit the quarterly Usage Report within fifteen (15) calendar days after the
end of each calendar quarter, even if no QCS-001 sources were utilized during a
calendar quarter. Usage Reports shall not be input prior to the end of each calendar
quarter. Seller’s Usage Report shall consist of processing activity accomplished in the
following activity categories:
i)
Seller subcontracting special processing activity to QCS-001 or Nadcap approved
sources,
ii)
Seller performing special processes on LM Aero Items for other LM Aero suppliers,
iii) Seller performing special processes on LM Aero Items the Seller manufacturers,
and
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iv) Seller’s sub-tier manufacturing source(s) who subcontract special processing
activity to QCS-001 or Nadcap approved sources.
Note: Usage Reporting is not required when Seller is performing QCS-001
processes for non-LM Aero contracts.
c) Seller’s Usage Report shall contain the following data elements and information:
i)
QCS-001 source name,
ii)
Buyer’s assigned QCS-001 Source number,
iii) process specification used by specification number, and
iv) quarterly frequency of use, e.g., “lots, batches”
15) Minimum Processing Instructions and/or Planning Requirements
a) General Requirements
i)
The processing instructions/planning requirements contained herein are, without
limitation, a part of Appendix QJ, Seller Quality Requirements – QCS-001
Processing Sources. Seller shall include such requirements in Seller’s processing
instructions/planning as defined herein.
b) Minimum Processing Instructions and/or Planning Requirements
i)
Seller and Seller’s sub-tiers shall ensure that processing instructions and/or
planning include, and meet, at a minimum, the requirements delineated herein.
ii)
Upon Buyer’s request therefore, Seller shall provide to Buyer, at no increase in
price, cost or fee to Buyer, copies of such processing instructions and/or planning.
iii) Seller shall submit all above noted Seller processing instructions and/or planning for
Buyer Items classified as “Critical”, for instance, Fatigue/Fracture Critical,
Fracture/Durability Critical, Safety Critical, etc. to Buyer for LM Aero Program Level
III review, approval and signature.
c) Pre-Penetrant Etch Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
pre-penetrant etch operations contain the following requirements:
(1) a job listing log is maintained that includes Item (part) number, material type,
shop traveler/planning router number, etch rate, time in etch tank, amount of
metal removed per surface, and identification of employee performing etch
operation,
(2) etch rate calculations are performed with a calibrated balance scale, (4 place)
when etch rates are determined using the weight loss method,
(3) etch rates are determined every 8 hours of operation or once each shift,
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(4) amount of metal removed from surface is in accordance with Buyer’s
specification(s), (minimum) plus .0001” per surface, not to exceed maximum
specified amount per specification, e.g., NDTS 1101 aluminum etch is .0003” to,
0007” per surface. Remove a minimum of .0004” and not to exceed .0007”, and
(5) etch rates, time in and time out of etch tank, and actual amount of metal
removed per surface are documented on Certificate of Conformance (“CoC”).
ii)
Seller shall document the following data on processing instructions and/or planning
when pre-penetrant etch is performed. Seller shall document that material being
etched, amount of removal per surface and specification will change as
specifications and requirements change:
(1) (Aluminum) Etch to remove 0.0003 - 0.0007” per surface per NDTS 1101 or as
required by Buyer specification(s),
(2) Daily Etch Rate (per established procedure): __________(in/surface/minute),
(3) Tank Number: _____________ Tank Temperature: ______________,
(4) Time in Etch Tank: ________________AM/PM, Date: ___________,
(5) Time Out of Etch Tank: ____________AM/PM, Date: ___________, and
(6) Amount of Metal Removed: ______________ PER SURFACE
d) Penetrant Testing Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
penetrant testing operations contain the following requirements:
(1) manufacturer of, and Sensitivity level of, penetrant material are documented and
recorded on processing instructions and/or planning,
(2) all batch numbers of penetrant material, emulsifiers and developers used are
documented and recorded on processing instructions and/or planning,
(3) penetrant, emulsifier and developer dwell times are documented and recorded
on processing instructions and/or planning,
(4) pre-cleaning method(s)/material(s), immersion times, temperatures and tank
numbers are documented and recorded on processing instructions and/or
planning, and
(5) a job listing log is maintained that documents Item (part) number, material type,
shop traveler/planning router number, number of Items inspected, number of
Items accepted/rejected and the acceptance criteria used.
e) Magnetic Particle Testing Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
magnetic particle testing operations contain the following requirements:
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(1) approved Technique Data Sheet(s) (“TDS”) are available and approval is signed
by a Seller Non-Destructive Test (“NDT”) Level III
NOTE: Buyer’s specification(s) may also require Buyer’s NDT Level III signed
approval of Seller TDS,
(2) required residual magnetism level is documented and recorded on processing
instructions and/or planning, and
(3) a job listing log is maintained that documents Item (part) number, material type,
shop traveler/planning router number, number of Items inspected, number of
Items accepted/rejected and the acceptance criteria used.
f) Radiography Testing Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
radiography testing operations contain the following requirements:
(1) approved TDS are available and signed by a Seller NDT Level III
NOTE: Buyer’s specification(s) may also require Buyer’s NDT Level III signed
approval of Seller TDS, and
(2) a job listing log is maintained that documents Item (part) number, material type,
shop traveler/planning router number, number of Items inspected, number of
Items accepted/rejected and the acceptance criteria used.
g) Ultrasonic Testing Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
ultrasonic testing operations contain the following requirements:
(1) approved scan plan/technique number, when required by Buyer’s
specification(s), are available and signed by Seller’s NDT Level III
NOTE: Buyer’s specification(s) may also require Buyer’s NDT Level III signed
approval of Seller’s scan plan/technique number
(2) serial number(s) of the standards used are documented and recorded on
processing instructions and/or planning, and
(3) a job listing log book is maintained that documents Item (part) number, material
type, shop traveler/planning router number, number of Items inspected, number
of Items accepted/rejected and the acceptance criteria used.
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h) Solid Film Lubricant (SFL)/ Prime/Paint/Fuel Tank Coating Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
sfl, prime, paint and fuel tank coating operations contain the following requirements.
Additionally, Seller’s specification data elements/information requirements, as
defined herein, shall be documented on applicable Seller’s processing instructions
and/or planning:
(1) material manufacturer’s identification for sfl, primer, paint (top coat) and fuel tank
coating,
(2) batch numbers of sfl, primer, paint (top coat) and fuel tank coating,
(3) Engineering Materials and Processes (EMAP) material numbers when EMAP
materials are required,
(4) mix times, stand times for primer, paint (top coat) and fuel tank coating,
(5) viscosity of primer, top coat and fuel tank coating at time of application,
(6) temperature and humidity at time sfl, primer, paint (top coat) and fuel tank
coating is applied,
(7) required and resulting actual thickness of sfl, primer, top coat, or fuel tank
coating based upon number of coats applied,
(8) cure cycles to include time in, time out of furnace, temperature and humidity
data,
(9) printed name and signature of Seller’s QCS-001 qualified applicator, and
(10) required and resulting actual inspections performed to include as applicable,
by material type:
(a) specification or Buyer requirement,
(b) required coating thickness verification,
(c) wet and/or dry tape tests,
(d) coating Adhesion tests,
(e) coating Cure verification, and
(f) coating Cure verification, and
(g) coating visual examination
ii)
Seller’s and Seller’s sub-tiers testing procedures for sfl, primer, paint (top coat) and
fuel tank coating shall include:
(1) applicable and reference testing specification, and
(2) accept/reject criteria
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iii) Seller’s and Seller’s sub-tiers equipment listing for processing sfl, primer, paint (top
coat) and fuel tank coating shall include:
(1) paint booths,
(2) curing ovens,
(3) preventative maintenance schedule, and
(4) equipment that is calibrated, with frequency and accuracies documented
iv) Seller’s and Seller’s sub-tiers CoC for sfl, primer, paint (top coat) and fuel tank
coating shall include:
(1) material manufacturer’s name and batch number of primer, top coat, fuel tank
coating,
(2) sfl, to include EMAP Material Code, as applicable,
(3) cure cycles used shall include temperature and humidity verification, as
required,
(4) coating thickness results, and
(5) coating adhesion results
i)
Chemical Processing Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
chemical processing operations include the following requirements. Additionally,
Seller’s processing parameters, as defined herein, shall be documented on Seller’s
applicable processing instructions and/or planning:
(1) tank number(s),
(2) tank sequence,
(3) time in tank at time of processing, and
(4) temperature of tanks at the time of processing when solutions are heated
ii)
When Buyer unique specifications are required, Seller and Seller’s sub-tiers shall
include process flow charts indicating EMAPS approved materials, including
chemicals, by EMAPS item number.
iii) Seller’s and Seller’s sub-tiers lot/monthly process and solution control testing
requirements shall include:
(1) required testing specification,
(2) accept/reject criteria, adhesion, thickness, salt spray, visual examination, and
(3) solution analysis frequency
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NOTE: If testing is accomplished at Seller’s facility, it shall be controlled by
documented instructions/lab procedures.
iv) Seller’s and Seller’s sub-tiers chemical processing equipment listing shall include:
(1) Tank size,
(2) curing and embrittlement relief baking ovens, and
(3) crucifiers/ammeters
NOTE: Seller shall have documented calibration data with accuracies available
for Buyer’s review for calibrated equipment.
j)
Heat Treatment Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
heat treatment operations include the following requirements, processing
parameters and manufacturing data. Additionally, Seller’s and Seller’s sub-tiers shall
document such processing parameters on applicable processing instructions and/or
planning:
(1) cleaning methods,
(2) furnace number(s),
(3) time in, time at, time out of furnace(s), in legible format,
(4) actual quench delay, as required by applicable heat treat specification,
(5) temperature of quench media at time of quench,
(6) transfer time into cold storage after solution heat treat,
(7) specification used and requirements for dew points, carbon potential vacuum
leak rate as required by applicable heat treat specification,
(8) specification used when in-process testing is required and actual test data
results, such as hardness after tempering,
(9) specification used for final hardness and conductivity readings, required and
actual, and
(10) specification used for part marking
ii)
Seller and Seller’s sub-tiers heat treatment processing instructions and/or planning
shall include:
(1) complete equipment listing, including furnace(s) classification, in accordance
with AMS 2750, e.g., size, furnace limits, and accuracy,
(2) how furnace charts are identified to ensure traceability,
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(3) as a minimum, Item number, quantity, shop traveler/planning number, time in,
time at, and time out of furnace shall be noted,
(4) a written procedure for pyrometry control in accordance with AMS 2750,
(5) reference to, and availability of, Seller’s documented personnel training program
for heat treatment, and
(6) a schedule for all required lotly and/or monthly process control tests required by
consensus industry standards and/or Buyer’s unique requirements, including
applicable ASTM test standards used.
iii) Seller’s and Seller’s sub-tiers documentation requirements for heat treatment logs
shall include the following data, as a minimum, and any additional documentation,
as required, by the heat treat specification(s) being used:
(1) shop traveler/planning traceable number(s),
(2) customer,
(3) Item (part) number,
(4) material type,
(5) material size,
(6) heat treat specification,
(7) furnace number,
(8) time in, time at required temperature, and time out of furnace, and
(9) quench delay
iv) Seller’s and Seller’s sub-tiers heat treatment CoC shall include:
(1) furnace number,
(2) temperatures by furnace used during heat treat process,
(3) furnace times,
(4) required and actual hardness/conductivity results, and
(5) any required statements embedded in heat treat specifications and the following
mandatory statements:
“All heat treatment processing performed on this order was accomplished using
heat treatment equipment that meets the requirements of AMS 2750. All heat
treatment operations were accomplished in accordance with the
requested/required heat treatment specification and all required verifications
tests have been performed and documented. No unauthorized changes or
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deviations to required heat treatment specifications or procedures have been
performed.”
k) Welding Requirements
i)
Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for
welding operations include the following requirements, processing parameters and
manufacturing data. Additionally, Seller’s and Seller’s sub-tiers shall document such
processing parameters on applicable processing instructions and/or planning:
(1) date, quantity, part number and detail numbers,
(2) material, joint pre-fit and tolerances,
(3) weld specification and class,
(4) type of weld (fillet, groove, etc.),
(5) approved weld procedure number, as applicable,
(6) approved weld schedule/technique number, if applicable,
(7) welder number/identification,
(8) weld machine number,
(9) welding rod identification/traceability number and specification,
(10) shielding gas, as applicable,
(11) purge flow rate, as applicable,
(12) pre-cleaning method and specification, and
(13) final weld inspection performed by process and specification, as applicable, to
include:
(a) radiographic inspection,
(b) penetrant inspection,
(c) magnetic particle inspection,
(d) ultrasonic inspection, and
(e) visual inspection