ML20062A636

QC Manual for Mercury Metals,Inc

ML20062A636
Person / Time
Site:	07100480
Issue date:	01/24/1980
From:	MERCURY METALS, INC.
To:
Shared Package
ML20062A623	List: ML20062A616 ML20062A636
References
NUDOCS 8208040069
Download: ML20062A636 (38)

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This manual is designed to assist quality control by the establishment of rules and regulations governing the standards of inspection and product quality.

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Paga 1 of 1 Section 10.00 Date of issua 1-24-80 O

MERCURY METALS INC.

QUALITY CONTROL MANUAL INSPECTION METHODS INDEX SECTION TITLE 10.00 Index 11.00 Organization Chart 50.00 Inspection Procedure and Quality Control 50.01 Receiving Inspection 50.02 Manufacturing inspection 50.03 Final Acceptance 50.04 Packaging and Shipping inspection O

50.05 Quality Control Stamp 50.06

. Drawing and Change Control 80.01 Tooling inspection 80.02 Gage Contrc!

80.03 Revisions 90.00 Training Program 100.00 Quality Control Audit 110.00 Approved S'ources 120.00 Receiving, Storing and Usage of Customer Tooling 130.00 Procedure for Material Review Record Procurement Document Control 140.00

Section: 11.00 Date of issue 1-24-80 0

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i Organization Chart Mercury Companies e

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f PRESIDENT i

EXECUTIVE VICE PRESIDENT i O vice eReSiDENT AND eRO;eCT ORDER DeSx MANAGER

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ACCOUNTING PURCHASING PRODUCTION QUALITY MANAGER CONTROL MANAGER I

SHIPPING AND STOCK MACHINE SHEET ELECTRONIC INSPECTION SHOP METAL ASSEMBLY RECEIVING ROOM 1

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t;W ge T F D S P. S. 50.00 Data of issu 1-24-80 MERCURY METALS, INC.

l QUALITY CONTROL MANUAL m

Subject:

Inspection Procedure and Quality Control Applicable Documents:

The following documents form a part of this manual to the extent specified herein:

MI L-145208A Inspection System Requirements MIL-L45208 Ord.

Inspection Requirements MI L-O-984A Sampling Procedures and tables for inspection by variables for percent defective.

Not applicable on Boeing Contracts.

MIL-1-45607 Inspection Equipment supply and Maintenance Ordnance MI L-C-45662 Calibration of Standard MI L-O-9858 A Quality Program Requirements 10-CFR-71 Appendix E transportation packages for normal /

special form radioactive material 1.0 Scope and Use This specification provides instructions and general requirements for proper inspection of work in process and completed items prior to next assembly or delivery to customer thereby insuring quality of workmanship and to promote quality consciousnessamong the employees.

1.1 Enforce adequate inspection during the entire process of manufacture to insure reliable function of the end product. Interchangeability of parts where required and general compliance with customer's requirements and specifications.

1.2 Establish better quality at lower cost by emphasising preventive rather than routine inspection.

1. 3 The quality control procedures will assure that non-conforming materials, tools, or test equipment will be identified as discrepant, segregated, and reviewed for disposition.

1.4 Provide evidence of inspection for all material, parts,and assemblies.

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• 50.00 Inspection Procedure and Ovality Control Date of issue

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1-24-80 Our quality control system shall assure that adequate records of materials review on discrepont material actions are maintained and kept available for review and analysis. These records shall show the cause and responsibility for the discreponey, the way in which the discrepancy was corrected, and shall note what oc-tion was taken to prevent its recurrence.

If we are not authorized by customer to hold formal materials re-view on the discrepont material, we shall submit his request for action to the customer Quality Control Representative assigned to our plant, if any, or to the customer Material Department.

Materials covered by such a request shall be witheid from pro-duction and delivery until the customer hos completed the Mot-erials Review action and advised us os to the materials disposition.

We connot conduct Materials Review actions on customer design items unless and until specific authorization for such actions has been received from the customer. We may request authority from the customer to hold formal materials review action by establishing adequate procedures to be approved by the customer, and designo-ting qualified quality control and engineering personnel to act on the materials review as authorized by the customers. A material review decision is binding upon all members of the suppliers organization.

s When we are approved to hold materials review actions, the cus-tomer reserves the right to reject the decisions of the suppliers mot-erial review.

We shall maintain', on a trend basis, o system of quality level or defect level reporting for the purpose of demonstrating progress in quality improvement. When requested, we will submit reports on defect levels and trends to customer. We shall take prompt and effective action to correct and prevent recurrence of discrepancies referred to us by the customer for which the supplier is responsible or for which we are best able (as determined by negotiation with the customer) to direct the corrective and/or non-recurrence action. We, when requested, shall send to the customer o descriptive report of the action taken.

If articles are proprietary designed, we cannot conduct Materials Re-view action on a discrepancy which will result in a departure from the requirements of the customer control drawing or specification as noted on the purchase order. Such departures must be authorized by the customer Materials Review Board action.

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Page 3 of 5 P.5. 50.00 Inspection Procedure and Quality Control Date of Issue (con't. )

1-24-80 r

Our quality control system shall incorporate provisions

1. 4.1 for the assurance of required reliability and for the collection and transmission of reliability data os spe-cified by the customer. The details of reliability e and failure data reporting will be determined assuranc by the requirements of the purchase order.

2. 0 Goolity Control exercises control over the following functions.

2.1 Inspection to safeguard the quality of:

A.

Row Material B.

Purchased Components C. Tooling D.

Fabrication E.

Processes F. Assembly and Adjustment G. Outside Production H. Completed Products' l.

Shipping Standard and Packaging J.

Initiates L.M.R. and/or customer MRB

2. 2 Complionce with specification and standard including procurement, engineering and customer requirements.

2. 3 Control of measuring, testing and other equipment and processes employed in evoluotion of the end product.

2. 4 Maintenance of up-to-dote drawing and drawing change infor-motion.

2.5 Maintenance of Inspection and certification records necessary to the performance of all above functions.

2.6 Full responsibility for quality control is assigned to the inspector who is responsible to the plant manager.

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2. 7 All inspection performed by others: Radiographic, Penetrant, Magnetic, etc. will be controlled by the Quality Control De-portment. All such results recorded.

2.8 Reject and properly identify supplied not conforming to the g

requirements.

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Page 4 of 5 P. 5. 50.00 Inspection Frocedure and Ovality Control Date of Issue (c on 't. )

1-24-80 0

Segregation and disposition of the rnaterial which does not meet established standards.

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Page 1 of 4 l

Section 50.01 i

Date of issue 1-24-80 0

MERCURY METALS INC.

OUALITY CONTROL MANUAL l

RECEIVING INSPECTION PURPOSE: To outline the procedure for the operation of Mercury Metals Inc. receiving inspection.

i.0 General 1.1 Receiving inspection will conduct the necessary inspection of all material received for the company.

2. 0 Inspection 2.1 The inspector will inspect the material for conformance to appli-cable purchase order requirements, specifications, blueprints, E. O.'S, inspection check sheets, test procedures, and inspection tooling.

2. 2 Material provisionally accepted by Mercury Metals Inc. source inspection will be checked for count, identity, domoge and re-quired inspection not performed by source inspection.

2. 3 Disposition of discrepont material.

Material received in a domoged or otherwise unusable condition will be rejected using our standard form MR per section 160.00 to define subject discrepancy. Wnether it is the suppliers defi-ciency or domoged in transit, we will treat the some excSpt domoge in transit will be photographed and so stated on the way bill and attested by the corrier. Material of a discrepont nature will be tagged and stored in material review crib pending dis-position to use the material or scrap.

3. 0 Designation of Inspection Status 3.1 The inspection status of Material routed through inspection will be designated at all times by the proper Mercury Metals Inc.,

forms.

3. 2 The following forms will be used:

3.2.1. Receiving report or indicate octual count and that material has been inspected for domoge and that it conforms to mo-terial ordered. This con be written on our copy of shipper, o copy of which will be kept in appropriate job folder.

I Shipper must be stamped by receiving inspector.

Foge 2 of 3 Section 50.01 RECEIVING INSPECTION (con't.)

Issued Date 1-24-80 v

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4. 0 Receiving Raw Stock 4.1 Receiving inspection will ascertain that certification or test reports required by the purchase order occompany the receipt of raw stock such os:

4.1.1 Sheet, Bar Tubular, and extrudedstock of metal or plastic.

4.1.2 Hardware and Etc.

4.1. 3 Bulk liquids or solids

4. 2 Wner, physical or chemical analysis of incoming row stock is questionable, on impartial analysis shall be obtained from a licensed laboratory. The row stock shall be held pending the results of the test sample.

4. 3 Inspection will maintain a systematic verification of certifi-(~]

cation and test report for each vendor.

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4. 4 Acceptable raw stock will be identified.

4. 5 Our receiving inspection system shall include, but not be limited to, the following:

4.5.1 All incoming materials shall be inspected by arr opproved statistical quality control plan.

Such inspection shall include visual, dimensional, functional, hardness, mognetic porticle, penetrant, etc., or other methods necessary to offirm required material composition and quality.

4.5.2 Material test reports shall be checked 100% ogainst the purchase order requirements. Idaterial certifi-cotions and test reports shall be filed and preserved as specified in the purchase order.

4.5.3 Independent laboratory facilities equipped to perform required tests shall be used by /Aer cury Metals Inc.

when testing material.

4.5.4 An identification system shall be provided to pre-ciude the use of wrong materials during manufacture.

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All material purchased for or furnished by a customer

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Page 3 of 3 i

Section 50. 01 l

RECElVING INSPECTION (con't.)

Issued Date 1-24-80 O

shall bear sufficent identification to identify it with the purchase order and/or certification form of standard identification or it shall be re-jected. Wnen material is sheared or cut in such a manner os to remove this identification from the remaining portion, inspection shall be responsible for the proper reidentification of the remaining

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portion.

4.5.5 All materials shall be properly stored to prevent domoge, corrosion, etc., and will be properly segregated. IActerio! will be used on a "First-in-first-out" basis.

4.5.6 1Acterials shall be stored in such a manner os to prevent withdrawal by unauthorized personnel.

4.5.7 Our Receiving inspection acceptance shall be based on the requirements of our purchase orders.

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Page 1 of 4 Section 50.02 Date of issue 1-24-80 g!

C MERCURY METALS INC.

QUALITY CONTROL MANUAL MANUFACTURING INSPECTION PURPOSE: To establish the procedure for inspection of parts and assemblies manufo:tured by or for Mercury Metals, Inc.

1.0 General 1.1 Inspection will be conducted in accordance with the planned o

inspection operations called for on the shop order, and any detailed information. Roving inspection will maintain pre-ventive surveilance.

1.2 Each controlled characteristic will be inspected at the planned inspection station in the production cycle. Thereafter, the some characteristic will be re-inspected only if subsequent events indicated that:

1. 2.1 The original inspection was inadequate.

1. 2. 2 The chorocteristic has been damaged or has deteriorated

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in storage or handling.

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1. 2. 3 The inspection history is lost or has become invalid.

1.3 Chorocteristics which are under satisfactory control will be inspected in accordance with the approved inspection plan.

1.4 Characteristics which are not under satisfoctory control will be subjected to 100 per cent screening until they are brought under control.

1.5 Chorocteristics which are designated as being so important that no fault con be tolerated, will be subjected to 100 per cent screening at some noint in the manufacturing cycle. This nor-mally will be the original inspection point for the chorocteristic.

' l.6 Characteristics acceptability of which is determined by control of the manufo:turing process will be inspected to assure that the process produces satisfactory parts. Thereafter, periodic inspection in accordance with approved plan (S) will be performed.

1.7 Every inspection which is mode will be recorded in the appropriate inspection space on the shop order, and validated by the appli-cotion of the inspection stamp.

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Page 2 of 4 Section 50.02 Date of issue MANUFACTUPING INSPECTION (con't) 1-24-80 4

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2. 0 Acceptance Criteria Inspectors will use as criteria of acceptance only the following:

2.1 4

2.1.1 Blueprints, specifications, and E. O.'s issued via production control.

2.1. 2 Officially released shop practice standards.

2.1. 3 Inspection tool, gages, and instruments which have been calibrated as scheduled.

j 2.1. 4 Production tooling which has been classified and col-1 ibrated for inspection use.

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3. 0 Identification 3.1 Material, at all times shall be positively identifiable by i

markings either on the material or on accompanying paper 1

work.

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3. 2 All material shall be accompanied by a shop order, blueprint, traveler, etc., which identifies the material and indicates its production and inspection status.

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processing, the paper work may be temporarily de-loched. During this interval, particular care shall e

be exercised to avoid the mixing of lots or other com-promise of inspection continuity.

3.2.2 Material in storerooms and occumulation areas will be identified as required by paragraph 3.1.

4. 0 Condition of material before inspection.

4.1 Material shall be free of dirt, loose particles, burrs, oil and moisture.

4.2 All paper work shall be complete and in good order.

Operations scheduled to be performed prior to inspection shall 4.3 have been completed.

4. 4 The producing department shall present to inspection only ma-terial which to their knowledge is acceptable, or shall indicate to inspection the known or suspected discrepancy.

5. 0 Inspection 5.1 The inspector will pass to next operation or stores only lots or material whose chorocteristics are within acceptable limits.

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Section 50.02 MANUFACTURING INSPECTION (con't.)

Date of issue 1-24-80 m

5. 2 The inspector will suspend any part which contains a known defect, even though the lot is acceptable.

5. 3 The inspector will reject any lot if the number of defectives in the lot causes the quantity to be less than the number in-dicated in porontheses on shop order.

5.4 The inspector will tog the lots as out of control per shop order.

6.0 Disposition of Ports and Assemblies 6.1 Acceptable parts and ossemblies will be released to the area dispatcher with the shop order properly stomped off.

6. 2 Non-acceptable ports will be handled as follows:

6.2.1 Discrepont parts, with properly accomplished rejec-tion report, will be routed to the salvoge area for preliminary review.

6.2.2 Defective ports to be removed from on assembly will be rejected with properly accomplished rejection re-port, indicating replacement requirement and travel with the assembly until defective part is removed.

The ossembly will be togged as out of control per shop order until replacement is assembled and ossembly re-inspected.

6. 3 Non-occeptable ossemblies will be handled as follows:

6. 3.1 Assemblies which con be reworked shall have all the discrepancies listed on ossembly discrepancy log and routed back to the submitting department.

6.3.2 Assemblies which cannot be reworked by the submitting department shall have all discrepancies listed on the assembly discreponcies log and then routed through the preliminary review.

6.3.3 When a reworked assembly is returned for reinspection the inspector will verify that the rework has been prop-erly accomplished and place his inspection stomp on the accompanying paper.

6.3.4 Assembly rework resulting from assembly discrepancies log will be reinspected mechanically. If occeptable, the dis-crepancy will be stamped off prior to odditional testing.

6. 4 Unidentified material, i.e., material which has no togs, shop traveler, etc., ottached will be brought to the attention of proper O"

supervision. If immediate corrective action is.not obtained, the material shall be sent to the salvage creo.

s uge, ui Section 50.02 MANUF ACTUP. LNG INSPECTION (con't.)

Date of issue 1-24-80 OV

7. 0 Process Control 7.1 Our quality control system shall monitor all processing operations and shall enforce all applicable process re-quirements. We shall manufacture to detail drawings l

ond specifications listed unless exception is authorized l

by the customer.

7. 2 Processing to specifications listed on the customer detail design drawing or to our specification used in lieu of the customer specification shcIl be accomplished by the cus-tomer opproved facilities.

7. 3 Process control shall not eliminate the requirements for final inspection and test of the end item, but it may be used to reduce these requirements. Records such as the Quality Control Cnorts, Frequency Distribution Charts, etc., of process controls used as acceptance devices shall be re-toined as inspection records.

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Approve Jim Flowers Jim Kelley O

Page 1 of 3 Section 50.03 Date of Issue 1-24-80 MERCURY METALS INC.

QUAllTY CONTROL MANUAL FINAL ACCEPTANCF PURPOSE:

To establish the requirements for quality control of productions assembly functional testing procedures.

1.0 General 1.1 As considered necessary by the company to fullfill contractual requirement, assemblies and sub-ossemblies shall be subjected

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to functional tests or inspection.

1.2 Final Inspection dato sheets are not subject to interpretation.

The unit inspection either does, or does not foil within the limits specified.

2. 0 Types of Inspection 2.1 Two types of Inspection ore maintoined by the Company Monu-facturing and Final Acceptance. The limitations of manufac-turing inspection are covered by this manuol.

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2. 2 Final acceptance inspection shall commence at inspection stations where recorded data for insertion on the inspection y

dato sheet first appears.

2. 3 The compiling of this dato may begin in sub-ossembly stages or not be recorded until final, prior to Government inspection.

2. 4 Any inspection conducted requiring the dato to be recorded on the inspection dato sheets shall be witnessed by a member of quality control deportment.

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2. 5 This witnessing of inspection is not indicative of the acceptance of the unit. A qualified representative of the quality control staff office shall review the recorded dato and accept or reject the unit.

3. 0 Final Acceptance 3.1 Assemblies will be acceptoble for final review by Quality Control Staff member when:

3.1.1 Shop order clearly indicates that the preceding opero-tions have been completed.

3.1. 2 All opplicable procedures, inspection dato sheets (properly stomped off os being witnessed), and specifications are O

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l>cge 2 of a section 50.03 FINAL ACCEPTANCE (con't)

Date of issue 1-24-80 MERCURY METALS INC.

QUAllTY CONTROL MANUAL FINAL ACCEPTANCE i

3. 2 The staff representative may request any or all of the in-spections to be re-run of his discretion.

3. 3 The staff representative shall survey the ports for final visual inspection.

3. 4 The staff member, upon being completely satisfied with the function and appeorance of the parts shall sign and stamp off the ports in behalf of the company.

4. 0 Disposition - Government Contro:ts 4.1 Government items bought off for the company shall be so indicated on the shop order.

4. 2 Non-acceptable assemblies will have the discrepancies listed on the assembly discreponey log sheet, and a re-jection report filled out. The unit will be handled as follows:

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4. 2. i part needs replacement.

4.2.2 Wnen rework has been accomplished, the assembly will be submitted for mechanical inspection.

4.2.3 If the part posses inspection it will be handled as paragraph 4.1 of this section.

4.2.4 If a defective part is removed and replaced, the discrepont item will be rejected and forwarded to preliminary review.

5. 0 Disposition - Commercial items 5.1 Commercial items bought off by quality. :,r. trol shall be for-worded to shipping for further processing.

5. 2 Defective items will be processed as follows:

5.2.1 The item will be returned to the manufacturer or ven-dor if a port needs replacement, with rcjection report.

5.2.2 Returned items will then be processed per 4.2.3 through 4. 2.6 above.

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Page 3 cf 3 Section 50.03 FINAL ACCEPTANCE (con't)

Date of issue 1-24-80 6.0 Government inspection 6.1 Units cleared through Governmen; inspection shall be sent to shipping and be processed per job order.

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6. 2 The Quality Control representative shall be responsible to process all paper work in accordance with procedures and to obtain all signatures as required from the Government repre-sentatives.

6. 3 If a unit is formally rejected by Government inspection, a meeting shall be convened of the material review board per this manual.

6.4 If Government inspection reveals an apparent anomally, the functional review board shall be convened per this manual.

6. 5 Rework and reinspection shall be indicated by either of the boards called out in paragraph 6.3 or 6.4.

7. 0 Inspection Report 7.1 Each lot or release submitted for inspection as specified by shop order shall be entered in the Inspection Report, number of sam-pies per MIL-STD-105, or 100% as stated by the shop order.

7. 2 Inspection Reports to be reviewed by n.c Plant Manager. His signature indicating complete acceptance by company inspection.

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Jim Flowers Jim Kelley O

Page i of 3 Section 50.04 Date of Issue 1-24-80 MERCURY METALS INC.

QUAllTY CONTROL MANUAL PACKAGING AND SHIPPING INSPECTION PURPOSE: To establish requirements for packaging and shipping inspection for all parts and assemblies.

1.0 seneral 1.1 It is the responsibility of the Quality Control Department to inspect all packaging and accompanying shipping instructions for compliance with applicable specifications and requirements.

2. 0 General Inspection Requirements 2.1 Prior to delivery to shipping, all parts shall:

2.1.1 Be accepted 100% by all previous inspections and so stamped. All "D" stomped, "Witheid for Material Review", articles must be cleared with a triangle

?' Accepted by Material Review" stamp.

2.1.2 Be tested and stamped, if required.

2.1. 3 Show no evidence of damage.

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2. i. 4 Befree efdirt, excessi e ereese er meistere end foreign matter.

2.1. 5 Be identified with specific marking (s), part or article number (s), special nomenclature, identification and serial number tags, etc. if required.

3. 0 Receipt of Articles in Shipping 3.1 Upon receipt of articles to be shipped, the inspector will:

3.1.1 Inspect for possible domoge during transit.

3.1. 2 Reject all articles considered to be below Mercury Metals Inc. standards of quality and workmanship.

3.1. 3 Dieck parts against shipping specifications.

4. 0 Inspection of Packaging Material 4.1 The inspector will inspect, on a spot-check basis, the packaging rnaterial and contents before the package is closed.

4. 2 Packaging must conform to applicable specifications for:

4. 2.1 Conioiner 4.2.2 Cushioning or demoge

FACGGiNG AND SHUPING INSPECTION (con't)

Page 2 of 2 Section 50.04 Date of issue 1-24-80

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4.2.3 Type and Date of preservation 4.2.4 Wropping 4.2.5 Toping 4.2.6 Sealing 4.2.7 Marking f

5. 0 Government inspection Prior to Closing 5.1 The Government representative may choose to inspect the package of this or any point.

6. 0 Closing the Package 6.1 The copy of the shipping order will be placed inside the package before sealing.

6. 2 The closed package will be inspected and the inspection stamp shall be offixed to the package.

7. 0 Prior to Shipping

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7.1 The shipping department will submit the shipping documents

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to o Coality Control representative.

7. 2 If the documents conform to requirements the representative will stamp the document with the acceptance stomp and pre-sent it to the Government inspector.

7. 3 The packaging inspector will assure that the required exterior markings comply with MIL-STD-129.

8. 0 Storage 8.1 The packaging inspector will take normal precaution to assure that the material is safely stored on the corrier.

9. 0 List of Approved Processing Sources:

9.1 Finco, Inc.

9. 2 Quality Point

9. 3 Julian's Point

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rage e o m Section 50.04 PACKAGING AND SHIPPING INSPECTION (con't)

Date of Issue l-24-80

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9. 4 Hawkin's Point

9. 5 Del's Plating Works

9. 6 Ther mo-E le c. ti on

9. 7 Dixie Electro Plating O

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__ __ A proved Written y:

Jim Flowers Jim Kelley O

Section 50.05 Date of issue 1-24-80 MERCURY METALS INC.

QUALITY CONTROL MANUAL QUALITY CONTROL STAMPS PURPOSE: To establish the types, use, and regulation of Ovality Control Stamps.

1.0 General 1.1 The Chief Inspector will be responsible for approval of the issuance of all stamps and for the maintenance of complete written records of stomp type and assignment.

1.2 Stamps shall be rubber or steel, impression types, of a size suitable to the particular application. For general use, rubber stamps approximately 3/8" in diameter will be standard.

2. 0 Use of Stamps 2.1 Ouality Control stamps are used to indicate the acceptance or rcjection of material, parts, and assemblies. All items going to stock must bear evidence of inspection; stamps will also be used to show acceptance of critical sfoges of manufacture.

O 2.i.i inse ctor, wiii normaiix use onix th accentonce stames:

salvage analyst will be responsible for disposition of in-process rejections by:

A.

Scrapping obviously unusable material.

B.

Reference to material review board for decision.

C.

Originating necessary paper to rework the mot-crial to conform to prints and specifications.

Ooolity Control stamps are available for items A and B.

Stamps are not used for identifying material to be reworked.

2.1.2 Wnenever practical the stamp impression shall be applied to the part itself. For parts which are too small or otherwise unsuited to stamping, the inspec-for will offix this stamp to the package (if necessary arranging for individual or group packaging of the 4

l parts).

2.1. 3 Stock room personnel are responsible for refusing to accept i

unstamped material and for assuring that parts which are container-stomped are maintained in their original package i

until issuance to the line.

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QU ALITY CONTROL STAT #5 (con' f)

Page 2 of 2 Section 50.05 Date of issue 1-24-80

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2. 2 Stamps shall be kept clean and must produce a legible impression worn and damaged stamps will be replaced immediately.

2. 3 Inspectors may use only the stamp assigned to them; they must not lend or borrow stamps. Lost stamps are to be reported immediately to the Chief Inspector.

3. 0 Regulation 3.1 Assigned stamps will be turned in prior to approval of employee transfers, leaves of absence, or terminations.

3. 2 Stamps assigned to one inspector and turned in for any reason, will not be re-assigned to another inspector for a period of one year.

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Appr+oved Jim Flowers Jim Kelley v

Page 1 of 1 Section 50.06 Date of issue 1-24-80 O

MERCURY METALS INC.

QUALITY CONTROL MANUAL DRAWING AND CHANGE CONTROL PURPOSE: To establish procedures for control of drawings and changes.

1. 0 General 1.1 Drawings, sketches and/or purchase descriptions and changes received from the customer will be processed as follows:

1.1.1 Drawings, sketches and purchase descriptions re-ceived with purchase order shall be checked against purchase order call out and distributed as follows:

One in shop and inspection file, " supervised by in-spection", and one shall accompany work order through all phases of manfoeture and inspection.

1.1. 2 New issue drawings and engineering changes shall be received by the management and a determination of the effect upon the job involved will be mode.

If not applicable one copy shall be filed in inspec-tion only. Otherwise distribution shall be as per paragraph 1.1.

1.1. 3 All obsolete drawings, etc., shall be removed and destroyed or returned to the customer os directed.

2.1 Drawing revisions listing on shippers and drawings changes control.

2.1.1 Effective April 16, 1969, it is mondatory that all shippers list the latest drawing revision letter to which the part has been mode. This is the respon-sibility of the inspection department.

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- Date of issue 1-24-80 q

V MERCURY METALS INC.

1 O'JAllTY CONTROL MANUAL TOOLING INSPECTION i

PURPOSE: To outline the procedure for inspection of production and i

inspection of. Tooling.

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General l

1.1 The inspection Department is responsible for inspection of:

1.1.1 Newly fabricated or reworked production tooling or inspection fixtures.

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1.1. 2 Tooling or fixtures prior to shipment to outside vendors for use on Mercury Metals Inc. contract.

1.1.3 Active inspection fixtures and templates within ninety (90) days of lost inspection.

1. 2 The tooling inspection record will be prepared when the tool is first inspected and is maintained as on inspection history record. All results of each tool inspection will be recorded I

on the applicable tooling inspection record.

1.3 All new or reworked tools will be identified by the latest

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Engineering Order change letter or number. If an E. O.

is the cause for the manufacture or rework, the E. O.

4 number will be stamped on the tools.

2. 0 Definitions 2.1

" Tools" as herein referenced, include jigs, fixtures, dies, templates, patterns, form tools, adopters, specially devel-oped machine attachments, etc., which have been indi-vidually designed or modified to meet production or in-spection requirements.

2. 2 Standard equipment of a vendor proprietory nature, or-ficles which are adopfohle to multipurpose use, and reg-ular operating occessories to standard equipment are not included within the scope of this definition.

2. 3 Devices which are exclusively used for the measurements l

determination of physical, or mechanical properties, or precision control shall be differentiated from tooling as defined herein. Such items shall be liandled in accordance with section 80.02 of this manual.

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Page 2 of 3 Section 80.01 TOOLING INSPECTION (con't)

Date of Issue 1-24-80 0

2. 4 Tooling designed for inspection purposes and production tooling which is used wholly or partially for inspection purposes shall be termed " Inspection Tooling". Tooling used by production only shall be termed " Production Tooling. "

3. 0 Mercury Metals Inc. Fabricated or reworked Tooling 3.1 Wnen new Mercury Metals Inc. fabricated or reworked tooling is accepted by inspection, the " Tool Order" will be stomped with the in process acceptance stamp.

3.1.1 If acceptance of the tool does not require inspection of the first part produced, the tool is stamped with the in-process acceptance stamp only.

3.1. 2 If the Tool is acceptable to the tool drawings and final acceptance is contingent on the Tool's pro-ducing satisfactory parts, o Tool Tryout Tag will be offixed to the Tool.

3.1. 3 When the first article has been accepted, the Tool Tryout Tog will be removed and destroyed. The Tool will then be stomped with Tool proving stamp and in-process acceptance stomp.

4. 0 Vendor Manufactured or Repaired Tooling 4.I Wnen new, repaired or reworked tooling is received from o vendor or customer on o receiving report, the results of the tooling inspection shall be entered on the receiving report and handled according to Section 120.00.

5. 0 Re-Inspection of Inspection Fixtures 5.1 Tooling inspection will evoluote the inspection Fixture Log weekly to determine the use, and schedule the re-inspection of the fixtures. This shall apply to all fixtures in current use.

6.0 Defective Tooling 6.1 Wnen previously accepted inspection or production tooling is iaund defective because of damage, wear, design change, etc., the tool shall be togged as defective and routed to Tool control for disposition.

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Pooe 3 of 3 Section 80.01 Tooling inspection (con't)

Date of issue 1-24-80

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6. 2 Tools shall be reinspected before each release or each 100 production ports, whichever occurs first. Such inspection shall be recorded in a log maintained by inspection.

6. 3 Tools must be properly stored and controlled to prevent misuse, domoge, and deterioration. Tools in storage shall be periodically checked for condition and preser-votion in compliance with applicable portions of customers documents, tooling agreements or purchase order conditions.

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6. 4 Physical inventory of government furnished property will be be taken upon completion of the contract or on August 31, annually, whichever occurs first.

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Page 1 of 3 Section 80.02 Date of issue 1-24-80

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'u d MERCURY METALS INC.

QUALITY CONTROL MANUAL GAUGE CONTROL PURPOSE:

To outline the procedure for inspection and core of gauges, master gauges, Micrometers, and other Mechanical Measuring devices.

1.0 General 1.1 The inspection Department is responsible for the inspection, care, maintenance and records of:

1.1.1 Plug, Ring and Thread Gauges 1.1.2 Micrometers, Calipers, etc.,

1.1. 3 Dial Indicators a

1.1.4 Thread Measuring Wires

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l.1.5 Gauge Blocks and Master Gauges 1.1.6 Miscellaneous Gauges and other Mechanical Measuring Equipment.

2. 0 inspection 2.1 All new, re-designed, re-worked, and repaired Gouges, Master Gauges, Micrometers, etc., will be inspected for occuracy and conditions before acceptance for use.

3. 0 Care and Maintenance 3.1 Unless specifically authorized by the Chief Inspector, gauges shall be returned to the crib at the end of each shift or as the job is completed, whichever is sooner, for dimensional check and inspection for weer or dom-oge before stocking or re-issue.

3. 2 Wnen Gauges are permitted to be retained at work station, they shall be returned to the crib of least once every five days for o dimensional check.

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Page 2 of 3 Section 80.02 G AUGE CONTROL (con't)

Date of issue 1-24-80

O

3. 3 At specific intervals as established by the Chief Inspector, all company owned, os well as employee owned dial in-dicolors, Micrometer, Protractors, height gauges, master gauges, comparators, gauge blocks, calipers, etc., shall j

be inspected for malfunction, wear or domoge. All tools, whether personal or company owned, not within established tolerance, must be logged and removed fron) service at if rejected, tools con be repaired. They must be once.

repaired immediately either by Mercury Metals Inc., or by some acceptable tool and gauge repair shop with the facilities to certify the occuracy of said tool. Tools be-longing to employees that are beyond repair must be re-moved from the premises as customer Quality Control will remove us from their Ovalified Vendor list upon finding a measuring device in use that hos not possed our inspection.

3.3.1 All Master Gauges, and Master Squares are cer-tified by outside source on a semi-annual basis.

Al! equipment calibrated by outside source will be supported by a Certificate stating that calibration was performed using sicndards that was traceable to the Bureau of Standards. As a minumun the Certificate will contain.the date, occuracy, equipment number, and the eny ironmental con-ditions which the tests were performed.

4 3.3.2 Micrometers, Verniers, Height Gauges, Squares, and Cubes, are checked on o 90 day basis. All tooling will have a recall date for calibration be-fore returning to Gouges Storage area. Tools will r

be calibrated in on environmental controlled areo i

l of 68 F/50 I

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3. 4 All Gouges and Measuring Equipment, when found to be worn or domoged, shall be rejected in conformance with Tooling j

inspection procedure, Section 80.01 poro. 6.0 (Quality i

Control Manual).

3.4.1 Procedure for calibration of Micrometer, Vernier Calipers, etc., will be spelled out on each inspec-tion Control Card covering each tool.

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I Page 3 of 3 V

Section 80.02 i

f GAUGE CONTROL (con't)

Date of issue 1-24-80 j

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4. 0

. Records 4.1 The Chief inspector sho!! mairtain o cornplete record of i

the inspection and acceptance of newly acquired, re-j worked, or re-conditioned Gouges and other mechanical j

1 Measuring devices.

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4. 2 Each inspection tool, where possible, will have on ad-besive sticker offixed to the tools in a position so os not te interfere with its function or use, which will indicate the next programmed inspection date. On tools too small j

for the sticker, o tog bearing the some information shall I

be ottoched.

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MERCURY METALS INC.

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QUALITY CONTROL MANUAL I

REVISIONS A'5

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~h PURPOSE: To establish a revision progrom.

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M5 1.1 This manual shall be reviewed semi-annually or upon written J:}A request from o customer, production, inspection, or the man-

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ogement, in order to keep current with changing technology c[6 and to satisfy the customer requirements.

'N'y, A letter or memo to the Ouolity Control Management, stating 1.2

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5 the condition and a suggested remedy, will be sufficent to initiate revision procedures.

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Revisions are os follows:

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Page 1 of 1 Section 90.00 Date of issue 1-24-80 O

MERCURY METALS INC.

QUALITY CONTROL MANUAL TRAINING i

PURPOSE:

To establish a training program.

1.0 General 1.i We shall develop, implement, and maintain troning programs as deemed necessary by the monogernent, to maintain accep-table arcos of performance in quality control, purchasing, and manufacturing. Training programs shall include, as needed, familiarization with ports, components, equipment, systems, inspection and tests, checkout, quality control, statistical quality control, packaging and handling. Porticular emphasis shall be given to the function and mission of the end item, to new articles and to new or sensitive fabrication processes or materials. The training program shall include sufficent training to ensure personnel proficiency and moons of determining the O

proficiency of persons completing the courses. Inspector training programs shall, where practical, include the inspection of appropriate articles with known deficiencies, in order to evaluate the inspector's proficiency. Training needs shall be periodically assessed to determine requirement for additional training.

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Page 1 of I l

Section 100.00 Date of Issue 1-24-80 O

MERCURY METALS INC.

QUALITY CONTROL MANUAL AUDIT PROGRAM PURPOSE: To control on audit program.

1.0 General 1.1 We shall audit the adequacy of the quality program procedures, inspections, tests, process controls, and certifications performed 5

in each arco on timely basis. The audit shall be performed by on importial team familiar with written procedures and standards applicable to the areas being audited, but not having specific line responsibilities in those orecs.

The audit shall include examination of all quality operations and documentation, comparison with established requirements, notification of required corrective action, and follow up to assess results of corrective action. An example of an examination of an inspection operation would include, but not be limited to:

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A.

A reinspection of work occepted by the inspector in the creo.

B.

An investigation of the availability of all required documents.

C.

A determination of the familiarity of personnel con-cerned with required documents.

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D.

A review of failure onelysis and corrective action j-taken.

j E.

An evoluotion of the odequacy of acceptance and rejection documents.

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Page 1 of 1 Section 110.00 Date of Issue 1-24-80 0

MERCURY METALS INC.

QUAllTY CONTROL ' MANUAL APPROVED SOURCES

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PURPOSE: To establish on approved source program.

1.0 General ~

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1.1 An up-to-date list of opproved suppliers and processors.

shall be maintained by the management for the benefit s

of the Purchasing and inspection Departments, thereby assuring that only the approved suppliers and processors are used.

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/AERCURY IAETALS INC.

QUAllTY CONTROL MANUAL RECEIVING, STORING, AND USAGE OF CUSTOMER FURNISHED TOOLING (Ref. P. S.

SC. 01)

PURPOSE: To control all functions involving the receiving, storing, and usage of customer furnished tooling. '

The follow-up rework of customer tooling andwy invoicing required.

METHOD: Our method for receiving of the tools shall be os follows:

Step 1 The customer transmittal and pocking list shall be checked against the tools' received. Each line item to be checked to be certain the listed tool and its identity agrees with the packing list.

Step 2 Ouality assurance inspection personnel shall inspect the tools for visual damage or parts missing. If such occurs, they will advise the planning and tooling personnel Step 3 The produu..on control office shall odvise the customer of ony rework reqaired to the furnished tooling by pro-viding a copy of the LMR to the customer. The super-f visor of Tooling, shall advise all concerned, the esti-moied price of the rework. This price to be reviewed and approved by either Jim Flowers or Jim Kelley and then forwarded to the customer with the transmittal of the U' AR.

Step 4 The cost accounting office shall record all time against the work order so that verification of reworl. :horges can be established.

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,.,s Step 5 The production supervisor shall be on the back side of the traveler list any material being used to fabricate the rewor(.,

Step 6 The accounting department shall follow up the written request for compensation oad review some each 30 day n.

,-e period.

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MATERIAL.REVsEW RECORD L

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If The purpose of tb MRR, is to eirohlish a system of a I control on all rework of ports prior"to final inspec-tion. Note: The MRR, will not rep! ace the cus-tomer's Material Review Record where such is re-b ',c quired.

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METHOD:

The MRR will be originated by the Ir spection Deport-e i

c ment, either of the request of the Line Inspector or the

- y Department Supervisor. The MRR fum shall be filled out complete in duplicate and submitted to the Plant t

Supervisor and Production Control IAonager for dis-position. If the disposition con be~ catablished by the Inspector and Department Supervisor or the writing of the MRR, this shall be written and opproval given by

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,the Plant Supervisor and Production Manager. If the disposition connot be m ade or decided upon by the Department Supervisor and the inspector, the dis-position section of the MRR shall be left blank and g ';

filled in by.the Plant Supervisor and the Production i

Manager. The number assigned to the MRR shall be the some basic number os the' shop order number and 4

!' o suffix number sequentrolly established.

I DISTRIBUTION:

The original copy of the MRR shall be placed in the shop order jocket and accompany the work thru the plant. A duplicate copy shall be filled in the in-i spection's files. Upon completion of the rework the original shall be forwarded to the main office and filed in the job folder for future reference.

V[ritten by:

Approve J% Flowers Jim Kelley O

Page 1 of 2 Section 140.00 g

t Date of issus 1-24-80 MERCURY METALS INC.

4 QUALITY CONTROL MANUAL l

PROCUREMENT DOCUMENT CONTROLS PURPOSE: To establish procurement document controls.

4 1.0 Mercury Metals, Inc. quality shall review purchase orders to insure that applicable quality and technical requirements have been incorporated in the purchase order.

i 1.1 All purchase orders shall be made nvailable to the NASA Quality representative.

1.2 Applicable portions of the MSC-M-8080 Design and Procedural i

Standards 79 and 86 shall be incorporated in all purchase orders.

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1.3 Additional items of information to be required as applicable on the purchase order are as follows:

l 1.3.1 Raw material chemical and /or physical test certifications.

1.3.2 Adequate shipping instructions.

, O-1.3.3 Age control and limited life data.

4 1

1.3.4 Supplier records of tests and inspections must be maintained j

readily available for review.

1.3.5 Inspection and test characteristics to be verified at the supplier's facility.

1.3.6 When applicable, Mercury Metals Inc. source inspection.

1.3.7 When applicable, Government source inspection. The following statement shall be included on the purchase orders "All work on this order is subject to inspection and test by the Government at any time and place. The Government at any time and place. The Government qua'ity represen-totive who has been de egated NASA quality assurance func-l tions on this procurement shall be notified immediately upon receipt of this order. The Government representative shall also be notified forty-eight (48) hours in advance of the time articles or materials are ready for inspection or test. "

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Section 140.00 j

Date of issue 1

1-25-80 4

j MERCURY METALS INC.

i QUALITY CONTROL MANUAL j

PROCUREMENT DOCUMENT CONTROLS i

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i 1.3.8 Procurements which do not require Government source

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inspection shall include the following statements "The Government has the right to inspect any or all of 1

the work included in this order at the supplier's plant. "

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1.3.9 Mercury Metals Inc. suppliers shall be required tomaintain records of inspections and tests for three years from the end of the contract period.

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