INTRODUCTION
This manual details TKCA’s supplier quality and approval process.
In order to meet current and future challenges, maintain the ISO/AS
QMS, remain competitive, and ensure customer satisfaction, TKCA
must develop a close alliance with its key suppliers. Teamwork between
TKCA and its suppliers is obligatory in order to produce, ensure
and enforce the highest quality products and meet ever-increasing
customer needs. Improved and effective communication, coordination
and cooperation will be our insurance for achieving common goals.
TKCA’s supplier approval process is directed at identifying the
“best of the best” suppliers, who may be considered and evaluated
for future development and relationships.
TKCA’s products and services are of the highest standards of quality
and reliability. TKCA embraces the standards of ISO 2000:9001/AS9100
and continual process improvement. In order to fully guarantee our
customers accurately configured, safe and compliant material; TKCA
maintains the highest of quality standards and fully expects our
suppliers to share these efforts.
MISSION
To provide the highest quality material and services available at
the best value achievable for our customers.
1.0 PURPOSE AND SCOPE
This quality manual supplements the requirements stated on TKCA’s
Purchase Orders (PO) (as received) and relevant commercial and military
standards to include:
• FA0
• ISO 9001:2000
• AS 9100
• Mil-I-45208A
These requirements are necessary to ensure that material delivered
to TKCA by its suppliers will meet or exceed obligatory quality
directives. In order to ensure the best possible product and reliability,
TKCA’s processes are based on a defect prevention and configuration
control measures that will improve quality, lower costs and increase
productivity.
1.1 Purchase Orders
Receipt and acceptance of TKCA purchase orders is considered acceptance
of TKCA’s terms and conditions.
1.2 Specifications
It is the responsibility of each supplier is to ensure that drawings
and engineering specifications, tolerances and performance requirements
are met. TKCA encourages each supplier to work toward continual
improvement in all areas regarding quality, delivery, and performance.
The supplier is responsible for ensuring that all items regardless
if made by the supplier or a subcontractor, meet the technical specifications
for form, fit, function, and methods, using stated or recognized
industry best workmanship practices.
1.3 Sub-Tier Control
The supplier shall be responsible for flow down of all the requirements
and provisions of the TKCA purchase order applicable to the suppliers
subcontractors.
1.4 Facility Access
During the performance of this purchase order, Supplier Quality
Control or Inspection and Manufacturing process are subject to review,
verification and analysis by TKCA and/or Government/Customer representatives.
This requirement is applicable to the supplier’s facilities where
TKCA products and services are processed as well as the Supplier's
sub-tiers.
1.5 Reworked/Replaced Material
When returning previously rejected material to TKCA, the supplier
shall reference the rejection notice number on the shipping document,
and shall state if the items have been replaced or reworked.
1.6 Supplier Audits
TKCA reserves the right to audit its suppliers for compliance with
the requirements stated in this document and applicable standards.
Either TKCA or its authorized representative may accomplish this
through scheduled audits. Suppliers will be notified ahead of time
to arrange audits.
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2.0 MANUFACTURING AND QUALITY REQUIREMENTS
TKCA approved suppliers shall establish and document process standards
and criteria for all aspects of their manufacturing operations.
These standards shall include documented quality process route sheets
and processing specifications that identify specific requirements.
2.1 Inspection Standards
Inspection standards for evaluation of the manufactured product
based on drawings and engineering specifications, shall be established
and documented. Inspection sample plans may be used to evaluate
product quality. The use of established plans will be followed such
as:
• Mil-Std-105E
• Dodge-Romig LTPD/LQ • Mil-Std-414
2.2 Acceptable Quality Levels
It is incumbent upon the supplier to establish Acceptable Quality
Levels (AQLs) to ensure acceptable product quality levels are maintained.
AQL selection is regulated by the capability of the manufacturing
process to maintain tolerance. In all cases, it is based on statistical
probability and does not relieve the supplier from maintaining tolerance
conformance on all parts.
2.3 Workmanship Standards
Workmanship standards shall be in compliance with those specified
on the drawing or specification, or when not acknowledged, in accordance
with best available industry standards. If internal standards are
developed, or industry standards are used such as ANSI or SAE, they
must be compliant with invoked standards. Supplier quality standards
must also be acceptable to and approved by TKCA’s Quality Assurance
Department.
2.4 Statistical Process Controls
TKCA encourages the use of statistical methods to control quality.
Such methods include Statistical Process Control (SPC) techniques.
In some cases, TKCA may require the supplier to submit quality control
plans and process flow charts in advance of the manufacturing process.
2.5 TKCA Owned Material
Suppliers shall establish written procedures for the verification,
storage, maintenance, and accountability of TKCA provided material,
products, tools and equipment for use in manufacturing goods for
TKCA. Material includes drawings, specifications, and official correspondence.
Any items that are lost, damaged, or unusable, shall be reported
to TKCA promptly.
2.6 Manufacturing Processes
The supplier shall have procedures for the positive identification
and control of all components, including raw materials, used during
manufacturing, processing, and delivery in order to determine traceability
to raw materials and audit- in the event of a recall. The supplier
shall ensure that all materials used in the manufacturing process
of products to be delivered to TKCA shall be inspected, tested or
otherwise verified to be in conformance, prior to use, manufacturing,
assembly or shipment. Any material determined to be non-conforming
shall be noticeably identified and segregated to prevent commingling
with compliant material. Non-conforming material can only be reworked
back to drawing or specification requirements or rejected. Material
that cannot be reworked to specifications will not be used without
the approval of TKCA Quality Assurance. Packaging methods used by
the supplier shall will be to best commercial standards and will
be “over-packed” thereby assuring that the product will not be damaged
during transit and integrity maintained. The contents of any “multi-packed”
containers will be clearly marked and material segregated. Prior
to delivery, suppliers will ensure that product meets all requirements,
standards, and acceptance criteria. Supplier records shall be archived
for seven years and readily available. Records created by and/or
retained by suppliers shall be stored in such a manner as to prevent
deterioration and be readily retrievable and available.
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3.0 FIRST ARTICLE INSPECTION
All parts/material/components delivered to TKCA must comply with
all drawing and specification requirements by the manufacturer.
All dimensions and specifications must be validated by the supplier.
TKCA will randomly verify dimensions of incoming lots. Major characteristics
are inspected and verified with randomsampling. Any deviations
must be rationalized. Compliance to requirements must be demonstrated
by submitting a first article inspection report with the first lot
shipment of product and with the first lot shipment of each subsequent
revision. First article inspection reports must include serial numbers
(where applicable), all dimensions, general notes, tolerance ranges,
actual measurements, and where physical testing is required, the
results of the tests. First article parts must be identified as
"First Article" by tagging, painting, or other suitable means of
identification. Additional first article inspection shall be performed
when:
• New manufacturing processes or new methods are used that could
effect compliance to drawing requirements
• New, reworked or transferred tooling is used
• A drawing revision effects the operation(s) performed by the supplier.
Suppliers will provide measurements / test results and characterization
data in report format detailing results and findings as required
by PO.
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4.0 CORRECTIVE ACTIONS
Suppliers must have a system for tracking any corrective actions.
Corrective action refers to an internal problem solving process
initiated to prevent future delivery of defective product. Emphasis
should be on identifying potential problems and implementing a solution
at the source. Corrective actions should be integral to the supplier’s
Continuous Improvement Program. Corrective actions should be performed
by individuals knowledgeable in the area or process that caused
the defect. Failure analysis will conducted to identify the cause
of the problem, proposed resolution and solution implementation.
Corrective actions and solutions should be documented and verified.
4.1 Corrective Action Request
TKCA may request corrective action via a written Corrective Action
Request (CAR). A CAR may be initiated due to:
• Rejection of material
• Trends
• Repeated rejections or failures
The cause for rejection will be annotated on the CAR that accompanies
the returned material/parts. The supplier has the responsibilities
as described above and must explain corrective actions as required.
4.2 CAR POC
The supplier will provide a designated POC for CAR processing. The
CAR form originates from TKCA’s Quality Assurance and is addressed
to a designated POC within the supplier's facility. The CAR specifies
quantities of parts rejected and the nature of the rejection. The
supplier is responsible for analyzing the defect as stipulated in
the CAR. The CAR should be reviewed and authenticated by supplier’s
management for concurrence and then returned to TKCA’s Manager of
Quality for review and approval. Where applicable, suppliers must
provide a CAR response within 15 calendar days of receipt. If response
is not received within the 15 day period, a reminder call, email,
or letter will be sent by TKCA QA. If CAR’s are not responded to
within 30 days of receipt, TKCA reserves the right to terminate
for cause any outstanding or open purchase orders with the supplier.
Unusual or extenuating circumstances that require additional time
to resolve should be arranged in advance by the supplier through
TKCA' s Quality Assurance Department.
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5.0 SUPPLIER SURVEYS AND SOURCE INSPECTIONS
TKCA Quality Assurance representatives may perform on-site surveys prior to the first scheduled delivery of products. Surveys are employed to determine the supplier's ability and capabilities to produce a compliant product, in the correct configuration that will meet specified requirements of drawings, specifications, and purchase orders.
Surveys will be arranged through the supplier and can typically be accomplished within the duration of one day. The date and time of the survey will be arranged in advance through TKCA QA Department.
The success of the audit will be determined upon the supplier's ability to demonstrate its capability to consistently produce the product in compliance with the requisite specifications, applicable drawings and purchase orders. See Figure 5.1-1 Below.
Figure 5.1-1 Quality Survey Criteria
5.1 Dock to Stock Certification
TKCA may also survey qualifying suppliers for the purpose of dock-to-stock performance and ability to supply parts on a routine basis. Certification surveys will normally take one to two days to complete. Certification will be done on a part number basis arranged with TKCA Quality Assurance through the buyer.
Source inspections may be performed at the supplier's location/plant by TKCA or a designated representative.
A designated source inspector will verify that the material to be shipped complies with the requirements stipulated in the specifications, drawings and PO’s.
The supplier will provide required inspection information and manufacturing documentation to provide evidence of configuration control and acceptability.
The supplier will provide any required inspection/test equipment and personnel to permit the source inspector to conduct inspections and verify results.
A Certificate (Cert) of Compliance (CoC) will be supplied with each shipment of parts when required by the purchase order. Cert’s shall include:
• Supplier’s name, address, and telephone number
• Part Number/NSN (where applicable)
• Lot number and quantity (where applicable)
• Date code (where applicable)
• Certification references, i.e. Mil, FAA, DoD statement authenticating that all parts comply with drawing, specification, Technical Order (T.O.), and purchase order requirements
• Statement of traceability for raw materials and processes to the products delivered to TKCA
• Approval signature(s) by an authorized supplier representative(s)
• TKCA Purchase Order number
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6.0 REQUESTS FOR CONFIGURATION CHANGES/VARIATIONS
Upon receipt, the supplier must thoroughly review the documentation and Purchase Order provided by TKCA. All associated drawing changes and related engineering specifications and test procedures should be in the supplier's possession. Any relevant questions should be directed to the TKCA buyer representative.
When quoting a commodity, the supplier must thoroughly evaluate its capability to deliver. The supplier is solely responsible for making a quote based on drawings and specifications. The TKCA buyer representative should be contacted for any clarification.
The supplier is responsible for alerting TKCA to any discrepancies or problems as soon as they arise or are anticipated.
Requests may be through TKCA QA to accept the product with a minor variation. The variation should be of an inconsequential nature such that it will not affect form, fit, function or configuration. The product should be of a value that scraping it would be uneconomical. Requests will only be accepted in writing and considered only for unusual circumstances. Such requests will not be accepted on a routine basis. Variations will be considered only for those materials being shipped.
Deviation requests must include:
• Part Number
• Purchase Order Number
• Quantity
• Description of discrepancy(s)
• Corrective action(s)
Lots with the same discrepancy will not be accepted. The supplier must implement corrective action to prevent recurrence. If a specific parameter is impossible to meet, the supplier should request a review by TKCA.
note: Supplier agrees not to make any change in materials or design detail which would affect the part or any component part there of with regard to (A) Part Number Identification, (B) Physical or Functional Interchangeability, and (C) Repair, overhaul, processes, and material changes which effect these procedures without prior written approval of TKCA.
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7.0 METROLOGY
All TKCA suppliers are required to comply with the calibration system described by ISO 10012, Mil-Std-45662, ANSI/NCSL Z540-1, or equivalent.
The goals of this system are to ensure the accuracy of all measuring and test equipment used in a supplier's facility, and to prevent or readily detect inaccuracies and provide for immediate correction. Basic calibration system requirements are:
• Written Description
• Standards
• Equipment
• Traceability to National Institute of Standards and Technology (NIST)
• Calibration schedules and intervals
• Recall System/Procedures
• Individual equipment records/histories
• Written calibration instructions and
• Published standard practices
• Labeling
• Analysis of calibration results
• Provisions for out-of-tolerance conditions
