Quality Program Summary

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Aerostar Manufacturing – Quality Program Summary

Creating a comprehensive Quality Program for a machining company adhering to ISO-9001:2015 and IATF 16949:2016 requires meticulous planning and execution. The program is aimed at ensuring a high level of quality, efficiency, and consistency in product output, along with meeting all the requirements of international quality management systems. Here’s a detailed outline of how a quality program may be devised for inspection and testing procedures you’ve mentioned.

Quality Program Outline

1. Introduction and Scope

  • Description of the machining processes
  • Scope of the Quality Program in accordance with ISO-9001:2015 and IATF 16949:2016

2. Roles and Responsibilities

  • Identifying roles and assigning responsibilities for quality control, audits, and compliance

3. Training and Skill Development

  • Detailed training plans and competency requirements for quality control personnel

4. Calibration and Maintenance of Instruments

  • Procedures for maintaining and calibrating the gages, AOI systems, and other inspection instruments

5. Documentation

  • Quality Manual
  • Procedure Documents
  • Work Instructions
  • Records and Forms

6. Inspection & Testing Procedures

A. Variable Gage Inspection

  1. Procedure: Steps for setting up and calibrating the variable gage
  2. Inspection Criteria: Tolerances, specifications
  3. Data Collection: Data logging methods
  4. Audit Plan: Schedule for internal audits

B. Automatic Optical Inspection (AOI)

  1. Procedure: Calibration and setting up of the AOI system
  2. Inspection Criteria: Defect detection parameters
  3. Data Collection: Image capture, defect logging
  4. Audit Plan: Regular audits to ensure effectiveness

C. Surface Finish via Attribute Gage

  1. Procedure: Instructions for using attribute gages for surface finish checks
  2. Inspection Criteria: Acceptable surface finish grades and tolerances
  3. Data Collection: Data logging methods
  4. Audit Plan: Schedule for internal audits

D. In Process Inspection (IPI)

  1. Procedure: Steps for conducting in-process inspections
  2. Inspection Criteria: Quality checkpoints, tolerances
  3. Data Collection: Real-time data capture
  4. Audit Plan: Regular audits to verify procedures

E. Go Thread Gage

  1. Procedure: Calibration and gaging procedures
  2. Inspection Criteria: Thread tolerances and specifications
  3. Data Collection: Data logging methods
  4. Audit Plan: Periodic internal audits

F. Notched to Depth

  1. Procedure: Inspection methods for checking notch depth
  2. Inspection Criteria: Depth tolerance, specifications
  3. Data Collection: Data logging methods
  4. Audit Plan: Internal audits as required

G. Bore Gauge

  1. Procedure: Calibration and bore measurement procedures
  2. Inspection Criteria: Bore size tolerances
  3. Data Collection: Data logging methods
  4. Audit Plan: Scheduled audits

H. Spray with RP (Rust Preventative Application)

  1. Procedure: Steps for RP application
  2. Inspection Criteria: Checkpoints for even coating, longevity
  3. Data Collection: Application log, coating checks
  4. Audit Plan: Audits to ensure compliance

7. Non-Conforming Products

  • Procedures for identifying, segregating, and addressing non-conforming products

8. Corrective and Preventative Actions

  • Process for identifying root causes of non-conformities and implementing corrective and preventive measures

9. Audits and Reviews

  • Plan for internal and external audits
  • Management review procedures

10. Continuous Improvement

  • Methodologies like PDCA (Plan-Do-Check-Act), Six Sigma for continual improvement

11. Appendices

  • Relevant standards, forms, logs, and templates

Key Considerations

  1. Internal Audit: Regular audits to ensure that the procedures are followed rigorously.
  2. External Audit: Audits by external agencies to ensure compliance with ISO-9001:2015 and IATF 16949:2016.
  3. Data Analysis: Advanced data analysis methods, possibly involving statistical methods, to analyze data collected during inspections.
  4. Risk Management: FMEA (Failure Modes and Effects Analysis) for risk assessment.
  1. Traceability: Ensuring traceability of products to allow for recall and analysis in case of non-conformity.
  2. Review and Update: Periodic review of the Quality Program to incorporate changes in standards, technologies, and business requirements.
  3. Customer Feedback: Mechanism to collect customer feedback and integrate findings into the Quality Program.