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Braddock Quality Assurance Manual

Document Pages 1 of 30 Braddock Quality Assurance Manual Approved By:* George Gieger, President Roy Adkins, Corporate Director of Quality *(Actual Signature Page on file.) Document Pages 2 of 30 Braddock




Document Pages 1 of 30 Braddock Quality Assurance Manual Approved By:* George Gieger, President Roy Adkins, Corporate Director of Quality *(Actual Signature Page on file.) Document Pages 2 of 30 Braddock Metallurgical has strategically developed and implemented a quality management system using; the organizational environment, changes in the environment, and the risks associated with that environment. Braddock s varying needs, particular objectives, the service we provide, the processes employed, and lastly the size and organizational structure, to demonstrate our ability to provide consistent activities that meet customer, statutory and applicable regulatory requirements applicable to the services we provide. Braddock addresses customer satisfaction through the effective application of the system, including continual improvement and the prevention of nonconformities. The quality system complies with the international standards ISO 9001:2008, and AS9100, other Customer Requirements, and Mil-I The purpose of this manual is to define and describe the quality system, to define authorities and responsibilities of the management personnel involved in the operation of the system, and to provide general procedures for all activities comprising the quality system. Another purpose of this manual is to present the quality system to our customers and other external interested parties, and to inform them what specific controls are implemented at Braddock Metallurgical to assure quality. Braddock Metallurgical Locations included in the Scope of this Manual: Duval Place West Jacksonville, FL Chimney Rock Road Bridgewater, NJ S. 78 th Street Riverview, FL Industrial Way Boynton Beach, FL Fentress Boulevard Daytona Beach, FL (Includes Corporate Office) 1590 Huber Street NW Atlanta, GA Sam Wilson Rd. Charlotte, NC 28214 Document Pages 3 of GENERAL POLICY Braddock Metallurgical uses the process approach methodology when developing, implementing and improving the effectiveness of our quality management system to enhance customer satisfaction by meeting our customer requirements 1.1 Braddock has determined, managed and linked numerous activities known as a Braddock process. The Braddock definition of a process is an activity or a set of activities using resources and managed in order to enable the transformation of inputs into output and often the output from one process directly forms the input to the next. 2.0 Continuous Improvement is based on the methodology known as Plan-Do-Act-Check-Act and can be applied to all processes. A model of the Braddock Metallurgical Process-Based Quality Management System is shown below: Plan: Do: To establish the objectives and processes necessary to deliver results in accordance with customer requirements and Braddock policies. Implement the process. Check: Monitor and measure the processes and product against policies, objectives and requirements for the product and report the results. Act: Take the appropriate action(s) to continually improve process performance. Continual Improvement of the Quality Management System Management Responsibility Customers Requirements Input Resource Management Measurement analysis and improvement Product Realization Product Output Customers Satisfaction Pages 4 of :2008/AS9100C The quality management system at is relevant to the nature of our organization, product / services and to customer and regulatory requirements. Those requirements of AS 9100C and/or ISO 9001 (2008) that do not apply are excluded from the scope of our quality management system. The Director of Quality Assurance is responsible for identifying and reporting to Top Management those sections of the AS9100 and ISO 9001 standards that do not apply to our organization or our products and services, and to propose exclusions to such requirements from the scope of the quality management system. Top management and the Management Representative have the responsibility and authority for evaluating whether the proposed exclusions are appropriate, and for approving them. EXCLUSIONS 3.0 Exclusions: AS 9100C/ISO 9001 (2008) Section 7.3, Design and/or Development, including all subsections. Section , Post Delivery Support, subsection a, c, d, e). 3.1 Justification of AS 9100C/ISO 9001 (2008) Section 7.3, Design and/or Development, including all subsections and , Post Delivery Support, subsection a, c, d, e): Braddock Metallurgical does not design or develop product. All principal product characteristics are specified by our customers or their consultants. Our engineering activities are limited to developing methods, means of processing and streamlining production. In addition, Braddock Metallurgical does not offer servicing or post-delivery support on any product other than warranty of our service(s). Our activities are limited to processing metals to customer requirements, specifications. Providing re-processing or rework when problems are detected after delivery. Note: The FAA Manual used by the Boynton Beach facility is not subject to the controls and requirements of this Quality Manual, the AS9100 certified QMS, or supporting procedures. The FAA Manual applies to the Boynton Beach Repair Station, Certificate # S2UR808J only. Although the Repair Station activities may generally follow the Braddock Metallurgical QMS, should contradictions occur; the FAA Manual will take precedence for Repair Station activities. All other activities at the Boynton Beach FL facility, excluding the FAA Repair Station, are covered by this Quality Manual, the AS9100 certified QMS, and supporting procedures. Document Pages 5 of General Requirements PROCEDURAL POLICIES Braddock Metallurgical is committed to establish, implement, and maintain a documented Quality Management System and continually improve its effectiveness, in conformance with requirements of the AS9100 and ISO 9001 Quality Standards, Statutory and Regulatory requirements, and the requirements of our Customers. Quality System Processes Processes needed for the quality management system have been determined, and are defined in this quality manual, and associated operational procedures and work instructions. This documentation shows the clear sequence and interaction of processes, and how to effectively implement and apply these processes throughout the organization. Quality system documentation also determines criteria and methods needed to ensure that the operation and control of quality system processes are effective. This includes assignment of responsibilities and allocation of resources needed, and definition of monitoring and measuring methods, analyzing data for effectiveness of the QMS processes. Resources and information The Quality Assurance Representative for each plant is responsible for determining resource and information requirements necessary to support the operation and monitoring of quality system processes, and for communicating these requirements to the top management. The top executive management is responsible for ensuring the availability of necessary resources and information. Section 6.1 of this quality manual, Provision of Resources, explains in more detail how resource requirements are identified and satisfied. Monitoring and measurement The performance of quality system processes is systematically monitored and/or measured. This is to ensure their effectiveness and identify opportunities for improvement. The performance of product realization processes is monitored by measuring process parameters and/or product characteristics resulting from the process; and through the program of inspections and tests applied to the product. The performance of processes required for the quality management system is monitored through internal quality audits, by review of data presented during Management Review meetings, and by measuring customer satisfaction. Monitoring and measuring activities are defined in Sections 8.1 and 8.2 of this quality manual, and in the corresponding operational procedures. Outsourced processes When processes that affect product conformity are outsourced, Braddock ensures that special controls are implemented to ensure that these processes meet specified requirements. Such controls shall include: Pages 6 of 30 Risk assessment evaluation and pre-qualification of suppliers; assessment of supplier realization processes and quality system; monitoring of supplier quality performance; requirements for inspection, testing or other records demonstrating product conformity; or containment and verification of the supplied product. Section 7.4 of this quality manual and the corresponding operational procedures define the purchasing control system. Processes needed for quality management system referred to above, may include processes for management activities, provision of resource, product realization, measurement, analysis and improvement. An outsourced process is a process that the organization needs for its quality management system and which the organization chooses to have performed by an external party General The scope of the quality system documentation is defined. Establishment and revision of documents, records and their distribution are controlled. New documents, records and revisions are reviewed and approved prior to issue; and are identified with respect to their revision level. Appropriate documents and records are available at locations where they are used. Obsolete documents and records are removed from points of use. Documents of external origin determined by Braddock Metallurgical to be necessary for the planning and operation of the Quality Management System (QMS) are identified and their distribution is controlled. Quality records are identified and indexed to facilitate their retrieval, and are stored in a suitable environment to minimize deterioration. Quality records are retained for a period of time at least equivalent to the lifetime of the product. Scope Braddock Metallurgical quality system documentation comprises the following types of documents and records determined by Braddock to be necessary to ensure the effective planning, operation, and control of the processes: Quality manual (including a documented quality policy); Documented statements of quality objectives Quality system requirements imposed by the customer and/or regulatory authority Operational procedures required by the AS9100 standard; Travelers; Furnace Log Sheets; Furnace Records and other documented records; Work instructions; Standards and other technical reference materials; Engineering documents, including drawings, specifications, procedures, and other documents defining products; Pages 7 of 30 NOTE: No O.E.M. Specifications shall be shared with any non Braddock Metallurgical Employee unless they have written authorization to view and research the specifications, due to Proprietary Agreements between Braddock Metallurgical and the various O.E.Ms. Customer engineering documents; Product realization and control plans; The Purpose, scope, and responsibility for controlling various types of documents are defined in Operational Procedure SOP-42-02, Control of Documents. A single document may address the requirements for one or more procedures. A requirement for a documented procedure maybe covered by more than one document Quality Manual The top level document defining the overall quality management system is the Quality Manual. It includes: The scope of the quality system, including details of and justification for any exclusions Description of quality system processes, their sequence and; References to documented procedures; Note: The FAA Manual used by the Boynton Beach facility is not subject to the controls and requirements of this Quality Manual, the AS9100 QMS, or supporting procedures. The FAA Manual applies to the Boynton Beach Repair Station, Certificate # S2UR808J only. Although the Repair Station activities may generally follow the Braddock Metallurgical Inc. QMS, should contradictions occur; the FAA Manual will always take precedence Document control Braddock Metallurgical is gradually transitioning from paper to electronic documentation. As this transition progresses, new categories of documents are transferred from paper to electronic document control system. Both systems are currently used, and are defined in Procedure SOP-42-02, Control of Documents. Documents of external origin determined by Braddock Metallurgical to be necessary for the planning and operation of the quality management system are identified and their distribution controlled and records are controlled in accordance with clause New documents and document changes may be initiated by anyone in the organization, but may only be issued by an authorized function. The authorized functions and the rules governing the issue of documents are defined in procedure SOP-42-02, Control of Documents. Documents may be distributed to personnel and locations where they are used. Electronic documents, which include the entire quality management system, are available to all employees and Document Pages 8 of 30 Customers and/or regulatory authorities in the Q Drive and are accessible any terminal linked with the Braddock network. Document placement is regulated by Procedure SOP Obsolete documents are removed from points of use. Retained masters or copies of obsolete documents are properly marked and are kept separate from active documents. Obsolete electronic documents if retained, are stored in directories or areas that are only accessible to authorized personnel. Document changes are reviewed and authorized by the same function that issued the original document, or the current relevant authority. All electronic Master documents are be controlled by password access only. Read only electronic documents are open to anyone linked to the Braddock network. The server used for Visual Shop (all electronic processes which create Travelers) is backed up daily to prevent loss of data due to any failure. Due to varying activities performed at each individual Braddock Metallurgical Inc. plant, site specific procedures or work instructions may be created and established that apply to that particular plant only. These documents are created and approved in accordance with procedure SOP-42-02, Control of Documents Control of quality records Quality records shall be established, maintained and controlled to provide evidence of conformity to the requirements and of the effective operation of the quality management system: Records are established by personnel performing the task, operation, or activity the results of which need to be recorded. Records are dated; and identify the product, person, or event to which they pertain. Records are normally stored by the same department that initially established the record. Records are stored in dry and clean areas, and electronic records are regularly backed up. Quality records and documents may not be stored in private desk drawers, unauthorized computer drives, or other obscure locations that are not generally known. Retention periods for quality records are determined on the basis the lifetime of the product or the event to which the record pertains, and on regulatory and contractual requirements. Categories of quality records maintained by Braddock Metallurgical are listed in Operational Procedure SOP-42-03, Control of Quality Records. The list identifies specific types of records for each category; their storage location; and retention period. 5.1 Top Management For the purpose of administrating the quality management system, top management is defined to include the President and managers responsible for operations, engineering, marketing, sales, human resources, and quality assurance. Document Pages 9 of 30 Customer requirements Top management is committed to communicate the importance of meeting customer as well as regulatory and legal requirements. Management representative is responsible for implementing this commitment by promoting awareness of customer requirements throughout the organization. This responsibility of management representative is stipulated in Section 5.5, Organization and Communication. Quality policy and quality objectives Top management defines the purpose and objectives for the quality management system. They are documented and communicated in the form of quality policy and quality objectives. Processes for establishing the quality policy and quality objectives are defined in this manual in Section 5.3, Quality Policy, and Section 5.4, Quality System Planning. Management Reviews Top management periodically reviews the quality management system to ensure its continuing suitability, adequacy, and effectiveness. The review evaluates current status and performance of the quality system and initiates actions for further improvement of the system. The process for conducting management reviews is defined in Section 5.6 of this manual and in Operational Procedure SOP-56-01, Management Review. Resources Top management is committed to providing resources necessary for establishing, implementing, and improving the quality management system. Section 6.1 of this manual defines processes for identifying resource requirements and allocation of resources for specific activities and projects. 5.2 Customer Focus Determining customer requirements Customer requirements are understood broadly to include all aspects of products and associated services that can influence customer satisfaction. When relevant, this may also include customer needs and expectations, measuring product conformity, and On Time Delivery (OTD) through trending and internal audits. When planned results are not met, the use of corrective action, preventive action, and customer depositions are used. Customer requirements are determined and verified through the process of order review. This process is defined in operational procedure SOP Customer Purchase Order/Contract Review. Customer needs and expectations Marketing is responsible for collecting and analyzing information on customer needs and expectations. Information about customer needs and expectations is also extracted from customer Document Pages 10 of 30 Feedback, complaints, and customer satisfaction data. Operational Procedures SOP-72-03, Customer Feedback and Complaints, and SOP-82-01, Customer Satisfaction, define how this data is collected and used. Fulfillment of customer requirements The whole quality system is designed and implemented to ensure that customer requirements can be consistently fulfilled. 5.3 Quality Policy QUALITY POLICY/MISSION STATEMENT We are dedicated to providing our customers with an exceptional level of heat treating quality and customer service utilizing value added continuous improvement. We accomplish this by having the proper FOCUS on our customers and PRIDE among our employees. Facilitating partnerships with customers and employees Optimizing technology Continually improving Understanding customer s needs Sustaining organizational excellence And Personal Responsibility In Developing Excellence George Gieger, President The Quality Policy is established by the top management and is approved by the President and the board of directors and ensures the quality policy is appropriate to the purpose of Braddock Metallurgical. Any changes to the policy must be likewise approved by the President and the board. Pages 11 of 30 The quality policy is posted throughout the company, and its role is explained to all employees. The quality policy is also communicated to customers, consumers and other interested parties. For this purpose, it is displayed in the reception area and posted on the company s internet site. The quality policy is periodically reviewed within the framework of management reviews of the quality system, to ensure its continual relevance and suitability Quality Objectives Quality objectives are established throughout the organization to implement the quality policy, to meet requirement