SUPPLIER QUALITY MANUAL Valcor Engineering Corporation SQM-001
Valcor Engineering Corporation SUPPLIER QUALITY MANUAL SQM-001 August 20, 2014 Uncontrolled when printed. Verify document revision online at www.Valcor.com ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual Contents 1.0 Supplier Quality Visual Model ........................................................................................................... 4 2.0 Valcor’s Quality Policy ....................................................................................................................... 5 3.0 Introduction ...................................................................................................................................... 5 3.1 Precedence of documents ............................................................................................................ 5 3.2 Certificate of Conformance and Analysis ...................................................................................... 6 3.3 Record Retention .......................................................................................................................... 6 3.4 Flow-Down to Sub-Tier Suppliers.................................................................................................. 6 3.5 Foreign Object Damage (FOD) Prevention.................................................................................... 6 3.6 Right of Access .............................................................................................................................. 7 3.7 Export Control ............................................................................................................................... 7 4.0 Supplier Approval Process ................................................................................................................ 8 5.0 Supplier Audit Process .................................................................................................................... 10 6.0 Change Request .............................................................................................................................. 12 7.0 Non-Conformances ......................................................................................................................... 13 7.1 Supplier Deviation Flow Chart .................................................................................................... 13 7.2 Supplier Quality Escape Flow Chart ............................................................................................ 15 8.0 Supplier Corrective Action .............................................................................................................. 17 9.0 Delivery Requirements.................................................................................................................... 19 9.1 Packaging .................................................................................................................................... 19 9.2 Foreign Object Damage (FOD) .................................................................................................... 21 9.3 Labeling ....................................................................................................................................... 21 10.0 10.1 Supplier Performance ..................................................................................................................... 22 Overall Performance Rating ........................................................................................................ 24 11.0 Dock-to-Stock Authority.................................................................................................................. 25 12.0 Valcor Owned Property................................................................................................................... 26 13.0 Appendix A: Valcor Supplier Quality Survey SF1016A .................................................................... 27 14.0 Appendix B: Deviation/Change Request SF1019A .......................................................................... 32 15.0 Appendix C: Material Rejection Report SF-104/R.03/12 ................................................................ 34 16.0 Appendix D: Corrective Action Request/Report SF1018A .............................................................. 36 Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 3 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 1.0 Supplier Quality Visual Model Budget Time Cost Supplier Managment Supplier Collaboration Supplier Information Customer Satisfaction Potential Supplier Deviation Request ScoreCard Real-time data driven Decisions Certificate Management SCAR Reference Documents Supplier Improvement Performance Audit/ 3rd Party Audit Change Request Valcor Documents and Specifications Dock-to-Stock Risk Assesmnet Certificate of Analysis/ Conformance Warranty and Cost Recovery Reduce Risk Supplier Related Customer Complaints Engineering Purchasing Quality Inspection Data ESTITRACK Quality Assurance Information Management Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 4 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 2.0 Valcor’s Quality Policy Achieve total customer satisfaction by continuously improving all work processes to satisfy our internal and external customers 3.0 Introduction Valcor’s mission is to provide innovative, high quality, reliable fluid control components and systems to customers in response to their specialty requirements. This supplier quality manual is based on prevention and continuous improvement rather than defect detection. Valcor expects their suppliers to aspire to zero defects, zero failures, and zero losses. Valcor encourages all suppliers of components, materials, or services to institute a Quality Management System that follows: AS9100 Quality Management System Requirements for Aviation, Space & Defense Organizations and/or ISO 9001:2008 International Industry Quality Standards. The Nuclear division may impose additional nuclear specific requirements depending on the nature of work. Valcor may choose to conduct on-site assessment(s) to determine the supplier’s ability to meet Valcor’s requirements. 3.1 Precedence of documents In the case of a conflict and between the requirements, the precedence of documents is as follows; 1. 2. 3. 4. Purchase order Terms and Conditions Part Drawing Supplier Quality Manual 3.2 Applicable Forms The following forms are referenced within this manual and are available from http://www.valcor.com/customer-product-support/suppliers/ Form Number Form Title SF1016A Valcor Supplier Quality Survey SF1019A Deviation/ Change Request SF1018A Supplier Corrective Action Request Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 5 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 3.3 Certificate of Conformance and Analysis All suppliers shall provide a Certificate of Conformance, Physical or Chemical Analysis, or Calibration, when applicable. Each shipment must be certified by an authorized representative with their signature, title, and date. The supplier shall verify and confirm compliance with the drawing, specification, and/or any special processes as described on the Purchase Order. Without this documentation, Valcor cannot receive the parts, and both the payment and parts will be placed on hold until resolution in documentation can be provided. The following information is required on the Certificate of Conformance at a minimum: Supplier Name, address and contact information and manufacturer’s name (if different from Supplier) Purchase Order Number Valcor part number, revision, lot, and quantity Specification Number including revisions and amendments Additional information may be required for parts returned for rework Identify when parts have been reworked Return Purchase Order Number Non-conformance Deviation Number 3.4 Record Retention Valcor shall identify supplier records requirements on the purchase order, drawing notes, or procurement specifications. The delivered product’s records shall be maintained for a minimum of fifteen (15) years at the supplier, unless otherwise specified. Upon request, the supplier shall provide copies to Valcor. 3.5 Flow-Down to Sub-Tier Suppliers Suppliers shall flow down applicable requirements noted on Valcor’s Purchase Order and Terms and Conditions to all sub-tier suppliers. 3.6 Foreign Object Damage (FOD) Prevention When applicable, noted on Valcor’s purchase order, the supplier shall establish, document, and maintain a program to control and prevent FOD during manufacturing, assembly, test, inspection, and any subtier supplier operations. This program can follow NAS412 or be an otherwise approved control by Valcor. The supplier shall maintain work areas and inspect for foreign objects/materials to reduce the risk of FOD incidents. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 6 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 3.7 Right of Access Suppliers shall allow Valcor, customers and regulatory agencies reasonable access to the applicable areas of all facilities involved in fulfilling the purchase order requirements and to all applicable documentations. Valcor has the right to conduct surveys, audits, inspections, and surveillance of Supplier’s facilities and sub-tier suppliers with prior coordination to determine capability. When required, source and/or government inspection will be noted on the purchase order. The supplier shall ensure the product is not released until source and/or government inspection is completed. 3.8 Export and Import Compliance The products, technical data and services produced and/or provided by Valcor Engineering Corporation may be subject to the provisions of the Export Administration Act of 1979 (50 USC 2401-2420), the Export Administration Regulations promulgated there under (15 CFR 730-774), and the International Traffic in Arms Regulations (22 CFR 120-130). These statutes and regulations impose restrictions on import, export, re-export and transfer to third countries of certain categories of hardware, data, technical services and information, and that licenses from the U. S. Department of State and/or the U. S. Department of Commerce may be required before such hardware, data, technical services and information can be provided/disclosed hereunder, and that such licenses may impose further restrictions on use and further disclosure of such data, technical services and information. Disclosure of data, technical services and information to foreign persons, as defined at ITAR 120.16, and at EAR 734.2(b), is subject to the above regulations regardless if the export occurs in the U.S. or abroad. Violation of these export laws are subject to severe criminal penalties. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 7 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 4.0 Supplier Approval Process This process applies to all new potential Valcor suppliers and defines Valcor’s criteria of selection and assessment. Flowchart Potential Supplier? Supplier Send survey to Supplier Supplier to fill out Survey Purchasing Quality Assurance Supplier to return survey and other required documents Review if Supplier requirements were met per survey Supplier Approved? YES Approve Supplier YES NO Determine if an Audit is needed? YES Supplier Agrees to an Audit? NO Disqualify Supplier NO NO Accept CA? Review Supplier CA YES Supplier to return corrective Action Perform Audit NO YES Supplier approved per audit? NO Work with Supplier? YES Request for Supplier Corrective Action Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 8 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual Supplier Approval Process Responsibility All potential suppliers are required to fill out a quality survey (SF1016A) to collect general information about the company and its products or services. This form will be used to indicate the standards of a potential supplier and will be performed as a self evaluation survey. Potential suppliers will be evaluated on their ability to provide a quality product based on the Supplier Quality Survey Form and the Supplier’s quality system certifications. Valcor recognizes all third –party certifications that are compliant to ISO-9001, AS9100, NADCAP, and/or ISO 17025 accreditations which an onsite audit may be waived. The supplier quality survey form and attached certifications will be assessed by Valcor’s Quality department and will reserve the right to conduct an onsite audit when deemed necessary. Suppliers that meet all requirements will be placed on the Approved Supplier List. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 9 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 5.0 Supplier Audit Process The purpose of this procedure is to establish a process to evaluate the supplier’s quality system, control of process and product quality, and the maintenance of product compliance. Audit Flow Chart Supplier Quality Assurance Audit is required Purchasing YES Disqualify Supplier NO Supplier Agrees to an Audit? YES YES Determine if a follow-up audit is needed NO YES Schedule Audit and send the Audit agenda to the Supplier NO Accept CA? Perform Audit Review Supplier CA Send Audit Report to Supplier Request for Supplier Corrective Action YES Supplier to return corrective Action NO Supplier to Review Audit Report and send a response when applicable Review Audit Report Response Send Feedback to the supplier NO Accept Supplier Response? YES Update Supplier List Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 10 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual Supplier Audit Process Procedure Valcor may conduct an audit at the supplier to make a physical evaluation of the supplier’s quality system. Audits performed at the supplier will be completed by the appointed lead auditor. Non-conformities observed during Audit Upon detection of a nonconformance, the auditor’s first concern will be to determine if any work in process is affected and will verbally notify the supplier. The supplier will immediately need to stop work on that item. In all cases of a non-conformance a quality audit report will be sent to the supplier for the purpose of initiating a corrective action plan. The report shall be submitted within a specific time period not exceeding 30 days. Follow-up audit A follow up audit at the supplier, when directed by Quality Assurance, will be performed to assure effective action has been taken to correct the significant condition. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 11 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 6.0 Change Request When required, the supplier shall not change the plans, drawings, designs, product definition, processes or specifications associated with the parts referenced on the Purchase Order. If a change is needed, the supplier and sub-supplier must receive prior written approval from Valcor. Configuration Control Flow Chart Change Request is initiated Supplier Repeat Request YES Purchasing MRB Review NO Review Change Request Approve Change Request NO Update Request database YES Make appropriate changes and update PO Communicate Y/N to supplier Procedure The supplier submits a Change Request form (SF1019A) and includes a complete description of the proposed change to Valcor’s Purchasing Department. Based on the change request, it will be evaluated by engineering, purchasing, and/or quality assurance. Once the Change Request is dispositioned, Valcor will inform the Supplier. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 12 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 7.0 Non-Conformances A non-conformance exists when a discrepancy is found in packaging, documentation, and/or quality (defects in form, fit, or function) to the part or P.O. requirements. Non-conformances will be identified: At supplier prior to shipping – Supplier Deviation Flow Chart – Section 7.1 At Valcor – Quality Escape Flow Chart – Section 7.2 7.1 Supplier Deviation Flow Chart Detect a quality deviation Supplier Purchasing Issue and forward the Deviation Request to Valcor Receive Deviation Form MRB Review Quality Assurance Send Corrective Action Request to Supplier Follow section 8.0 Recieving YES Corrective Action Required NO Approve deviation request? YES NO Notify Supplier of rejection Parts need to be replaced Send Rejected Deviation Report to the Supplier Notify Supplier of approval Annotate Deviation # on CofC Receive parts into inspection Send parts and a copy of an approved deviation to Valcor Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 13 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual Non-Conformance: Supplier Deviation Procedure The supplier shall initiate and submit a formal Deviation/Change Request (SF1019A) to Valcor for disposition (approval or rejection) of the non-conforming parts or process. The deviation form shall be completed per the following: Supplier and Part Information Current Requirement: Fully describe the current part or process requirements and specifications. Request for Deviation: Fully describe the requested deviation from the current part or process requirements and specification Reason for Request: Describe the reason for the deviation. And forwarded to Valcor’s Purchasing Department (use email unless not available, otherwise send as facsimile). The Supplier shall provide any test and inspection data to support their request for approval of the deviation. Purchasing will coordinate the disposition within Valcor and return a response to the supplier within 72 hours. Deviation Approval If the deviation request is approved, Purchasing will inform the supplier of the disposition. The Supplier is required to indicate the approved deviation number on their Certificate of Compliance/Conformance and include an approved copy of the deviation with the parts. When all paperwork has been completed and approved, the product may then be shipped. The parts or materials shipped under an approved deviation request shall be tagged with the deviation number. Deviation Rejection In the case that the deviation request is rejected, Purchasing will notify the supplier and return the rejected deviation form. The discrepant material and/or parts may not be shipped to Valcor. The supplier will then need to replace the parts to fully meet the Purchase Order specifications. Corrective Action Valcor may issue a Supplier Corrective Action based on deviation request. Suppliers must follow Corrective Action steps as identified in Section 8.0. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 14 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 7.2 Supplier Quality Escape Flow Chart Non-conformance detected Supplier Material Rejection Report (MRR) initiated and reviewed Send Corrective Action Request to Supplier Follow Section 8.0 YES Quality Assurance MRB Review Is a Corrective Action Required NO Communicate and send reports to Supplier Containment of affected items Use as is Rework in house Scrap, Rework, or Replace Return compliant parts to Valcor Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 15 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual Non-Conformance: Supplier Quality Escape Procedure The discrepancies will be documented on a Material Rejection Report (MRR). The MRR will be evaluated by Valcor’s Material Review Board (MRB) personnel who will determine the disposition of the discrepant parts and a copy will be sent to the Supplier. The supplier may contest the quality escape with objective evidence. Valcor will disposition the supplier’s parts per the following: Return to Supplier Use as is Rework in house When returned, the supplier must have a method to distinguish on paper and clearly identify if each shipped part has been: reworked replaced left unchanged If requested on the PO or drawing, the Supplier shall make Valcor aware of any processes that are outside of the regular production procedures or controlled work conditions in critical processes (forging, casting heat-treating, welding, stamping, and any other special processes). Corrective Action Valcor may issue a Supplier Corrective Action based on a quality escape. Suppliers must follow Corrective Action steps as identified in Section 8.0. Charges to Supplier Valcor, at their discretion, may choose to rework or sort any non-conforming parts to prevent interruption of the production line. Valcor reserves the right to charge the supplier for all costs associated with the quality escape. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 16 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 8.0 Supplier Corrective Action This process is to outline the Supplier’s submission of a Corrective Action report. Corrective Action Flow Chart Identify Corrective Action is needed Supplier Quality Assurance Send Correction Action Request to the Supplier Contain defective hardware MRB Review Determine Root Cause Develop a Corrective Action Plan Send Corrective Action to Valcor Communicate with Supplier Review CA Plans NO Approve CA? Audit Required? YES YES Verify findings on CA have been adressed Complete Audit at Supplier NO Close Corrective Action CAR effectiveness review Closeout CAR YES Effective? NO Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 17 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual Supplier Corrective Action Procedure A Supplier Corrective Action Request/Report (SF1018A) may be required when a nonconformance is identified. Containment must be completed within 72 hours and the corrective action plan must be submitted within 30 calendar days of the initial request. Upon Supplier notification that a Corrective Action Request plan is approved, the supplier is expected to complete all planned actions within 60 calendar days unless otherwise agreed to by Valcor. Valcor and the supplier will verify and ensure that all findings on the Corrective Action have been addressed; however they do not need to be closed at the same time. The effectiveness review due date will be determined as appropriate and will conclude if the achieved results were met. A supplier corrective action request form will stay open until the verification and effectiveness review have been validated by Valcor. An extension may be granted, only if the supplier made an initiative and periodic updates were provided to Valcor. When there is no communication made between the supplier and Valcor, the request will be denied and the supplier’s scorecard will be affected. A repeated nonconformance is an indication of poor root cause analysis and/or corrective action. If such a case arises, Valcor will pose rigid containment requirements based of the severity of the nonconformance and re-assign a second corrective action request. Due to the risk it may present to Valcor or its customers, an onsite supplier audit may be required. If the Supplier does not know how to complete the corrective action request, it is the responsibility of the Supplier to contact Valcor’s Supplier Quality Department for assistance. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 18 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 9.0 Delivery Requirements The Supplier will inform Valcor of any delay in delivering the product and provide a new date. If the Supplier ships non-conforming (quality escape) parts and materials to Valcor, the Supplier will be responsible for the return expenses. 9.1 Packaging Suppliers are responsible to ensure that parts meet same quality conditions as they were manufactured. All supplier packaged shipments shall follow good commercial practice, unless otherwise stated on the purchase order and/or drawings. Piece part Cell Packaging Acceptable Bulk Packaging - Sub- assemblies - Washers - Critical parts* - Nuts - Tubes (non-raw material) - Screws - Seats - Springs and Helicoils - Seal discs - O’Rings - Machined threaded parts - Bodies - Filters - Other parts will be noted on PO *All items that have a 16 Ra surface finish or lower (defined on the drawing) are considered as “critical parts”. The shipping container and parts requirements are, but not limited to: package each item separately to ensure adequate protection from physical contact with other parts packaging must be strong enough for the weight of the part for it to remain intact parts are cushioned against impact from each other parts are secured to prevent movement during shipment package to provide enough clearance from the item and the external packaging o To prevent product damage against shock and vibration there should be cushioning placed away from the walls of the box. Machined castings, forging parts, and other parts subject to corrosion shall be packaged with anticorrosive packaging such as capping, VCI anti-rust wrapping/bagging, plugging, covering, or any other suitable methods to prevent against cosmetic and functional damage of the part. Additional special packaging requirements will be identified on the Purchase Order or drawing. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 19 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual Packaging Requirements Examples Acceptable Packaging Suggestions -Parts packaged in single tubes to protect ends (size can vary). -Cushioned from each other to prevent shock, vibration, and damage -Sub-assembly/valves protected and adequately cushioned from the external walls -Inlet/outlet ports capped and plugged Unacceptable Packaging- will be written up on a non-conformance -Parts are able to move freely -Not protected from each other -Not enough clearance from external packaging -Sub-assembly/ valves not protected from each other. -Threaded inlet/outlet ports not protected Rust -Parts not wrapped and subject to corrosion -Parts wrapped in anti-corrosive bags Further examples go to www.Valcor.com and click the “Supplier” link. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 20 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 9.2 Foreign Object Damage (FOD) As defined on the purchase order, all parts with openings, internal and external threads shall be protected from foreign object damage. Packaging materials that generate particles, fibers, or other debris are not acceptable. Any form of “free flow or loose fill” material (such as peanuts, popcorn, or similar) regardless of material type is not acceptable as this will create a FOD hazard. Example of Packaging a FOD prone item: Example: Threaded part with caps and plastic bag Packaging Requirements 9.3 Labeling Parts and material must be identified by the supplier with an identification label on each box, crate, or container shipped to Valcor. When shipping a product, the Purchase order number must be referenced on the UPS, FedEx, or other carrier shipping label. An identification label at minimum should have the following information: Purchase Order Supplier name Box X of Y (example “Box 2 of 3” if it is the second box of a total of 3). Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 21 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 10.0 Supplier Performance Supplier performance will be monitored on a monthly basis through the purchasing and quality departments and will be available quarterly to the supplier. The data will show comparative results and will provide the strengths and weaknesses amongst individual suppliers. The measurement for supplier performance will be evaluated on the following criteria; quality and delivery. Main Categories Category Total Points Quality 100 Delivery 100 Sub-category # Quality Escapes # Deviations Past due Corrective Actions Accuracy of Paperwork/Documentation % On time Delivery Weight 60% 20% 10% 10% 100% Sub-Categories Main Category : Quality Sub-category # Quality Escapes Total Weight : 100% Weight 60% Points 100 0-99 Evaluation Basis 0 quality escapes Measures a supplier's quality impact at Valcor to meet agreed specifications .6 x (total lots -# quality escapes/ total lots ))x 100 100 # Deviations 20% 0-99 0 deviations Measures a supplier's quality impact prior shipping to Valcor to meet agreed specifications. .2 x (total lots - # deviations/ total lots ))x 100 100 On time Corrective Actions Accuracy of Paperwork/Documentation 10% 10% 0-99 0-100 0 late Corrective Actions Measure the responsiveness of a corrective action .1 x (On time Corrective Actions/ Total Corrective Actions) x 100 Measures errors that appear on the C of C (qty received PO #, part number, revision, and/or missing special processes) .1 x (# accurate documents/ total lots received) x 100 Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 22 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Main Category : Delivery Sub-category Supplier Quality Manual Total Weight : 100% Weight Points 100% 0-100 Evaluation Basis Measures the agreed delivery date on the PO % On time Delivery (on-time shipments/ total shipments received) x 100 Separate consideration will be given for low volume suppliers. Adjustments will be made as applicable to the performance categories and their weights to reflect the different purchase order requirements. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 23 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 10.1 Overall Performance Rating Valcor’s supplier rating system measures the performance of current suppliers and rates them based on a supplier scale. Performance Rating Supplier Classification Description 95 - 100% 85 - 94% Preferred Acceptable Meets all Valcor requirements in quality, cost, and delivery. Meets minimum Valcor requirements. Does not meet Valcor minimum requirements. Required written corrective action. Management approval to bid new work On Probation unless documented evaluation justifies continued use. No new business and the existing business will be phased out. Corrective Action Plan needs to be implemented and “Acceptable” status within 60 days. 75 - 84% Restricted 0 - 74% Unacceptable Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 24 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 11.0 Dock-to-Stock (DTS) The DTS program exempts a supplier’s parts from routine incoming inspection at Valcor. Suppliers that produce high quality parts and have an effective quality system can be considered a candidate for the Dock-to-Stock program. To become a DTS candidate, the supplier must achieve: A performance level of 100% lot acceptance based on the most recent 12 months or 10 most recent lots 98% or better piece count acceptance An approved on-site surveillance (if appropriate) to assure that product quality will be maintained No open or late corrective actions for the part number (or family of parts) Demonstrate certification and/or compliance to AS9100, ISO9000, or equivalent The supplier’s part will continue to be put through a random inspection frequency determined by Valcor. Note: This program does NOT apply to Valcor Nuclear products. Advantage of DTS: Certified “Dock-to-Stock” suppliers will be considered ahead of non-DTS for additional business Non-compliant part If a deviation to the blueprint is found at the supplier’s facility follow Section 7.1 (Supplier Deviation). However, when a nonconformance is identified at Valcor, the supplier’s part may be removed from Dock-to-Stock authority, and will follow Section 7.2 (Supplier Quality Escape). In addition, suppliers failing to maintain an overall score of 95% rating two consecutive quarters may be put on probation. A supplier on probation may only be returned to the Dock-to-stock program when 10 consecutive lots have been accepted without rejection or when the quarterly performance rating meets the 98% requirement in two consecutive quarters. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 25 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 12.0 Valcor Owned Property The supplier, at their facilities, is responsible for the maintenance and protection of Valcor owned property. The supplier is required to establish control methods that will help prevent property loss, damage, or mishandling. Valcor owned products can consist of the following but not limited to: Re-usable packaging containers Tooling Gages Inspection gages damaged or not sent to Valcor with the product will be considered as late, and result in an on time delivery score reduction. To protect Valcor’s investment, the supplier is responsible for the following furnished items: Raw material Partially process components Sub-assemblies The supplier needs to notify Valcor immediately of a nonconformance, and if needed, a corrective action will be requested. Liability for the occurrence, per case, shall be determined and discussed with the supplier. Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 26 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 13.0 Appendix A: Valcor Supplier Quality Survey SF1016A Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 27 of 39 VALCOR SUPPLIER QUALITY SURVEY FORM GENERAL INFORMATION Street Address Supplier’s Name City State Zip Phone Fax Website Major Product/Process CHECK APPLICABLE BOXES SURVEY TYPE: Self Evaluation On-Site Evaluation rd 3 Party For VALCOR use Only SURVEY CLASSIFICATION: Distributer Processor Manufacturer Other _________________________ # OF EMPLOYEES Manufacturing Engineering Approved Disapproved Conditional Approved By:__________________Date_________ KEY SUPPLIER MANAGEMENT PERSONNEL President/ Owner Quality Mgr. Name Total Personnel Sales/Service Production Quality Assurance Engineering Other BUILDING/FACILITIES Type: Square Footage Corporation Partnership Established since Individual % of Manufacturing Capacity Utilized To whom does the Quality Organization report to? Is a current organization chart available? YES NO Quality Control Inspection Is security clearance required? YES NAME OF MAJOR CUSTOMERS: THREE (3) MINIMUM APPROVAL DATE CUSTOMER NAME CUSTOMER NAME NO APPROVAL DATE QUALITY PROGRAM Do you have a written quality manual? YES NO If yes, Title of Q.A. Manual_____________________________ Rev____________ Date _________________ Does your quality program meet the following (check all those applicable) For suppliers ISO-9001, AS9100, NADCAP, and/or 17025 accredited: complete the above section only, and sign the last page. Include a copy of your certificates and your Quality Assurance Manual. MIL-Q-9858A MIL-I-45208A MIL-STD-45662 AS9001 ISO-9001 NQA-1 10CFR50, Appendix B ANSI N45.2 ISO 17025 NADCAP A2LA If none of the above are applicable, describe the Quality Management System: 2 LAWRENCE ROAD ▪ SPRINGFIELD, NJ 07081 TELEPHONE: 973-467-8400 ▪ FAX: 973-467-9391 Valcor Supplier Quality Survey Form Revision Date: 21 November 2013 Form # SF1016A Page 1 of 4 VALCOR SUPPLIER QUALITY SURVEY FORM SPECIAL PROCESS For each special process performed in-house and at sub-tier suppliers, list the processes and governing specifications and standards (AWS D17.1, J-STD-001, AMS2700, etc.). Attach supporting evidence that substantiates process approval. Process Specification(s) Standard(s) Expiration Date Welding Soldering Plating Painting Surface Finishing Other SUPPLIER SELF EVALUATION QUESTIONNAIRE 1.0 MANUFACTURING CONTROL & INSPECTION A. Is there a definite training program for inspectors & other personnel whose job function affects product quality? On job training, Classroom B. Are inspections documented and do records provide evidence of the following: Lot quantity, Level of inspection, result of inspection C. Are incoming parts/material inspected to verify compliance to PO requirements? YES NO N/A YES NO N/A D. Are end products inspected/tested before delivery to customer? E. Does the program provide provision of material traceability where applicable? F. Do you use Statistical Process Control (SPC) to control major processes? G. Is sampling inspection utilized? Based on what plan? _________________________________________________________ H. Does the program address retention time of inspection records? __________months/years. I. Is software, when used in the manufacture and inspection of product, controlled? 2.0 CALIBRATION CONTROL A. Is there a gauge calibration system? B. Do you allow the use of personal gauges? C. Are procedures in effect which describe the method and frequency of calibration? D. Is measuring and test equipment marked to indicate calibration status and when next calibration is due? E. Is adequate measuring equipment available to inspection for verifying conformance of supplies/materials? 2 LAWRENCE ROAD ▪ SPRINGFIELD, NJ 07081 TELEPHONE: 973-467-8400 ▪ FAX: 973-467-9391 Valcor Supplier Quality Survey Form Revision Date: 21 November 2013 Form # SF1016A Page 2 of 4 VALCOR SUPPLIER QUALITY SURVEY FORM F. Is there an evaluation recall and notification procedure of hardware inspected by a gauge later found to be out of tolerance? 3.0 PROCUREMENT/ MATERIAL CONTROL YES NO N/A YES NO N/A YES NO N/A YES NO N/A YES NO N/A YES NO N/A A. Are procurement sources controlled to assure that all procured material meets all imposed requirements? B. Is a list of approved sources maintained and periodically reviewed for status? C. Are certifications/test reports of purchased material required? 4.0 EVALUATION OF SUBCONTRACTORS A. Are the records of acceptable subcontractors such as an “Approved Supplier List” or other such document? B. Is there confirmation that the quality system controls are effective at the subcontractors? 5.0 DOCUMENT CONTROL POLICY A. Has a process been established to control all documents, data, and engineering drawing that relate to the purchase order, including to the extent applicable, external standards, and customer drawings? B. Is there a system for identification/ retrieval/ removal of obsolete documents from all points of issue or use? C. Are all inspection records being kept and maintained? 6.0 NON-CONFOROMANCE AND CORRECTIVE ACTION A. Is control established to prevent nonconforming material from inadvertent use? B. Does the Material Review Board consist of both Engineering and Quality Personnel? C. Is corrective action obtained on significant or repetitive non-conformance? D. Is customer authorization obtained before delivering items that deviate from contractual requirements? E. Do you perform Internal Audits? 7.0 PACKAGING/SHIPPING/STORAGE A. Are procedures written controlling the preservation, packaging, and shipping processes? B. Do you maintain in-house or subcontracted packaging facility to meet special customer requirements? C. Is material with life, age or other limitations controlled and identifiable to the limitation and remaining usefulness? 8.0 HOUSEKEEPING/SAFTEY A. Do you enforce 6S? B. Are facilities equipped with automatic sprinkler system? C. Does facility have well marked and well located fire protection equipment? 2 LAWRENCE ROAD ▪ SPRINGFIELD, NJ 07081 TELEPHONE: 973-467-8400 ▪ FAX: 973-467-9391 Valcor Supplier Quality Survey Form Revision Date: 21 November 2013 Form # SF1016A Page 3 of 4 VALCOR SUPPLIER QUALITY SURVEY FORM 9.0 DO YOU HAVE A GOVERNMENT INSEPCTOR? YES NO N/A Resident Itinerant: Agency Name _________________ SELF-EVALUATION SURVEY PARTICIPANTS I certify the above Self-Evaluation Survey has been completed in accordance with our Quality Assurance procedures and is accurate and correct. Surveys without a supplier signature will not be accepted. Filled Out By: ____________________________________ (Print Name) Signature: Date: ___________________ ____________________________________ 2 LAWRENCE ROAD ▪ SPRINGFIELD, NJ 07081 TELEPHONE: 973-467-8400 ▪ FAX: 973-467-9391 Valcor Supplier Quality Survey Form Revision Date: 21 November 2013 Form # SF1016A Page 4 of 4 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 14.0 Appendix B: Deviation/Change Request SF1019A Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 32 of 39 DEVIATION/CHANGE REQUEST FORM SUPPLIER INFORMATION PART INFORMATION Date: Part Number: Supplier Name: Part Description: Supplier Code: Revision Level: Contact: DCR # Phone #: Quantity: PO Number: DESCRIPTION st 1 Time Repeat, DCR#______________ Product Related Process Related Current Requirement: DEVIATION REQUEST Request for Deviation: Reason for Request: CHANGE REQUEST Request for Change: Reason for Request: Acknowledgment (Departments to sign when needed) Date Approve/Disapprove Purchasing: YES NO Engineering: YES NO Manufacturing: YES NO Quality Assurance: YES NO Comments VALCOR DISPOSITION Drawing/Spec Change Required? YES NO If Yes, ECO# __________________ Corrective Action Required? YES NO If Yes, CAR# __________________ Final Disposition and Comments: Supplier Note: If deviation is approved, a copy of this form shall be included inside the shipping container with each affected shipment. Form # SF1019 Rev. A ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 15.0 Appendix C: Material Rejection Report SF-104/R.03/12 Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 34 of 39 ® Valcor Engineering Corporation 2 Lawrence Road, Springfield, NJ 07081 CAGE Code 96487 Supplier Quality Manual 16.0 Appendix D: Corrective Action Request/Report SF1018A Unauthorized use, manufacture or reproduction in whole or in part is prohibited. Drawing, design and other disclosures are property of Valcor Engineering Corporation®. Copyright © 2014, Valcor Engineering Corporation®. Uncontrolled when printed. Verify document revision online at www.Valcor.com SQM-001 Revision Sheet 36 of 39 SF1018A Supplier Corrective Action Request CAR Number 4 Date Defined / / Status Open Defined by 1111 TEST USER Nonconformance Serial No Inventory Number Part Number Operation No 0 Customer Valcor Engineering Corporation Supplier P.O No Workcenter Department Standard 1. Problem Description What, Where, and When? Include evidence observed. 2. Team Members Establish a team of people with product/process knowledge. Responsible: Date Completed: / / Status: 3. Containment Actions / Reinspection Findings Define and execute actions to isolate discrepant and/or potentially discrepant materials/parts until corrections have been implemented and verified. Define the action(s) taken to eliminate the existing situation at each manufacturing phase (ex. Shipped, Raw Material, Finished Goods, WIP, etc.). Responsible: 08/11/2014 08:40:30 AM Date Completed: / / Valcor Engineering Corporation Status: Page 1 SF1018A Supplier Corrective Action Request CAR Number 4 Date Defined / / Status Open Defined by 1111 TEST USER Nonconformance Serial No Inventory Number Part Number Operation No 0 Customer Valcor Engineering Corporation Supplier P.O No Workcenter Department Standard 4. Root Cause(s) Determine and verify what caused the defect to be produced. Support with evidence by using root cause analysis (Recommended Tools: 8D, 5 Whys, Fishbone, Flowchart, etc.) Responsible: Date Completed: / / Status: 5. Select / Verify Corrective Actions Describe all planned and completed actions which address the root cause and prevent recurrence of the nonconformance. Approvals - Supplier Signature confirms accuracy of, and commitment to the corrective action. Management Signature: ____________________________________________ Date: __________________ Printed Name: Title: Note: If Supplier, then forward to Valcor. Responsible: 08/11/2014 08:40:30 AM Date Completed: / / Valcor Engineering Corporation Status: Page 2 SF1018A Supplier Corrective Action Request CAR Number 4 Date Defined / / Status Open Defined by 1111 TEST USER Nonconformance Serial No Department Standard Inventory Number Part Number Operation No 0 Customer Valcor Engineering Corporation Supplier P.O No Workcenter 6. Implement Corrective Actions Provide objective evidence (photos, training records, work instructions, ECOs, and etc.) to verify that all findings have been addressed. Responsible: Date Completed: Status: / / 7. Verification Determine and provide objective evidence that a change has occurred and that the product and process achieved desired results. Responsible: Date Completed: Status: / / 8. Congratulate Team Preventative Actions: Determine and implement actions to prevent the recurrence of this root cause and all similar problems. Responsible: Date Completed: Status: / / Approvals - For Valcor QA use only Acceptance of Corrective Action: Acceptable Not Acceptable for reasons noted below, resubmit a corrective action by: ________________ Notes: Follow up Audit is required? Yes No Attach audit results of Corrective Action and Closeout, if required. Nuclear Items only: Is evaluation for 10CFR21 per S2110 required? Yes Management Signature: ____________________________________________ 08/11/2014 08:40:30 AM Valcor Engineering Corporation No Date: __________________ Page 3
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