QA022-02 Seller Quality Requirements - QCS-001 Processing

QA022-02Revision: InitialMay 13, 2013Page 1 of 21

Seller Quality Requirements QCS-001 Processing Sources

The latest issue to this document is the version that is available on the Lockheed Martin Logistics Services Supplier Quality Management website: http://www.lockheedmartin.com/us/suppliers/bu-info/aeronautics/sustainment-services.htm l

TABLE OF CONTENTSSECTION TITLE PAGE PAGE

1. General Requirements 22. Quality System 33. Access to Facilities 34. Contract Review and Planning 45. Selection, Control and Requirements Flow Down to Every Tier 46. Selection, Control and Contract Flow Down to Quality Control

Specification (QCS)-001 Sources5

7. Seller’s Performance of QCS-001 Processes 88. QCS-001 Requirements for Seller-Designed items 89. Calibration 910. Control and Processing Nonconforming Material and Corrective Action 911. Material Review Authority 912. Product Certifications and Acceptance 1113. Changes to Seller’s Operations 1314. Records 1315. Minimum Processing Instructions and/or Planning Requirements 14

The terms “Item(s)”, “PO”, “Seller”, and “Buyer” as used herein, have the same meaning as the terms “Work”, “Contract”, “Seller”, and “Lockheed Martin”, respectively.

Questions regarding QA022-02 or the applicability of QA022-02 shall be addressed to Lockheed Martin’s Supply Chain Management Representative (Buyer) who administers this PO.

Copies of Aerospace Standards (AS/EN documents) from the Society of Automotive Engineers may be obtained at www.sae.org.

http://www.sae.org/

http://www.lockheedmartin.com/us/suppliers/bu-info/aeronautics/sustainment-services.html



1) General Requirementsa) The terms “Item(s)”, (including “item(s)” with lower case “i”), “PO”, and “Buyer” as used

herein, have the same meaning as terms “Work”, “Contract”, “Seller”, and Lockheed Martin, respectively.

b) Seller shall use the QCS-001 Directory to identify both the process sources and the controlled processes that require Buyer approval, prior to use for Items delivered to Buyer. * Seller shall have Internet access for obtaining requirements of the “PO”, of which this document is a part (“PO”).

c) Language - Unless otherwise authorized by Buyer in writing, all records, reports, specifications, drawings and other documentation shall be in English.

d) Supplier Control - Seller is responsible for ensuring all Items procured from its suppliers for this PO conform to all requirements of this PO.

e) Seller’s documented quality system shall provide for the review of the PO to ensure that quality requirements are incorporated into manufacturing planning, and inspection and test instructions, as applicable, to assure compliance with the PO. Seller shall retain evidence of such review as defined in Section/paragraph 14(a) of this PO.

f) Seller shall utilize written instructions for all manufacturing, processing and inspection operations. Instructions shall be in the form of planning, manufacturing operation sheets, shop orders, travelers or any other identifying document. Such instructions shall identify, in sufficient detail, the controls and conditions of manufacturing peculiar to the Item being manufactured, assembled, inspected and tested. Changes to planning instructions shall be traceable and approved prior to use (refer to Section/paragraph 15).

g) Certified Materials - Seller shall establish controls to prevent the use of non-certified materials when certified materials are required.

h) Seller shall establish controls to ensure that material subject to age control, shelf life, or environmental controls are properly identified, monitored and maintained.

i) Seller shall control drawings, specifications and supplemental instructions and changes thereto to the extent necessary to ensure that only documents of the revision specified in the PO are utilized.

j) Seller shall maintain a system to ensure removal of obsolete documentation from the manufacturing, inspection and test areas.

k) Notification - Seller shall notify Buyer when:

i) Seller or Seller’s sub-tiers are found to be non-compliant to Buyer specifications,

ii) Seller’s sub-tier is disapproved by Seller

iii) Seller or Seller’s sub-tiers are disapproved by a Government Agency,



iv) Government/Industry Data Exchange Program (GIDEP) Alert is required or received affecting Buyer Items.

2) Quality Systema) Seller shall maintain a documented Quality System that meets the requirements of the

PO including, without limitation, this QA022-02.

3) Access to Facilitiesa) Work under this PO is subject to Buyer's periodic surveillance/audit of Seller's

compliance with Seller’s internal procedures and other documents applicable to this PO.

b) Seller shall provide or obtain for Buyer, Buyer’s Customers and regulatory agency personnel, access to any and all facilities, including those facilities of Seller’s subcontractors, where work is being performed or is scheduled to be performed. Buyer shall have the right to perform in-process inspections, audits or system surveillance at Seller’s and Seller’s subcontractors’ facilities as part of verification of conformance to the requirements of this PO. Denial of any such access may result in inactivation of Seller’s approval. Seller shall include the provisions of this facility access requirement in its Pos with its subcontractors.

i) Seller shall provide, at no increase in price, cost or fee to Buyer, Government or appropriate regulatory agencies, suitable facilities at Seller and Seller’s Subcontractors’ manufacturing locations for Buyer, Government, and regulatory agency representatives to perform compliance verification.

ii) Seller shall provide Buyer’s Field Representative with internet access via one of the following methods:

(1) Direct Non-Digital telephone line

(2) ISDN line

(3) DSL Line

(4) High-Speed Internet Access via Seller’s Network

iii) Seller shall include the provisions of this paragraph “3” in each purchase order. If any, with each of its subcontractors where Item processing is being performed or is scheduled to be performed in connection with the PO, and shall require that this paragraph “3” is inserted in all subcontracts at every tier, and noting that the term Buyer refers to Lockheed Martin acting through its Lockheed Martin Aeronautics Company business unit.



4) Contract Review and Planninga) Seller must maintain and control QCS-001 processes through written processing

instructions and/or planning

NOTE: Seller shall ensure that work instructions and/or planning include, as a minimum, the applicable requirements in section/paragraph 15.

b) Seller shall have a system in place to ensure that all Buyer unique requirements are translated to operational processing instructions and/or planning.

c) Seller shall review all sub-tier purchase orders to ensure that such sub-tier purchase orders contain referenced specification(s), revision level(s) and drawing(s) requirement(s).

d) Seller shall have a documented system to ensure that processing instructions and/or planning changes are reviewed, at a minimum, by its production, engineering (when available and/or applicable), and quality organizations.

e) Seller shall clearly define control of processes, training, certification of its personnel, interpretation of results, and final disposition of parts in documented procedures.

f) Seller shall ensure that its personnel have the required training and experience commensurate with the requirements necessary for the performance of this PO.

g) Seller shall inspect Items or materials received from Buyer or Items from Buyer’s sub-tiers for verification of condition, quantity, serialization, when required, and dimensional data, when required.

h) Seller shall have a documented quality system for controlling and maintaining traceability of Items processed. The use of correction fluids and/or correction tapes on Seller documentation for traceable Buyer Items is prohibited.

i) Prior to performing any QCS-001 controlled process, Seller shall review QCS-001 to ensure Seller is approved to perform such process.

j) Seller shall ensure that, for any furnace used for curing, or embrittlement relief, the furnace/oven chart(s) and/or supporting documentation are identified with process planning or traveler number, time in, time out, quantity, stamped or signed off as directed herein by Seller’s operator to assure Item traceability is maintained.

5) Selection, Control and Requirements Flow Down to Every Tiera) Seller's documented quality system shall include procedures for determining the

capability of sub-tier suppliers prior to issuance by Seller of a purchase order to any such sub-tier.

b) When Seller performs a Quality System Survey or Evaluation for a sub-tier facility, Seller shall document the results of each survey or evaluation.



c) Seller is responsible for ensuring all materials, services and components it procures for incorporation into Items processed for Buyer conform to all requirements of the PO.

d) Seller shall define and establish a program for determining the need for periodic re-survey or re-evaluation of Seller's sub-tiers to ensure compliance with the PO.

e) Prior to production and award of subcontracts, Seller shall institute a program that will ensure control of its quality and control of such quality at sub-tiers at all levels for all Items procured by Seller in support of the PO.

f) Seller shall include the applicable portions of the PO in each of its purchase orders, if any, with each of its sub-tiers where processing is being performed or is scheduled to be performed in connection with the PO and require that, where applicable, such portions are inserted in all subcontracts at every tier.

g) Seller shall include in its purchase orders to its sub-tiers the applicable revision and amendment level, as applicable, for referenced Buyer specifications and other Buyer and/or Seller documents.

h) Seller shall include a complete description of Buyer requirements in purchase orders issued to Seller’s sub-tiers.

i) Seller shall maintain a documented Receiving Inspection function to ensure material and/or Items received from Seller’s sub-tiers are inspected to and meet the requirements of the PO. Verification of Item(s) conformance to drawings, specifications and requirements of the PO shall be in accordance with inspection plans, including sampling where applicable, surveys, and certifications of conformance at Seller or Seller’s sub-tier’s facilities, as appropriate. Seller shall properly physically segregate inspected Items from Items awaiting inspection.

j) Seller shall identify and document incoming material as to acceptance or rejection status. Seller shall ensure that such material is identifiable to the PO and material certifications.

6) Selection, Control and Contract Flow Down to Quality Control Specification (QCS)-001 Sourcesa) Prior to use, for Items delivered to Buyer, Seller shall use QCS-001 to identify the

process sources, processes and specifications requiring Buyer approval. By Buyer definition, and for Seller’s benefit, a controlled process is an operation performed on an Item where the operation is not readily conducive to being inspected subsequent to its conclusion. Controlled processes have verifiable controls inherent to the process, i.e. heat treat, plating, non-destructive testing, etc.

b) Seller is not required to use approved sources listed in QCS-001 for standard hardware (nuts, bolts, washers, etc.) ordered to military, federal or industry specifications or standards (e.g., MS, AN, NAS, etc.) or for metallic raw material (plate, sheet, bar, extrusion, etc.) purchased from a mill.



c) Buyer hereby authorizes Seller to use Nadcap approved sources for Industry Standard processes controlled by QCS-001. Seller shall ensure that a source is currently approved by Nadcap, prior to a source performing processing on Items. Seller may access Nadcap approved sources at http://www.pri.sae.org or http://www.eauditnet.pri.sae.org. Upon request by Buyer, Seller shall provide Buyer with objective evidence that Seller selected and used a source approved by Nadcap at the time processing was performed and at the time Item(s) is/are delivered to Buyer. Buyer does not mandate Seller’s use of Nadcap approved sources and shall not be responsible for any cost associated with Nadcap accreditation or the use of a Nadcap approved source or process. Buyer shall have the right to validate any Nadcap approved source or process using normal survey practices, and shall have the right to disapprove Seller’s use of any such source in connection with this PO.

d) The list of both Buyer-controlled processes and Buyer-approved sources can be found at: http://www.lockheedmartin.com/us/aeronautics/materialmanagement.html

i) Select “Quality Requirements”

ii) Select “Supplier Quality Management System”

iii) Select “Supplier Quality Management” and follow instructions

e) Seller shall use Buyer-approved sources for Buyer-controlled processes, either Buyer “Unique” or “Consensus Industry Standard (CIS)” processes, except as noted in “c” above.

f) Seller shall review the list of Buyer-approved sources for Buyer-controlled processes, prior to using a process source for a controlled process listed in QCS-001, and select process sources that are approved by Buyer. Seller shall provide objective evidence of Seller’s review to Buyer upon request.

g) If Seller performs or directs its sub-tier to perform processes controlled by QCS-001 without Buyer’s prior approval, Buyer shall have the right to disapprove Seller’s quality system.

h) Seller’s utilization of Buyer-approved sources does not relieve Seller from the obligations to ensure subcontracted sources are in full compliance with applicable process specifications and to deliver conforming Items. Upon request by Buyer, Seller shall provide objective evidence that such compliance was attained and that such conforming Items were delivered.

i) Seller shall be responsible for ensuring that Seller or QCS-001 sources have the appropriate revision level of the process standards/specifications prior to performing processing in connection with the Items.

j) Seller shall maintain objective evidence that each Buyer-approved process source selected by Seller is being monitored to ensure compliance with all applicable process

http://www.lockheedmartin.com/us/aeronautics/materialmanagement.html



specifications. Upon request by Buyer, Seller shall promptly provide Buyer with objective evidence of such compliance.

k) Seller shall ensure process controls are established and required process control tests are accomplished at required intervals to ensure continued compliance with process specifications.

l) Seller shall ensure all Seller sub-tier purchase orders and/or associated purchase order documents for Buyer-controlled processes include the following data elements, statements, or the statement in the Note after “vi)”:

i) Seller’s unique LM Aero identification number (“vendor code”) and all LM Aero unique “process codes” for each Buyer-controlled process to be performed,

ii) a statement with the words, “Processing to be accomplished in performance of this purchase order is directly related to a Lockheed Martin Logistics Services purchase order and must be accomplished in accordance with process specification(s) on this purchase order and Lockheed Martin Logistics Services QA022-2”,

iii) a statement that Seller’s supplier must file and maintain a copy of all purchase orders containing the above statement and make these available for review by Buyer, upon request,

iv) a statement that Seller’s supplier must submit a Certificate of Conformance ("CoC”) with a unique certification number containing the following information:

(1) title and specification number (including revision letter) of the process,

(2) name and address of the process or non-destructive testing (“NDT”) facility,

(3) Seller’s supplier’s unique LM Aero identification number (“vendor or processor code),

(a) If processor is utilized based on a Nadcap approval, a statement to the effect “Source utilized based on current Nadcap accreditation” shall be included,

(4) date the CoC was issued,

(5) purchase order part number,

(6) quantity of parts (to include quantity accepted/ rejected),

(7) signature and title of authorized quality agent of Seller, and

(8) fracture durability classification or serialization, when required

v) a statement to ensure Seller’s sub-tiers suitably wraps, boxes or racks parts to guard against shipping damage and to apply rust or corrosion protection, and

vi) a statement requiring Seller’s sub-tier to identify specification(s) title, specific revision level(s) and drawing(s) requirement(s) to be performed by a QCS-001 source.



Note: Seller can also use the following statement in lieu of the above statements i) –vii) to meet the requirements of this paragraph:

Include Seller’s unique LM Aero identification number (vendor code) and a statement with the words:

“Processing to be accomplished in performance of this purchase order is directly related to a Lockheed Martin purchase order and must be accomplished in accordance with process specification(s) on this purchase order and the revision in effect as of the date of this PO of Lockheed Martin Logistics Services QA022-02. All requirements of such QA022-02 paragraph l. i through vii shall be accomplished.

vii) Seller shall review testing lab Certificate of Conformance to ensure all required testing has been accomplished and meets all requirements of the applicable specification. Upon Buyer’s request, Seller shall provide objective evidence of Seller’s review.

viii) Seller shall submit all requests for additional QCS-001 process approvals in writing to Buyer.

7) Seller’s Performance of QCS-001 Processesa) When performing QCS-001 Controlled Processes in Seller’s facility, Seller shall

accomplish QCS-001 processes in accordance with the applicable process specification(s) and the then current Lockheed Martin Logistics Services QA022-02.

QA022-02 is located at http://www.lockheedmartin.com/us/suppliers/bu-info/aeronautics/sustainment-services.html

8) QCS-001 Requirements for Seller-Designed itemsa) Seller has the responsibility and authority to approve and control its own processing

sources, including in-house processes with the following exception:

For those Seller designs invoking Buyer-designed technical specifications that require LM Aeronautics Materials and Processes Engineering (“M&PE”) qualification or approval, Seller shall ensure LM Aero M&PE qualifies and/or approves the Seller’s source prior to use, or Seller may use a source approved in QCS-001.

Seller shall notify and disclose details to Buyer when Seller and/or any of its sub-tiers are determined non-compliant with Buyer requirements, specifications, are disapproved by Seller and/or a Government Agency, or when Seller or a Government Agency initiates a GIDEP Alert related to Seller actions.

b) Seller shall ensure that the assignment of personnel is commensurate with their respective levels of experience, training and proficiency.





c) Buyer shall have the right to review and maintain surveillance of Seller’s system for approval and control of Buyer-approved processes, including those performed in-house. If Buyer determines Seller’s system has failed to control processing or testing, Buyer shall have the right to withdraw Seller’s authority to approve and control Buyer-approved processes listed in QCS-001. In the event of withdrawal of such authority, Buyer shall have the right to direct Seller, at no increase in price, cost or fee to Buyer, to use Buyer-approved sources listed in QCS-001.

d) Seller design shall include Buyer drawings identified as Source Control Drawings or Specification Control Drawings for purposes of Paragraph 8.

9) CalibrationSeller shall maintain a documented calibration system for the calibration and maintenance of tools, jigs, inspection and test equipment. Seller’s calibration system shall be compliant to prevailing industry requirements in accordance with Seller’s Quality Management System (“QMS”), including without limitation ISO 17025, ISO10012-1, ANSI Z540.

10) Control and Processing Nonconforming Material and Corrective Actiona) Seller shall implement and maintain a documented quality system that provides for

identification, documentation, segregation and disposition of nonconforming material. Seller shall ensure effective corrective action is taken (including repetitive nonconformance(s) dispositioned “Use-As-Is” by Buyer’s or Seller’s Material Review Board (“MRB”) actions) to prevent, minimize, or eliminate nonconformance(s).

b) Seller’s QMS shall ensure that non-conforming material is not used for production purposes.

c) Seller shall maintain records of all nonconforming material, dispositions, assignable causes, corrective actions, and effectiveness of corrective actions for the period specified in this PO.

d) Seller shall evaluate each nonconformance for its potential to exist in previously produced or delivered Items. If a nonconformance exists,

e) Seller shall notify Buyer, in writing, within 24 hours for issues impacting flight safety, and, in writing, within 5 working days for all other issues.

f) Seller shall respond to all Buyer requests for corrective action. When requested by Buyer, Seller shall provide trend data and findings for Buyer returned Items.

g) Seller shall assess all Buyer identified nonconformance(s), whether or not Item(s) was/were returned to Seller, and take appropriate actions to ensure causes of nonconformance are corrected. Seller shall notify Buyer of actions taken to prevent recurrence by completing Quality Notification (QN).

11) Material Review Authoritya) Material Review Authority for Seller-Designed Items



i) Seller has Material Review Authority (“MRA”), except for nonconformance(s) that affect a parameter controlled by Buyer drawing or specification, where form, fit or function, interchangeability, service life or reliability is affected. Seller shall submit dispositions of nonconformance(s), if any, affecting any such parameter(s) to Buyer for approval.

ii) Buyer has the right to remove MRA if Seller demonstrates abuse of the MRA process.

b) Material Review Authority for Buyer-Designed Items:

i) Seller disposition authority is limited to scrapping of Items, eliminating the nonconformance by rework to engineering, or returning to Seller. On Items of Buyer design, Seller shall document nonconformances for submittal to Buyer’s Material Review Board (“MRB”) for dispositions as required by this PO. Seller’s continued processing, prior to Buyer’s MRB disposition, of any Buyer-designed Items containing a nonconformance prior to Buyer’s MRB disposition will be at Seller’s risk.

ii) If Buyer has delegated MRA to Seller on Buyer-designed Items, Seller shall exercise such MRA except for nonconformances of a parameter that affects form, fit, function, interchangeability, service life or reliability.

iii) Seller shall submit requests for MRA on Buyer-designed Items in writing to Buyer.

c) Material Review Board Submittals

i) Seller’s request for Buyer MRB disposition of Seller or Buyer-designed Items shall be submitted to the Buyer.

ii) Seller shall not incorporate any nonconformance(s) into any Item, process, procedure or data that affects a parameter controlled by Buyer drawing or specification or affects form, fit or function, interchangeability, service life or reliability unless and until Seller has received prior written approval from Buyer to do so.

iii) Buyer and Buyer’s customers shall each have the right to refuse to accept any nonconformance(s). When Government Source Inspection is a requirement of this PO, and Buyer’s customer has delegated MRA to Seller’s cognizant Government source representative, Seller shall submit material review dispositions to Seller’s local Government representative for concurrence.

iv) Prior to delivering Items that have Buyer MRB dispositions, Seller shall ensure that root cause analysis and corrective action plans for all discrepancies have been completed. Seller shall submit corrective action plans to the Buyer or Buyer’s Representative with final acceptance paperwork.



12) Product Certifications and Acceptancea) Seller’s documented quality system shall provide a means for maintaining accurate

indication of inspection status, at all times while in the possession of Seller and during shipment to Buyer, for Items to be delivered to Buyer.

i) Seller shall use inspection stamps of a design distinctively different from inspection stamps used by Buyer and Buyer’s Customers.

ii) Seller’s documented quality system shall provide a method for the control and issuance of inspection stamps and for the prevention of unauthorized use of such stamps. If indication of inspection status is accomplished using signatures or initials, Seller shall have a documented procedure addressing how signatures or initials are distinguished and/or controlled. The use of signatures or initials are prohibited for Non-Destructive Testing Inspectors. Upon request by Buyer, Seller’s procedure shall be available for review.

b) Certificate of Conformance

i) Seller shall prepare a Certificate of Conformance (“CoC”) asserting that the Items contained within this shipment are in total compliance with the requirements of this PO. Items provided under this PO must meet all applicable requirements. Any exceptions shall be annotated in the delivery package. A copy of the CoC shall be included with Seller’s product shipper.

ii) Seller’s CoC prepared for each shipment shall include the following data elements/information:

(1) title and specification number (including revision letter) of the process

(2) name and address of the process or NDT facility

(3) Buyer’s assigned processor number

(4) date the CoC was issued

(5) purchase order part number

(6) quantity of parts (to include quantity accepted/ rejected)

(7) signature and title of authorized quality agent of seller, and

(8) fracture durability classification or serialization when required

iii) When QCS-001 controlled processes are performed by Seller or Seller’s sub-tier(s), Seller shall provide Buyer, at time of Buyer’s acceptance, objective evidence that Seller or such sub-tier(s) used is/are approved by Buyer on date of acceptance by Buyer, regardless of when processing was performed. If Seller and/or sub-tier(s) used were approved at the time processing was performed but subsequently is/are not approved at time of Buyer’s acceptance, Seller shall contact Buyer for Item(s) disposition.



iv) When Buyer’s customer requires source inspection, Seller shall obtain objective evidence of Buyer’s customer representative’s inspection by signature and title or by stamp on any shipping documents required by the PO.

c) Buyer Inspection at Source Requirements

i) The point of acceptance is indicated on each PO issued. Seller is responsible for ensuring all requirements of this PO have been met. Buyer shall have the right to conduct surveillance and/or audits at any time, without increase in price, cost or fee to Buyer.

(1) Items designated “Buyer Accept at Source” shall be subject to final acceptance by Buyer’s PQAR at Seller’s facility prior to shipment.

(2) Items designated “Buyer and Government Accept at Source” shall be subject to acceptance by Buyer’s PQAR and the assigned Government Representative at Seller’s facility prior to shipment.

(3) Items designated “Seller at Source” shall be subject to acceptance by Seller’s quality assurance representative prior to shipping. Should Seller’s performance result in a change to the point of acceptance to “Buyer at Source”, Seller shall be subject to costs associated with the added task.

(4) Items designated “Purchase Order Administrator/User” are not subject to acceptance by PQAR.

ii) When this PO calls for “Buyer Accept” or “Buyer and Government Accept at Source” Seller, not less than five (5) days after receipt of this PO, shall notify the Buyer’s PQAR who normally services Seller's facility, unless Seller has received written Buyer authorization to accept Items and/or processing on behalf of Buyer. The notification shall include PO number, date of scheduled shipment and any special security clearance required to perform Buyer activities. If Seller does not know Buyer PQAR assigned to this facility, Seller may request this information from Buyer.

iii) When this PO calls for “Buyer Accept at Source”, Seller shall notify Buyer’s PQAR not less than 48 hours prior to Items being ready for shipment, unless Seller has received written Buyer authorization to accept Items and/or processing on behalf of Buyer.

iv) Seller shall not claim entitlement to an increase in the PO price, cost, or fee based upon an assertion that “Buyer Accept” or “Buyer and Government Accept at Source” imposes additional cost(s) or task(s) on Seller.

v) Work under this PO is subject to Buyer's periodic surveillance/audit of Seller's compliance with Seller’s internal procedures and other documents applicable to this PO.



13) Changes to Seller’s Operationsa) Quality System Changes - Seller shall notify Buyer, in writing, of any adverse change in

its quality system status resulting in the loss of 3rd Party registrar’s certification status, or any action taken by Seller’s customer, the Government, Federal Aviation Administration (FAA) or Civil Aviation Agency (CAA). Seller shall also notify Buyer upon any sale, relocation or transfer of Seller’s manufacturing operations or upon any change in the quality organization, process or procedures that could affect conformity verification of Items. Notification by Seller shall be made within 30 days of such changes.

b) Seller shall notify Buyer within 48 hours of any changes in Nadcap accreditation and/or NDT Level II or III personnel, and all other personnel changes within five (5) normal work days.

14) Recordsa) Seller shall maintain complete records of all manufacturing, process capability (if

applicable), inspection and test, including copy of CoC. Seller shall make records available to Buyer, upon request, for at least three (3) years after completion of this PO and for longer periods as may be specified elsewhere in this PO. Upon request, Seller shall forward specific records to Buyer at no additional cost, price, or fee to Buyer. For at least seven (7) years after completion of this PO, Seller shall maintain and provide to Buyer upon request, records of all QCS-001 process control tests performed by Seller, and inspection records of processed Items.

b) Seller shall maintain special processing activity data on each Buyer-approved process performed for Buyer, including processes performed by Seller on Buyer Items, or any QCS-001 Source utilized, and Seller shall compile a quarterly Usage Report of this activity data and submit it to Buyer at http://elli.lmtas.lmco.com/qads/QCS001Menu.asp. Seller shall also include in this Usage Report all special processing activity accomplished which may have been subcontracted by Seller’s sub-tier manufacturing sources. Fax and e-mail submittals are prohibited, and will not be accepted by Buyer. Seller shall submit the quarterly Usage Report within fifteen (15) calendar days after the end of each calendar quarter, even if no QCS-001 sources were utilized during a calendar quarter. Usage Reports shall not be input prior to the end of each calendar quarter. Seller’s Usage Report shall consist of processing activity accomplished in the following activity categories:

i) Seller subcontracting special processing activity to QCS-001 or Nadcap approved sources,

ii) Seller performing special processes on LM Aero Items for other LM Aero suppliers,

iii) Seller performing special processes on LM Aero Items the Seller manufacturers, and



iv) Seller’s sub-tier manufacturing source(s) who subcontract special processing activity to QCS-001 or Nadcap approved sources.

Note: Usage Reporting is not required when Seller is performing QCS-001 processes for non-LM Aero contracts.

c) Seller’s Usage Report shall contain the following data elements and information:

i) QCS-001 source name,

ii) Buyer’s assigned QCS-001 Source number,

iii) process specification used by specification number, and

iv) quarterly frequency of use, e.g., “lots, batches”

15) Minimum Processing Instructions and/or Planning Requirementsa) General Requirements

i) The processing instructions/planning requirements contained herein are, without limitation, a part of Appendix QJ, Seller Quality Requirements – QCS-001 Processing Sources. Seller shall include such requirements in Seller’s processing instructions/planning as defined herein.

b) Minimum Processing Instructions and/or Planning Requirementsi) Seller and Seller’s sub-tiers shall ensure that processing instructions and/or

planning include, and meet, at a minimum, the requirements delineated herein.

ii) Upon Buyer’s request therefore, Seller shall provide to Buyer, at no increase in price, cost or fee to Buyer, copies of such processing instructions and/or planning.

iii) Seller shall submit all above noted Seller processing instructions and/or planning for Buyer Items classified as “Critical”, for instance, Fatigue/Fracture Critical, Fracture/Durability Critical, Safety Critical, etc. to Buyer for LM Aero Program Level III review, approval and signature.

c) Pre-Penetrant Etch Requirementsi) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for

pre-penetrant etch operations contain the following requirements:

(1) a job listing log is maintained that includes Item (part) number, material type, shop traveler/planning router number, etch rate, time in etch tank, amount of metal removed per surface, and identification of employee performing etch operation,

(2) etch rate calculations are performed with a calibrated balance scale, (4 place) when etch rates are determined using the weight loss method,

(3) etch rates are determined every 8 hours of operation or once each shift,



(4) amount of metal removed from surface is in accordance with Buyer’s specification(s), (minimum) plus .0001” per surface, not to exceed maximum specified amount per specification, e.g., NDTS 1101 aluminum etch is .0003” to, 0007” per surface. Remove a minimum of .0004” and not to exceed .0007”, and

(5) etch rates, time in and time out of etch tank, and actual amount of metal removed per surface are documented on Certificate of Conformance (“CoC”).

ii) Seller shall document the following data on processing instructions and/or planning when pre-penetrant etch is performed. Seller shall document that material being etched, amount of removal per surface and specification will change as specifications and requirements change:

(1) (Aluminum) Etch to remove 0.0003 - 0.0007” per surface per NDTS 1101 or as required by Buyer specification(s),

(2) Daily Etch Rate (per established procedure): __________(in/surface/minute),

(3) Tank Number: _____________ Tank Temperature: ______________,

(4) Time in Etch Tank: ________________AM/PM, Date: ___________,

(5) Time Out of Etch Tank: ____________AM/PM, Date: ___________, and

(6) Amount of Metal Removed: ______________ PER SURFACEd) Penetrant Testing Requirements

i) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for penetrant testing operations contain the following requirements:

(1) manufacturer of, and Sensitivity level of, penetrant material are documented and recorded on processing instructions and/or planning,

(2) all batch numbers of penetrant material, emulsifiers and developers used are documented and recorded on processing instructions and/or planning,

(3) penetrant, emulsifier and developer dwell times are documented and recorded on processing instructions and/or planning,

(4) pre-cleaning method(s)/material(s), immersion times, temperatures and tank numbers are documented and recorded on processing instructions and/or planning, and

(5) a job listing log is maintained that documents Item (part) number, material type, shop traveler/planning router number, number of Items inspected, number of Items accepted/rejected and the acceptance criteria used.

e) Magnetic Particle Testing Requirementsi) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for

magnetic particle testing operations contain the following requirements:



(1) approved Technique Data Sheet(s) (“TDS”) are available and approval is signed by a Seller Non-Destructive Test (“NDT”) Level III

NOTE: Buyer’s specification(s) may also require Buyer’s NDT Level III signed approval of Seller TDS,

(2) required residual magnetism level is documented and recorded on processing instructions and/or planning, and


f) Radiography Testing Requirementsi) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for

radiography testing operations contain the following requirements:

(1) approved TDS are available and signed by a Seller NDT Level III

NOTE: Buyer’s specification(s) may also require Buyer’s NDT Level III signed approval of Seller TDS, and


g) Ultrasonic Testing Requirementsi) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for

ultrasonic testing operations contain the following requirements:

(1) approved scan plan/technique number, when required by Buyer’s specification(s), are available and signed by Seller’s NDT Level III

NOTE: Buyer’s specification(s) may also require Buyer’s NDT Level III signed approval of Seller’s scan plan/technique number

(2) serial number(s) of the standards used are documented and recorded on processing instructions and/or planning, and

(3) a job listing log book is maintained that documents Item (part) number, material type, shop traveler/planning router number, number of Items inspected, number of Items accepted/rejected and the acceptance criteria used.



h) Solid Film Lubricant (SFL)/ Prime/Paint/Fuel Tank Coating Requirementsi) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for

sfl, prime, paint and fuel tank coating operations contain the following requirements. Additionally, Seller’s specification data elements/information requirements, as defined herein, shall be documented on applicable Seller’s processing instructions and/or planning:

(1) material manufacturer’s identification for sfl, primer, paint (top coat) and fuel tank coating,

(2) batch numbers of sfl, primer, paint (top coat) and fuel tank coating,

(3) Engineering Materials and Processes (EMAP) material numbers when EMAP materials are required,

(4) mix times, stand times for primer, paint (top coat) and fuel tank coating,

(5) viscosity of primer, top coat and fuel tank coating at time of application,

(6) temperature and humidity at time sfl, primer, paint (top coat) and fuel tank coating is applied,

(7) required and resulting actual thickness of sfl, primer, top coat, or fuel tank coating based upon number of coats applied,

(8) cure cycles to include time in, time out of furnace, temperature and humidity data,

(9) printed name and signature of Seller’s QCS-001 qualified applicator, and

(10) required and resulting actual inspections performed to include as applicable, by material type:

(a) specification or Buyer requirement,

(b) required coating thickness verification,

(c) wet and/or dry tape tests,

(d) coating Adhesion tests,

(e) coating Cure verification, and

(f) coating Cure verification, and

(g) coating visual examination

ii) Seller’s and Seller’s sub-tiers testing procedures for sfl, primer, paint (top coat) and fuel tank coating shall include:

(1) applicable and reference testing specification, and

(2) accept/reject criteria



iii) Seller’s and Seller’s sub-tiers equipment listing for processing sfl, primer, paint (top coat) and fuel tank coating shall include:

(1) paint booths,

(2) curing ovens,

(3) preventative maintenance schedule, and

(4) equipment that is calibrated, with frequency and accuracies documented

iv) Seller’s and Seller’s sub-tiers CoC for sfl, primer, paint (top coat) and fuel tank coating shall include:

(1) material manufacturer’s name and batch number of primer, top coat, fuel tank coating,

(2) sfl, to include EMAP Material Code, as applicable,

(3) cure cycles used shall include temperature and humidity verification, as required,

(4) coating thickness results, and

(5) coating adhesion results

i) Chemical Processing Requirementsi) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for

chemical processing operations include the following requirements. Additionally, Seller’s processing parameters, as defined herein, shall be documented on Seller’s applicable processing instructions and/or planning:

(1) tank number(s),

(2) tank sequence,

(3) time in tank at time of processing, and

(4) temperature of tanks at the time of processing when solutions are heated

ii) When Buyer unique specifications are required, Seller and Seller’s sub-tiers shall include process flow charts indicating EMAPS approved materials, including chemicals, by EMAPS item number.

iii) Seller’s and Seller’s sub-tiers lot/monthly process and solution control testing requirements shall include:

(1) required testing specification,

(2) accept/reject criteria, adhesion, thickness, salt spray, visual examination, and

(3) solution analysis frequency



NOTE: If testing is accomplished at Seller’s facility, it shall be controlled by documented instructions/lab procedures.

iv) Seller’s and Seller’s sub-tiers chemical processing equipment listing shall include:

(1) Tank size,

(2) curing and embrittlement relief baking ovens, and

(3) crucifiers/ammeters

NOTE: Seller shall have documented calibration data with accuracies available for Buyer’s review for calibrated equipment.

j) Heat Treatment Requirementsi) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for

heat treatment operations include the following requirements, processing parameters and manufacturing data. Additionally, Seller’s and Seller’s sub-tiers shall document such processing parameters on applicable processing instructions and/or planning:

(1) cleaning methods,

(2) furnace number(s),

(3) time in, time at, time out of furnace(s), in legible format,

(4) actual quench delay, as required by applicable heat treat specification,

(5) temperature of quench media at time of quench,

(6) transfer time into cold storage after solution heat treat,

(7) specification used and requirements for dew points, carbon potential vacuum leak rate as required by applicable heat treat specification,

(8) specification used when in-process testing is required and actual test data results, such as hardness after tempering,

(9) specification used for final hardness and conductivity readings, required and actual, and

(10) specification used for part marking

ii) Seller and Seller’s sub-tiers heat treatment processing instructions and/or planning shall include:

(1) complete equipment listing, including furnace(s) classification, in accordance with AMS 2750, e.g., size, furnace limits, and accuracy,

(2) how furnace charts are identified to ensure traceability,



(3) as a minimum, Item number, quantity, shop traveler/planning number, time in, time at, and time out of furnace shall be noted,

(4) a written procedure for pyrometry control in accordance with AMS 2750,

(5) reference to, and availability of, Seller’s documented personnel training program for heat treatment, and

(6) a schedule for all required lotly and/or monthly process control tests required by consensus industry standards and/or Buyer’s unique requirements, including applicable ASTM test standards used.

iii) Seller’s and Seller’s sub-tiers documentation requirements for heat treatment logs shall include the following data, as a minimum, and any additional documentation, as required, by the heat treat specification(s) being used:

(1) shop traveler/planning traceable number(s),

(2) customer,

(3) Item (part) number,

(4) material type,

(5) material size,

(6) heat treat specification,

(7) furnace number,

(8) time in, time at required temperature, and time out of furnace, and

(9) quench delay

iv) Seller’s and Seller’s sub-tiers heat treatment CoC shall include:

(1) furnace number,

(2) temperatures by furnace used during heat treat process,

(3) furnace times,

(4) required and actual hardness/conductivity results, and

(5) any required statements embedded in heat treat specifications and the following mandatory statements:

“All heat treatment processing performed on this order was accomplished using heat treatment equipment that meets the requirements of AMS 2750. All heat treatment operations were accomplished in accordance with the requested/required heat treatment specification and all required verifications tests have been performed and documented. No unauthorized changes or



deviations to required heat treatment specifications or procedures have been performed.”

k) Welding Requirementsi) Seller and Seller’s sub-tiers shall ensure processing instructions and/or planning for

welding operations include the following requirements, processing parameters and manufacturing data. Additionally, Seller’s and Seller’s sub-tiers shall document such processing parameters on applicable processing instructions and/or planning:

(1) date, quantity, part number and detail numbers,

(2) material, joint pre-fit and tolerances,

(3) weld specification and class,

(4) type of weld (fillet, groove, etc.),

(5) approved weld procedure number, as applicable,

(6) approved weld schedule/technique number, if applicable,

(7) welder number/identification,

(8) weld machine number,

(9) welding rod identification/traceability number and specification,

(10) shielding gas, as applicable,

(11) purge flow rate, as applicable,

(12) pre-cleaning method and specification, and

(13) final weld inspection performed by process and specification, as applicable, to include:

(a) radiographic inspection,

(b) penetrant inspection,

(c) magnetic particle inspection,

(d) ultrasonic inspection, and

(e) visual inspection

Documents

QA022-02 Seller Quality Requirements - QCS-001 Processing