QUALITY - · PDF fileVisual Quality ... early 1900’s. ... EMCO MAXXturn 65 CNC Bar Turning Centre 12 Station VDI-30 Tool Turret with 12 Driven Tools

QUALITY

MANUAL

Canada Metal (Pacific) Limited 7733 PROGRESS WAY, DELTA, B.C. CANADA V4G 1A3 PHONE: (604) 940-2010 FAX: (604) 952-2650

OUR GOAL … WORLD CLASS

Section: 010 Table of ContentsDate: 22-May-14 Issue: 4 Rev: C Page: 1 of 1

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Table of Contents ................................................................................ Section 010

Company History and Profile ............................................................... Section 020

Quality Policy and Certifications .......................................................... Section 030

Management Principles ....................................................................... Section 040

Organization Chart .............................................................................. Section 050

Process Map ........................................................................................ Section 060

Manufacturing Capabilities .................................................................. Section 070

Inspection Equipment .......................................................................... Section 080

Document Control ................................................................................ Section 090

Visual Quality ....................................................................................... Section 100

Lean Manufacturing ............................................................................. Section 110

Measurements ..................................................................................... Section 120


Section: 020 Company History and ProfileDate: 22-May-14 Issue: 4 Rev: F Page: 1 of 1

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Originally owned by Cominco and NL Industries, this Vancouver based operation first began foundry operations that serviced the plumbing and forestry industries during the early 1900’s.

The company’s non-ferrous capabilities allowed it to expand its product offering to include the manufacture of gravity cast zinc and aluminum anodes for the commercial marine industry. The innovative development of new alloys and casting techniques enabled the company to gain an international reputation of superior quality for its “Martyr” brand of sacrificial marine anodes.

Building on the success achieved in the commercial marine market the company was able to offer the utility of their performance enhanced alloys to the worlds leading marine engine builders. Here the company was able to use the process of pressure diecasting to produce the more intricate castings that were needed by this fast growing “pleasurecraft” industry.

During 1987 the then majority owners purchased the Canada Metal Company from Cominco and continued to pursue opportunities in the traditional lines of marine, plumbing and forestry sectors. In 1991 the company acquired a 50% interest in Pacific Diecasting, a custom pressure diecast company. In 1993, the remaining 50% of this business was purchased.

The purchase of Pacific Diecasting provided the company with the necessary resources to improve the manufacturing efficiencies for its marine customers to such an extent that today it stands as the worlds largest producer of diecast marine anodes. The acquisition also provided the company with a very loyal base of “custom diecast” (standard zinc and aluminum castings) customers who added a new and exciting market focus for the management team.

In 1993 the Vancouver operation was incorporated as a separate legal entity under Canada Metal (Pacific) Limited. Under this name our company enhanced its capabilities yet again by purchasing Comprehensive Manufacturing Technologies Inc. (CMT) in the spring of 2000.

CMT manufactures and markets the Octopus line of marine autopilot drive systems. The synergies of the product lines as well as the expertise of their Engineering and Machining divisions ensured that this acquisition would further strengthen our companies abilities to service the ever expanding needs of our customers.

All of us at Canada Metal (Pacific) Limited are dedicated to customer service and committed to product quality. We look forward to providing you, our valued customer, with proof of our dedication and commitment.


Section: 030 Quality Policy Date: 22-May-14 Issue: 4 Rev: L Page: 1 of 2


Section: 030 Quality Policy Date: 22-May-14 Issue: 4 Rev: L Page: 2 of 2

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Section: 040 Management PrinciplesDate: 22-May-14 Issue: 4 Rev: B Page: 1 of 1

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Customer satisfaction achieved by applying the leadership principles in our process of continuous improvement: Systems, Processes, Suppliers. Continuous improvement and customer satisfaction are made possible by empowering our employees.


Section: 050 Organization Chart.docDate: 22-Jun-15 Issue: 4 Rev: N Page: 1 of 1

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Section: 060 Process Map Date: 22-May-14 Issue: 4 Rev: D Page: 1 of 1

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Section: 070 Manufacturing Capabilities.docDate: 22-Jun-15 Issue: 4 Rev: J Page: 1 of 5

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Aluminum Alloy: 384, 380, 413, 360, 356 Cold Chamber Automatic Diecast Machines 350 – 650 Ton Part Size = 0.3" x 0.3" to 20" x 20" Part Wt = 0.2oz to 12lbs.

Zinc Alloy: ZA-3, ZA-5, ZA-8, ZA-12, ZA-27

Cold Chamber Automatic Diecast Machines 350 – 650 Ton Part Size = 0.3" x 0.3" to 20" x 20" Part Wt = 0.2 oz to 24 lbs.

Lead Alloy

Hot Chamber Automatic Diecast Machines 60 Ton Part Size: 0.3" x 0.3" to 2.5" x 2.5" Part Wt: 0.2 oz (grams) – 4oz (grams)



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Mori Seiki SH-400

Horizontal Machining Centre

Automatic Pallet Changer Max. Part Size 22" x 20" x 20" Accuracy: - Position: +/- 0.0002 Repeat: +/- 0.00004 Max. Cutting Speed: 630 IPM Tool Holder Capacity: 40 Spindle Motor Max. Rating: 30 hp Max. Spindle Speed: 12,000 RPM Controls: Mori-Fanuc 8M Haas VF0 Vertical Machining Centre

Maximum Part Size: 20" x 16" x 20" Accuracy: - Position: +/- 0.0002 Repeat: +/- 0.0001 Max. Cutting Speed: 300 IPM Tool Holder Capacity: 20 Spindle Motor Max. Rating: 20 hp Max. Spindle Speed: 7500 RPM Controls: Haas-Fanuc

Mori Seiki SV-503/40 Vertical Machining Centre

31.5 x 20.8 x 20.8 Travels 10,000 rpm Spindle – 30 HP Max. Cutting Speed: 1653 ipm 30 Tool ATC Tool Change Time – 0.9sec. Accuracy - Positioning = 0.0002” Repeatability = 0.000039” Coolant through Spindle Fanuc 18I Control Cat 40 Taper Haas VF2 Vertical Machining Centre

Maximum Part Size: 30" x 16" x 20" Accuracy: - Position: +/- 0.0002 Repeat: +/- 0.0001 Max. Cutting Speed: 300 IPM Tool Holder Capacity: 20 Spindle Motor Max. Rating: 20 hp Max. Spindle Speed: 7500 RPM Controls: Haas-Fanuc



Haas HS-1 Horizontal Machining Centre

Automatic Pallet Changer Max. Part Size: 24" x 20" x 22" Accuracy: - Position: +/- 0.0002 Repeat: +/- 0.0001 Max. Cutting Speed: 300 IPM Tool Holder Capacity: 24 Spindle Motor Max. Rating: 30 hp Max. Spindle Speed: 7500 RPM Controls: Haas-Fanuc Mori Seiki NLX2500SY Max Turning Diameter:

14.02” (356mm) Max Bar Diameter Spindle 1:

3.15” (80mm) Max Bar Diameter Spindle 2:

2.87” (73mm) Spindle 1 Max Speed: 4,000 rpm Spindle 2 Max Speed: 6,000 rpm 12 Station Turret All Pockets Driven Turret Indexing Time 0.27 seconds Automatic In Machine Tool Setter M730BM Controller Quick Load Servo S3 Bar Feeder Mori Seiki Dura Turn

Max. Turning Diameter: 14.5" (370mm) Max Bar Diameter: 2.5" (65mm) Spindle Max. Speed: 4000 RPM 12 Station Turret Turret Indexing Time 0.45 seconds Manual Tool Setter Mori Seiki FOiTD Controller Robotic Loader Fanuc M-10iA Lean cell configuration with 5 drawer system

Haas EC400 Horizontal CNC

Dual Pallet Max. Part Size: 400mm x 400mm Accuracy: - Position: +/-0.0002

Repeat: +/-0.0001 Max. Cutting Speed: 500 IPM Tool Holder Capacity: 40+1 Spindle Motor Max Rating: 20 hp Max. Spindle Speed: 12000 RPM Controls: Haas

EMCO MAXXturn 65

CNC Bar Turning Centre 12 Station VDI-30 Tool Turret with 12 Driven Tools Speed Range 0-5000 rpm 29 kW Main Drive Power Bar Capacity 65mm 200mm Dia. 3-Jaw Chuck EMCO Auto Bar Loader Programmable Tailstock Parts Catcher Fanuc Auto. Tool Presetter Fanuc 18i Control

Manual Machines Bridgeport Type Milling Machines Drill and Tap Machines – Various Surface Grinder Part Washing Machine Glass Bead, Sand Blasting Unit Horizontal Honing Machine



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Aluminum alloy for sacrificial anodes Will produce to customer specification up to 2000 lbs. capacity using a GDH-1500 Gasmac Dry Hearth Melting c/w GRHA-3000 Holding Furnace. Zinc alloy for sacrificial anodes Will produce to customer specification using two Crucible Style Gas Fired Furnaces at 750 lbs. capacity, c/w automated robotic pour and ejection system. Babbits, Lead Counterweights to 10,000 lbs. capacity, Lead Bricks, Solders, and able to alloy non ferrous metals to customer specifications using one Steel Type, Gas Fired Furnace. Sheet-lead from .031” to 2” thickness at max. 48” width by 20’ long using a 300 Ton Falk Lead Rolls 1.200m x 6.000m Finish Area. Lead Wire/Rod from 1/8” to 3” dia., Lead Anodes to 2” dia., Custom Lead Alloy Extrusions to customer specification up to 4” dia. Using a 350 Ton Extrusion Press. Plumbing and Roofing Products, Roof Flashings and Caps, Standard sizing 11/4” - 4”

IP Custom Sizes available on request, Traps and Bends (Mechanical Joint, ABS, Aluminum, Cast Iron or Copper ferules), Leadburning as per customer requirements.



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Octopus designs and manufacture automatic pilot drive units for the marine industry. These drive units are the muscles to move rudders on all kinds of vessels from runabout boats to tugs.

Octopus carries a variety of products for hydraulic steering, ranging from Reversing

Pumps to Continuous Running Pumpsets and Hydraulic Linear Actuators. Octopus supplies automatic pilots for push – pull cable steered vessels. The

mechanical drive system has a built in motor and clutch and can be installed either behind the dashboard or in a remote location “below decks” in either a powerboat or a sailboat.

Octopus also offers a remote steering for the mechanical drives in the Intellisteer

product line. This product offers the convenience to the user of being able to steer the boat from any location they choose through an exclusive hand held unit.


Section: 080 Inspection EquipmentDate: 22-May-14 Issue: 4 Rev: G Page: 1 of 5

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Aurora AI 1200 Spectrometer Aluminum, Zinc and Lead/Tin based alloys



CNC Coordinate Measuring Machine Brown & Sharpe Xcel 7.10.7 Measuring Volume: X=26”, Y=40”, Z=26”

Coordinate Measuring Machine Starrett HGC 2018-16 Measuring Volume: X=20”, Y=18”, Z=16”



STARRETT HDV300 Horizontal Digital Projector:



Various Inspection and Test Equipment: More than 200 IDs calibrated and traceable

to National & International Standards Calipers Micrometers Fixed Gages (Thread and Plain) Gage Blocks Temperature Gages Electronic Measuring Devices Scales Chemical Standards Customized Pressure Testing State-of-the-art sub-components



Metrology Lab:

Inspection Benches at each Workstation:

Metrology Lab Inspection Bench:


Section: 090 Document ControlDate: 22-May-14 Issue: 4 Rev: H Page: 1 of 3

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With its proven performance in manual, networked, and hybrid systems the Document Distribution Log (DDL) provides links to most documents used at Canada Metal

Within its 15 tabs the DDL provides links to or information about more than 5,000 documents, including the ones required by the ISO 9001 Standard



Quality System Reference Table:

ISO 9001 Canada Metal (Pacific) Limited Quality Management System

1 Scope & Application Quality Manual Section 020

4 Quality Management System (Title Only) 4.1 General Requirements Quality Manual Section 060

SOP QA.048 Quality Management System 4.2 General Documentation Requirements (Title Only)

4.2.1 General Quality Manual Section 090 & 100

4.2.2 Quality Manual This table is part of document

4.2.3 Control of Documents Quality Manual Section 090 SOP QA.016 Document Control Form FQ.007 Document Distribution Log Form FQ.052 Document Change Request Log Form FQ.057 Document Review Log

4.2.4 Control of Quality Records SOP QA.016 Document Control SOP QA.043 Quality Records

5 Management Responsibility (Title Only) 5.1 Management Commitment Quality Manual Section 040

5.2 Customer Focus Reference Section 7.2 & 8.2.1 of this table

5.3 Quality Policy Quality Manual Section 030

5.4 Planning, Objectives & Targets Quality Manual Section 030 SOP QA.048 Quality Management System

5.5 Responsibility, Authority & Communication

Quality Manual Section 050 Job Descriptions and Personnel Roles - Reference Document Distribution Log (DDL)

5.6 Management Review SOP QA.048 Quality Management System SOP QA.072 Quality Objectives / Metrics Procedure

6 Resource Management (Title Only) 6.1 Provision of Resources SOP QA.048 Quality Management System

6.2 Human Resources Salaried Handbook Employee Handbook

6.3 Infrastructure Quality Manual Section 060 & 070 SOP QA.048 Quality Management System Various SOP’s for Preventive Maintenance - Reference Document Distribution Log (DDL)

6.4 Work Environment Safety Program Manual

7 Product Realization (Title Only) 7.1 Planning of Product Realization Quality Manual Section 060 & 100

Visual Quality Collect Module SOP PG.001 Engineering Master SOP PG.002 Work Order / Traveler SOP PG.063 Sample Run Process Form FQ.050 PPAP Log

7.2 Customer Related Processes SOP AA.003 Customer Return Goods SOP AA.004 Contract Review SOP AA.005 Sales Order Process Form FA.043 Return Authorization Log (RANUMS)

7.3 Design & Development SOP QA.070 New Product/Project Launch Form FQ.065 Product Development Log



Quality System Reference Table - Continued:

ISO 9001 Canada Metal (Pacific) Limited Quality Management System

7.4 Purchasing SOP AA.009 Supplier Assessment Questionnaire SOP AA.015 Approved Supplier Status SOP AA.016 Purchasing of Critical Product SOP AA.019 Critical Product List SOP AA.022 Purchasing of Contractor Services

7.5 Production & Service Provisions (Title Only) 7.5.1 Control of Production &

Service Provision Quality Manual Section 060 & 070 Visual Quality Collect Module SOP PG.002 Work Order / Traveler SOP PG.063 Sample Run Process Various SOP’s for Operating Instructions & Preventive

Maintenance - Reference Document Distribution Log (DDL) 7.5.2 Validation of Processes for Production &

Service Provision SOP PG.023 SDM Preparation SOP PG.024 Die Set-up Various SOP’s for Operating Instructions - Reference Document

Distribution Log (DDL) 7.5.3 Identification & Traceability SOP QA.012 Alloy Color Codes

SOP QA.014 Product Identification & Traceability 7.5.4 Customer Property SOP QA.047 Control of Customer Property

7.5.5 Preservation of Property SOP PG.015 Handling, Storage, Packaging, Preservation, Delivery

7.6 Control of Monitoring & Measuring Devices

SOP QA.030 Inspection Equipment Calibration/Verification

8 Measurement, Analysis & Improvement (Title Only) 8.1 General Quality Manual Section 120

SOP PG.064 Continuous Improvement SOP QA.072 Quality Objectives / Metrics Procedure

8.2 Monitoring & Measurement (Title Only) 8.2.1 Customer Satisfaction SOP AA.033 Customer Satisfaction Measurement

Customer Satisfaction Survey 8.2.2 Internal Audit SOP QA.017 Quality Audits

Internal Quality Audit Plan 8.2.3 Monitoring & Measurement of Processes Quality Manual Section 080

SOP QA.020 Material Specification SOP QA.022 Samples for Chemical Analysis SOP QA.073 AI 1200 Spectrometer Instructions SOP QA.045 ARL 3460 Spectrometer Procedure Form FQ.005 Material Test Results Log

8.2.4 Monitoring & Measurement of Product Quality Manual Section 080 SOP QA.005 Receiving Inspection SOP QA.006 Diecast Quality Levels SOP QA.009 First Article Inspection SOP QA.015 Final Inspection SOP QA.034 Gravity Casting Quality Levels

8.3 Control of Nonconforming Product SOP QA.004 Hold Tag SOP QA.025 Concession Request Form FQ.039 Concession Request Log

8.4 Analysis of Data SOP QA.048 Quality Management System

8.5 Improvement (Title Only) 8.5.1 Continual Improvement Quality Manual Section 040

SOP PG.064 Continuous Improvement SOP QA.048 Quality Management System SOP QA.072 Quality Objectives / Metrics Procedure

8.5.2 Corrective Action SOP QA.003 Quality Report / Visual Quality Correct Module

8.5.3 Preventive Action SOP QA.003 Quality Report / Visual Quality Correct Module


Section: 100 Visual Quality Date: 22-May-14 Issue: 4 Rev: B Page: 1 of 2

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Canada Metal (Pacific) Limited is currently implementing this integrated quality information system that provides for the strategic management of quality and business performance. Following are the features of the system:

Sixteen integrated modules: Quality Control (SPC, PDM, Inspection) Quality Assurance (Documentation, Process Mgmt.) ISO/QS/AS Registration (Across the system) Finance (Cost of Quality) Management (Advanced Reporting, Audits, etc.)


Section: 100 Visual Quality Date: 22-May-14 Issue: 4 Rev: B Page: 2 of 2

Collaboration & Workgroups: Direct email activation and functionality Data sharing across modules & functions Real-time “To Do Lists” for each user Automatic scheduling and event management Build and manage teams, groups, etc. Collaborate between suppliers, employees and customers

Standard reports and tools: 32-bit reports / SQL-compliant data Cost of Quality and Trend Analysis Object Link or Embed Manage quality across multiple plants Assign Tasks/People/Deadlines (To Dos)


Section: 110 Lean ManufacturingDate: 22-May-14 Issue: 4 Rev: C Page: 1 of 1

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Lean Manufacturing principles are employed by reducing:

Over production,

Waiting,

Non-value added processing,

Excess inventory,

Defects,

Excess motion,

Under utilized resources. Various tools are customized to support each unique process. Among them the following are the most common:

Task Teams,

5S projects,

Cost reduction projects,

Work-cell concept,

Cutting batch sizes,

Automating processes.


Section: 120 Measurements Date: 22-May-14 Issue: 4 Rev: G Page: 1 of 9

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Recognition for quality, service and cost objectives from one of our U.S. customers.



Commendation for reducing cost, maintaining quality and on-time delivery from one of our Japanese customers.



“Best Contribution to Sales Growth” and “Vendor of the Year” awards from this U. S. Distributor.



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