quality control manual - reddy-buffaloes pump · pdf filequality control manual change record...

QUALITY

CONTROL

MANUAL

R-B PUMP, INC.

#1 DIXIE DRIVE

P.O. BOX 557

BAXLEY, GA 31513

CAGE NO: 62503

PH. NO: (912) 367-6345

FAX NO: (912) 367-5024

__________________________________________________________

March 2004

QUALITY CONTROL MANUAL

CHANGE RECORD

CHANGE

NO

DATE TITLE AND DESCRIPTION SIGNATURE OF

VALIDATING

OFFICER

0 1/1/00 Original Issue Jay Reddy1 3/10/00 Section 2 –Contract Planning Review revised Jay Reddy - Retention & Control of Records added Section 5 – Inspection Receiving Report revised - AQL 2.5% Level II clarified for sampling plan Section 8 – Handling & Storage procedures added Section 9 – Sample Test Data Sheet added - Sample Performance Curve added Section 10 – Internal Quality Audit procedures added Section 11 – Training of Personnel added 2 7/01/01 Section 3 – Inspection and Test Equipment Log revised Jay Reddy3 7/01/02 Section 3 – Inspection and Test Equipment Log revised Jay Reddy4 9/01/03 Section 3 – Inspection and Test Equipment Log updated Jay Reddy - Added requirement for FM approval for drawing changes made to FM controlled dwgs 5 3/01/04 Section 2 – Sales Order Sheets added Jay Reddy - Yellow Tag removed Section 3 – Added Procedural Information to Drawing Change Controls Section 4 – Added Procedural Information to Inventory Control Section 5 – Added Procedural Information to Receiving Inspection and Process Control Section 7 – Added Procedural Information to Painting and Cleaning Section 9 – Added Procedural Information to Fire Pump Manufacture and testing

LIST OF EFFECTIVE PAGES

Date of issue for original pages is: Original . . . . . . . . . . 0 . . . . . . . . . . . . January 2000 1st Revision . . . . . . . 1 . . . . . . . . . . . . March 2000 2nd Revision . . . . . . .2 . . . . . . . . . . . . July 2001 3rd Revision . . . . . . .3 . . . . . . . . . . . . July 2002 4th Revision . . . . . . .4 . . . . . . . . . . . . September 2003 5th Revision . . . . . . .5 . . . . . . . . . . . . March 2004

The number of pages in this publication is 53, consisting of the following:

Page No. Change No.

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Q. C. Manual Change Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Referenced Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1 thru 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2-1 thru 2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3-1 thru 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4-1 thru 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5-1 thru 5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6-1 thru 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9-1 thru 9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A

TABLE OF CONTENTS

CHAPTER/SECTION TITLE PAGE CHAPTER 1 GENERAL ORGANIZATION & RESPONSIBILITIES . . . . . . . . 1-1

1.1 ORGANIZATIONAL CHART OF R-B PUMP, INC. . . . . . . . . . . 1-1

CHAPTER 2 QUALITY PROGRAM MANAGEMENT . . . . . . . . . . . . . . . . . . . 2-1

2.1 GENERAL POLICIES AND ORGANIZATION . . . . . . . . . . . . . . 2-1

2.2 QUALITY PLANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.5 CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.6 QUALITY RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.7 CONTRACT PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.8 GOVERNMENT FURNISHED MATERIALS/SERVICE . . . . . . 2-12

CHAPTER 3 FACILITIES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 DOCUMENTATION OF CHANGES . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 MEASURING AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . 3-2

CHAPTER 4 CONTROL OF PURCHASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 PURCHASING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 INVENTORY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

CHAPTER 5 MANUFACTURING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 MATERIALS AND MATERIAL CONTROL . . . . . . . . . . . . . . . . 5-1

5.2 RECEIVING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

i

TABLE OF CONTENTS

CHAPTER/SECTION TITLE PAGE

5.3 PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.4 NONCONFORMING MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5 IN-PROCESS CONTROL OF GOVERNMENT CONTRACTED MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

CHAPTER 6 GENERAL WELDING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 WELDING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 ELECTRODE STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.4 GROOVED WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.5 CONTROL OF STAMPS AND SIGNATURES. . . . . . . . . . . . . . . 6-3

CHAPTER 7 CLEANING AND PAINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

CHAPTER 8 HANDLING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 PRESERVATION AND PACKAGING . . . . . . . . . . . . . . . . . . . . . 8-1

CHAPTER 9 FIRE PUMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 MANUFACTURE AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 9-1

CHAPTER 10 INTERNAL QUALITY AUDIT SYSTEM . . . . . . . . . . . . . . . . . . . 10-1

10.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.2 INTERNAL AUDITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.3 AUDITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

ii

TABLE OF CONTENTS

CHAPTER/SECTION TITLE PAGE

10.4 REPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

CHAPTER 11 TRAINING OF PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.2 TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

iii

REFERENCED DOCUMENTS

(A) MIL-I-45208 Military Specification Inspection 16 December 1963 System Requirements

(B) MIL-C-45662 Military Standard Calibration 10 June 1980 System Requirements (C) ANSI/ASQC 21.4 Sampling Plan

iv

SECTION 1

GENERAL ORGANIZATION AND RESPONSIBILITIES

1.1 ORGANIZATIONAL CHART OF R-B PUMP, INC. (see Figure 1-1) 1.1.1 President

Responsible for managing all the jobs in their entirety. Liaison with Shop, Quality, Engineering, and Accounts.

1.1.2 Controller

Responsible for keeping accounts, credit and cost accounting the jobs, as well as monthly P.L. statements.

1.1.3 Chief Engineer

Responsible for drawings and designs and product developments. 1.1.4 Government Contract Administrator

Responsible for administrating the government jobs. 1.1.5 Quality Control Manager

Responsible for seeing that quality products are made or procured per drawings, and has the authority to reject any part which is defective.

1.1.6 Shipping/Purchasing Assistant

Responsible for purchasing all small items for pump and shop tools, as well as shipping all items.

1.1.7 Sales Manager

Responsible for quoting jobs, both Government and Commercial, and Public Relations. 1.1.8 Machine Shop, Fabrication and Assembly Foremen

Responsible for all shop problems, work organizations, and day-to-day decisions of Shop Management.

1.1.9 Service Manager

Responsible for keeping the equipment in the shop in good working condition. Make service calls in the field to start any pumping units.

1.1.10 Auxiliary Team 1.1.10.1 Receiving Inspector

Responsible for the control of incoming products/services, and to insuring that all the requirements of the issued purchase orders are met.

1-1

1.1.10.2 C.A.D. Operator

Responsible for the C.A.D. System and drawings maintenance. 1.1.10.3 Cost Accountant

Responsible for accounts posting of costs to each job, and auditing the job cost after completion of jobs.

1.1.10.4 Fire Pump Sales Assistant

Responsible for quoting all Fire Pumps and Submittals.

1-2

SECTION TWO

QUALITY PROGRAM MANAGEMENT

2.1 GENERAL POLICIES AND ORGANIZATION

2.1.1 The policy of R-B Pump, Inc. requires that all items supplied to our customers, whether

manufactured in-house or procured from qualified vendors, will equal or surpass the quality

standard which has been agreed upon between R-B Pump, Inc. and our customers.

2.1.2 It is our policy that products produced in this plant shall conform to all specified standards of

performance, reliability and quality.

2.1.3 The Quality Control Department is responsible for the quality of all articles manufactured by the

company and maintains sufficient authority to stop production of and/or suspend shipments of

articles which do not conform to the drawings and specifications.

2.1.4 Procedures for controlling quality are established by Engineering and enforced by the Quality

Control Manager.

2.1.5 The Quality Control Department shall establish and follow the following control activities:

(A) Receiving Inspection

(B) Parts In-process Inspection

(C) Testing and Final Inspection

(D) Packaging and Shipping

(E) Drawing and Change Control

(F) Instrument Calibration Inspection

2-1

2.1.6 The Quality Control Manager is directly responsible to the President of the company.

2.1.7 Inspection Personnel are directly responsible to the Quality Control Manager.

2.1.8 The adequacy of the Quality Program will be under constant surveillance, and shall be subject to

review or revision as required. Any revision or change shall be coordinated with the customer.

Copies of any revision shall be supplied to all holders of this manual.

2.1.9 R-B Pump, Inc. shall notify all affected parties in writing of any change to this inspection

system. The Inspection System shall be subject to disapproval, if changes hereto would result in

nonconforming products.

2.1.10 This plan is arranged into sections and sub-sections, each of which covers a particular control

activity. The numerical point system is used for identification of each section and sub-section.

2.2 QUALITY PLANNING

2.2.1 Upon receipt of a purchase order, a complete review of the contract documents or order

requirements shall be made by Engineering, Manufacturing and Quality Control so that they

might identify and make provisions for special controls, processes, test equipment, fixtures,

tooling and skills required for assuring product quality and reliability.

2.2.2 This initial planning will recognize the need and provide for research, when necessary to update

inspection and testing techniques, instrumentation and correlation of inspection and test

procedures with manufacturing methods and processes.

2-2

2.2.3 This planning will also provide appropriate review and action to assure compatibility of

manufacturing, inspection, testing and documentation.

2.2.4 Quality planning shall take place as early as possible, and means for providing successful

compliance will be considered.

2.2.5 A Contract Planning and Review Record, Figure 2-1, will be completed on a special job

purchase order. In all of the orders where there is a past history, the procedures followed in the

previous similar manufacturing process will be repeated. The sales order sheet shall be

completed and attached to the job folder Figure 2-3 (A special job purchase order is described as

one, which requires major fabrication or testing of newly designed products.)

2.2.6 In addition to the initial review of the contract, weekly meetings shall be held to discuss the

progress of a contract, and any problems, which may have been faced during the span of the

manufacturing process. In attendance at these meetings will be the affected production

personnel, Quality Control Manager, President, and Chief Engineer.

2.3 WORK INSTRUCTIONS

2.3.1 The Quality Program shall assure that all work affecting quality, such as manufacturing,

inspection, testing, and shipping shall be described in the Bill of Materials and Traveler Card.

2.3.2 The department responsible for writing the procedure shall be responsible for updating

procedures when required, so that efficiency can be effectively maintained.

2.3.3 The Quality Control Manager will monitor compliance of all parts to the design drawings.

2-3

2.3.4 As normal procedure, the work instructions that will be received by personnel working in the

production of parts in the shop areas will be in the form of a blueprint. It shall be the

responsibility of the Quality Control Manager to issue the drawings. The Quality Control

Manager will verify that each drawing is the most updated version, and that any and all changes

or variations are noted thereon as applicable to the job.

2.4 RECORDS

2.4.1 R-B Pump, Inc. utilizes a sequential numbering scheme, which assigns a year specific and

serialized number to arrive at a job number. This number is the serial identification number used

to identify a particular pump. With this number the complete manufacturing history of the pump

can be traced. A job folder is created with the job number as its reference and all quality records

pertaining to that particular job are stored in that folder.

2.4.2 R-B Pump, Inc. will maintain and use job drawings inspected by the Quality Control Manager,

and performance records generated after completion of tests as a reference for future spare parts.

These records, which are stored in the Job Folders, shall be available for review by the Customer

Representative, and copies of individual records, which are not considered proprietary as agreed

to between R-B Pump, Inc. and the customer, shall be furnished upon request.

2.4.3 At all designated inspection points, the Quality Control Manager shall inspect parts for

conformance to drawings or purchase order. Any non-conformance shall be subject to cause for

rejection.

2.4.4 Quality Control shall maintain all Certificates of Conformance from other vendors and suppliers

that items ordered adhere to the Purchase Order and any other specifications necessary.

2-5

2.4.5 Quality Control Manager shall document on the purchase orders whether material received is in

compliance to order. This documentation shall remain as a permanent record that will be filed

with the job or contract folder.

2.4.6 All Quality Records shall be stored in accordance to the Retention and Control of Quality

Records (Figure 2-2).

2.4.7 The Quality Control Manager will conduct a periodic audit of various records when they are

turned over to him for filing.

2.5 CORRECTIVE ACTION

2.5.1 The Quality Program is designed to detect areas of nonconformance through the use of

inspection stations and control of procedures.

2.5.2 R-B Pump, Inc. will take prompt action to correct conditions which have resulted, or might result

in submissions to the Government, of supplies and/or services which do not conform to one or

more of the following in a timely manner:

A) The Quality Assurance Provisions of the item(s) specification(s).

B) Inspections and tests required by the contract to substantiate product conformance.

2-6

2.6 QUALITY RESPONSIBILITIES

2.6.1 General Management

Maintain a consistent quality policy.

2.6.2 Accounting

Maintain suitable records and reports of quality costs.

2.6.3 Industrial Relations

(A) Provide adequate supervision to assure manufacturing of parts meeting specified

requirements.

(B) Investigate and correct chronic problems.

(C) Develop quality-mindfulness.

(D) Utilize Quality Control Department services as required.

2.6.4 Product Manufacturing Responsibilities

(A) Specify methods clearly, accurately, and completely, and assure that they permit high

quality production.

(B) Include all necessary inspection, operations, and procedures in work orders.

(C) Co-operate with the Quality Control Department to assure selection and receipt of

equipment meeting requirements and simplifying quality production.

(D) Improve methods to produce better products economically.

2.6.5 Engineering Responsibilities

(A) Define specifications and other product requirements clearly and completely.

2-8

(B) Establish designs which are readily adaptable to fabricating equipment and personnel

capabilities.

(C) Utilize reasonable standards for tolerance, finishes, etc.

(D) Assure adequate drawing clarity and system.

(E) Maintain schedules which permit shop planning and reasonable manufacturing spans.

(F) Co-operate with Quality Control, Manufacturing Engineering, and Production to evaluate

problems and to improve designs from manufacturing feedback information.

2.6.6 Purchasing Responsibilities

Assume prime responsibility for material conformance per Bill of Material.

2.7 CONTRACT PROCESSING

2.7.1 Contract Administration

Subsequent to the award of a contract, a Contract Administrator:

(A) Assigns the responsibility for coordination of the legal aspects of the contract.

(B) Advises the Engineering Department of the award of the contract and the extent of

release (engineering, materials, fabrication, shipments, etc.)

(C) Transmits all contract information to cognizant personnel and maintains complete

contract files for reference by personnel throughout the organization.

2.7.2 Contract Engineering Department

Upon notification of the awarding of a contract by the Contract Administrator, a Project

Engineer is assigned to process the work. The Project Engineer is responsible for all of the

following technical aspects of the contract:

2-9

(A) Assigns the responsibility for coordination of the legal aspects of the contract.

(B) Material requisition is forwarded to the Purchasing Department where the purchase order

is written.

(C) The Project Engineer, through the Contract Engineering Section, is responsible for proper

distribution of drawings. Initial release of the drawings is made to the Quality Control

Department.

(D) Originate the “Job Folder” by assigning shop order number.

(E) Prepare preliminary schedule in order to determine the schedule data for the supply of

vendor material as required by R-B Pump, Inc.

(F) Make necessary arrangements for material by preparation of a Purchase Requisition or

Stock Reservations.

(G) Determine the need for special shop aids and notify the Manufacturing Department to

design required fixtures or machines.

(H) Plan work load and schedule parts production.

(I) Expedite jobs that are behind schedule by notifying the appropriate foreman to give more

attention to the job.

(J) Work with Contract Coordinators in expediting component parts that are needed for final

assembly of the contract.

2.7.3 The inspection status of any in-process item which is being manufactured at R-B Pump, Inc.,

shall be positively identified by the Quality Control Inspector. The system will allow for the

identification of any end item, which has been placed at the designated Inspection Point prior to

2-10

assembly for dimensional review. It is at this point that a completed part must be approved

before continuing on into the assembly process or storage area. Inspection status of any in-

process item, which is being manufactured at R-B Pump, Inc., as well as vendor supplied, shall

be achieved by the use of a color coded sticker as follows:

(A) No Sticker/Tag - Item has not been inspected and cannot be used until inspection is

performed.

(B) Red Sticker/Tag – Item has been rejected and will be segregated.

(C) Green Sticker/Tag – Item is accepted and can be placed into the assembly process or

segregated storage area.

Only those items, which have been accepted with green tag shall be used in the assembly

process. Each job shall be identified with a serial number, which shall be prominently placed

on the work order pallet. All items placed on this pallet shall be recognized as approved parts

that have been pulled from approved storage areas or designated inspection points. Due to

sampling inspection of parts, many items on the work order pallet may not have green tags

attached thereto; however, this does not constitute a non-approved part.

2.7.4 Manufacturing Department

Upon receipt of the fabrication drawings and the Bill of Materials, the foreman, reviews the

information for compatibility and plans his operations in accordance with the requirements. In

the event operations, must be changed for any reason, the foreman notifies the Quality Control

Manager, who will access the situation and respond to the correct department to rectify the

problem. Upon issuing the Change Order to the appropriate department, this department will

2-11

correct the problem and repeat the steps previously mentioned for the movement of drawings,

Bill of Materials, etc., prior to distribution to shop personnel.

2.8 GOVERNMENT FURNISHED MATERIALS / SERVICES

2.8.1 When material is furnished by the Government, R-B Pump, Inc. procedures shall include, as a

minimum, the following:

(A) Examination upon receipt, consistent with practicability, to detect damage in transit.

(B) Inspection for completeness and proper type.

(C) Periodical inspection and precautions to assure adequate storage conditions and to guard

against damage from handling and deterioration in storage.

(D) Functional testing, either prior to or after installation, or both, as required by contract to

determine satisfactory operation.

(E) Identification and protection from improper use or disposition.

(F) Verification of quantity.

2.8.2 R-B Pump, Inc. shall report to the appropriate Government Representative any Government

furnished materials found damage or malfunctioning during or after installation. R-B Pump, Inc.

shall determine and record any probable cause and the necessity for withholding material from

use.

2.8.3 When Government inspection is required at R-B Pump, Inc. subcontractor’s facility, the

following statement shall be added to the Purchasing Documentation:

2-12

“Government inspection is required prior to shipment from your plant. Upon receipt of this

order, promptly notify the Government Representative who normally services your plant so that

appropriate planning for Government inspection can be accomplished.”

2.8.4 When under authorization of the Government Representative, copies of the Purchasing

Document are to be furnished directly by the subcontractor or vendor to the Government

Representative at his facility, rather than through Government channels. R-B Pump, Inc. shall

add to its Purchasing Documentation the following statement:

“On receipt of the order, promptly furnish a copy to the Government Representative who

normally services your plant, or, if none, to the nearest Army, Navy, Air Force, or Defense

Supply Agency Inspection Office. In the event the office or representative cannot be located, our

Purchasing Agent should be notified immediately.”

2-13

SECTION THREE

FACILITIES AND STANDARD

3.1 DOCUMENTATION OF DRAWING CHANGES

3.1.1 Drawing and change control shall be accomplished by the following procedure which concerns

itself with the correctness of drawings, procedures, and specifications.

3.1.2 Drawings, specifications, and changes in all forms that are required by the contract or purchase

order will be initially routed to the Engineering Department for checking and updating. The

Chief Engineer and Quality Control Manager shall maintain master copies of all drawings,

specifications, and other applicable data. Engineering shall be responsible for identifying all

drawing revisions on the drawings by adding an alphabetical character next to the drawing

number.

3.1.3 Following acceptance of a drawing or drawing change by the customer, Engineering will furnish

copies to the Quality Control and Plant Foreman to commence manufacturing.

3.1.4 After going through proper channels for distribution, the Shop Foreman, whose process is

directly affected by the drawing change will receive a copy of the print with the applicable

changes and approvals. Each manufacturing point shall have this drawing at all times that

process is being performed on the item at the particular work station. Upon completion of all

processes for the item, both the part and drawing shall be returned to the Shop Foreman, who

will place the two at the Specified Inspection Point. Quality Control will then check the part for

conformance to the shop drawings for the part being manufactured. The Chief Engineer will

review any deviations noted on the drawings and the Quality Control Manager will determine the

3-1

parts disposition. Any variations to subject reviewed drawings shall be held as permanent record

in the Job Folder. All the Job Folders are filed in the Service Department for future reference.

3.1.5 Any errors or necessary changes that are found during the shop processes shall be reported

immediately to the Foreman in charge. The Foreman will then contact the Quality Control

Manager, who will initiate an engineering change request that will reviewed by the Chief

Engineer. All changes made to subject drawings shall be logged into the Engineering Change

Record (Figure 3-1), which shall be maintained by the Engineering Department.

3.1.6 No changes shall be made on drawings for fire pumps manufactured to Factory Mutual Standards

without obtaining Factory Mutual approval first. A copy of Approved Product/Specification

Tested – Revision Report, Form 797 (Figure 3-2), shall be submitted to Factory Mutual for

review.

3.1.7 For Additional information, refer to Design, Production and Quality Control Procedures

Section 1.1 Drawing Change Control Procedure.

3.2 MEASURING AND TEST EQUIPMENT

3.2.1 R-B Pump, Inc. provides and maintains test equipment, which requires calibration. A copy of all

the calibration is kept in the Engineering Department. The calibration of each individual piece of

equipment will be documented on the Calibration Data Sheets.

3.2.2 The equipment mentioned shall be calibrated against certified measurement standards by

Quality Control once a year, or as required by industry standards. If a piece of equipment is

damaged or abnormally handled, it shall be re-calibrated and identified.

3-2

3.2.3 Any measuring or test equipment that requires calibration, according to the schedule stated

above, shall be accomplished in a manner traceable to the National Bureau of Standards.

3.2.4 A sticker on the item identifying the date calibrated and the due date for the next calibration shall

identify all measuring and/or test equipment that requires calibration. A log book is also

maintained identifying equipment that is to be calibrated. A Calibration Record (Figure 3-3) will

be filled out for each piece of equipment and kept up-to-date in the log book by the Quality

Control Manager.

3-5

SECTION FOUR

CONTROL OF PURCHASES

4.1 RESPONSIBILITY

4.1.1 R-B Pump, Inc. shall be responsible for assuring that all material and services procured from

their suppliers conform to the purchase order requirements.

4.1.2 Selection of suppliers shall be used on their ability to perform satisfactorily as well as evidence

of their capability to furnish quality supplies and services.

4.1.3 The suppliers shall be given the applicable design and quality information to the extent necessary

to assure quality supplies.

4.2 PURCHASING DATA

4.2.1 All purchase orders shall identify the required level of quality, applicable specifications and

standards.

4.2.2 Purchase order shall be clear and complete with regard to specific requirements not covered by

the drawing or the referenced specification.

4.2.3 Prior to release of purchase order, it will be checked by Purchasing and Quality Control to

determine if the following requirements are complied with:

(A) Special inspection requirements are clearly stated.

(B) The type, description, and quantity are clearly stated.

4-1

(C) Applicable requirements reference to, including drawings and specifications are in

accordance with the purchase order.

(D) Delivery schedule is specified.

(E) Proper certifications have been requested if required.

(F) If customer source inspection is required, determine if it is properly noted and approved

by Quality Control.

4.2.4 One copy of each purchase order (yellow copy) is filed in the Job Folder. A copy of all the

purchase orders is kept in the Purchasing Department.

4.2.5 A purchase order shall be typed for each major item (Motor/Diesel Engine, Controller, Jockey

Pump, Jockey Pump Controller, etc.) referred on sales order form.

4.3 INVENTORY CONTROL

4.3.1 Incoming inventory has three primary classifications for distribution, storage and documentation:

(A) Government Contracts

(B) Commercial Jobs

(C) Stock Items (or Inventory)

4.3.2 Inventory and distribution of such will be the responsibility of the Receiving Inspector, who will

answer to the Quality Control Manager.

4.3.3 The quality checklist for incoming items by the Receiving Inspector is as follows, as a minimum:

(A) Quality of product

(B) Rough dimensions on bulk items

4-2

(C) Quantity

(D) Visual Inspection

(E) Conformance of item to the description on the purchase order.

(F) Dimensional Accuracy on any finished products from another manufacturer’s drawings.

(G) The comparative accuracy between the packing ticket and the purchase order number, job

number and the item description.

4.3.4 The following items are needed as documentation of incoming supplies for Government

Contracts/Orders:

(A) Packing Ticket

(B) Certificate of Compliance (if applicable)

(C) Receiving Inspection Report

4.3.5 The Receiving Inspector shall check with the Purchasing Department for any purchase order to

received item comparison, and with the Quality Control Manager for any clarifications prior to

accepting incoming stock.

4.3.6 The Quality Control Manager shall have the ultimate responsibility for a decision to accept or

return an item, which does not pass the incoming inspection.


Section 3.2.2.1 Receiving Inspection

4-3

SECTION FIVE

MANUFACTURING CONTROL

5.1 MATERIALS AND MATERIAL CONTROL

5.1.1 A certificate of conformance or test report, if called out in the purchase order, will be required

with each shipment of raw materials and products, and shall be inspected upon receipt to the

extent necessary to assure compliance with the requirements of the purchase document. All

these test reports are filed in the Vendor Account Folder unless specially ordered for the Job

where it will be filed in the Job Folder.

5.1.2 Tested and approved products shall be identified by either Acceptance Tags or by written

notations directly on the item. Rejected or non-conformance material shall be returned to the

supplier for replacement with correct material or disposed of (whichever is more economical or

feasible).

5.1.3 A complete breakdown of the flow of processes upon the receipt of an order or contract can be

traced in Figure 5-1, 5-2 and 5-3.

5-1

5.2 RECEIVING INSPECTION

5.2.1 The following are the procedures for inspecting incoming materials:

(A) Mill test reports are checked against specifications for compliance with chemical and

physical requirements.

(B) Items requiring dimensional inspection shall be subject to sampling inspection before

moving to their designated storage areas.

(C) Items requiring dye penetrate inspection are routed to designated areas for this purpose.

(D) Items that are purchased to R-B Pump, Inc. drawing specifications with special

tolerances, are sent to an inspection bench for checking with precision tools.

(E) All items that are in-process for use on a job shall be identified through the use of a tag

attached to the item or to the container in or on which they are placed.

(F) Those items received against a purchase order shall be checked for compliance to order

and it shall be noted on purchase order of said compliance.

5.2.2 Every item received shall be inspected upon receipt as soon as possible, and always before being

placed in the Issuing Area. Bulk items, such as nuts, bolts, etc., shall be inspected as follows:

(A) Quantity (for correct amount)

(B) Visually (to show that no cracks are evident or parts are broken)

(C) Dimensionally (to measure that the size, length, etc., is by the purchase order)

(D) Physically (to assure that the materials are accurate)

These types of inspections on bulk items can be performed by sampling a few pieces of the product,

except for the overall quality. However, items delivered in small quantities shall receive 100% complete

5-5

inspection for any discrepancy to the item purchased. To determine the sampling plan requirements

ANSI/ASQC 21.4 shall be followed. The sampling plan grade shall be AQL 2.5%, Level II.

5.2.3 The Inspection Receiving Report (Figure 5-4) which is applicable to only Government Contracts

shall contain the following information:

a) Purchase Order Number

b) Job Number (item was purchased for a job) or Stock (item was purchased for stock)

(1) Customer Name (applicable only for job number) (2) Customer P.O. (applicable only for job number) (3) Estimated Ship Date (applicable only for job number)

c) Vendor

d) Description

e) Inspection Type

(1) Visual Inspections shall include obvious defects, cracks, and shortages (2) Dimensional Inspections shall have dimensional inspection sheet attached (3) Functional Inspections shall have performance data attached

f) Quantity Ordered

g) Quantity Received

h) Quantity Accepted

i) Quantity Rejected

j) The signature of the inspector

k) The date of inspection/receipt

l) A brief description of any non-conforming material, including the nature of the discrepancy and

the disposition of the item.


Section 3.2.2.1 Receiving Inspection.

5-6

5.3 PROCESS CONTROL

5.3.1 Special processes involved are:

(A) Machining ( Refer to Design, Production and Quality Control Procedures Section 2.1 )

(B) Welding ( Refer to Design, Production and Quality Control Procedures Section 2.4 )

(C) Assembly ( Refer to Design, Production and Quality Control Procedures Section 2.2 )

(D) Testing ( Refer to Design, Production and Quality Control Procedures Section 3.3 & 3.4 )

(E) Painting ( Refer to Design, Production and Quality Control Procedures Section 2.3)

5.3.2 On all new set ups for first runs, a complete detailed inspection will be conducted on the first

piece produced. If the first piece deviates from requirements in any respect, adjustments will be

made to bring the item within the requirements prior to commencing production.

5.3.3 The elements of control are as follows:

(A) Procedure and process instructions.

(B) In-process inspection of each individual part/operation. - Every item shall be inspected at

the designated inspection station as soon as possible, and always before being placed in

stock or issued to a Job Order. Parts shall be inspected as follows:

1. Visually (to show that no cracks are evident or parts are broken)

2. Dimensionally (to comply with drawing)

3. Physically (to assure that the materials are accurate)

Inspections of bulk quantity parts can be performed by sampling a few pieces of the

product, However, items examined in small quantities shall receive 100% complete

inspection. To determine the sampling plan requirements ANSI/ASQC 21.4 shall be

followed. The sampling plan grade shall be AQL 2.5%, Level II.

5-8

(C) Final assembly inspection of the pumps. – All pumps shall be examined for compliance

to customer order requirements. For fire pumps the additional test procedures outlined in

Section 9 Fire Pumps shall be followed. All documents required under this section shall

be permanently filed in the Job Folder.

5.3.4 If a special process is involved, a written procedure for carrying out the process will be presented

to the Shop Foreman and person(s) who will be performing the task. The procedure shall be in

the applicable work area for reference until the task is complete, at which time it may be

discarded.


Section 3.2.2.3 In-Process Controls.

5.4 NONCONFORMING MATERIAL

5.4.1 The R-B Pump, Inc. established system for controlling nonconforming material includes:

(A) Procedures for the identification, segregation and disposition of rejected supplies.

(B) All nonconforming supplies will be positively identified through the marking of the

container they are in, or individual marking to prevent use, shipment, and intermingling

with conforming supplies.

(C) All nonconforming material, regardless of source, be segregated and placed in an area

away from normal production flow. No items found to be nonconforming are to be left in

the production areas.

5-9

5.5 IN-PROCESS CONTROL OF GOVERNMENT CONTRACTED MATERIAL

5.5.1 R-B Pump, Inc. shall, through the use of a tagging system, identify the inspection status of all

materials throughout the manufacturing process.

5.5.2 Each item that is to be used in a Government Contract, or for sale to the Government, shall be

clearly identifiable. The tag shall be attached to the item/material itself or sufficiently attached

to the container in which, or on which, the item(s) is/are placed.

5.5.3 The identification tag, entitled the Shop Work Card, shall include the following information, as a

minimum:

(A) Contract Number

(B) Serial Number (if applicable)

(C) Previous Process (if applicable)

(D) Processes Awaiting (if applicable)

5-10

SECTION SIX

WELDING REQUIREMENTS

6.1 SCOPE.

6.1.1 Welding operators shall be qualified in accordance with current or applicable standards.

6.1.2 All welding procedures and processes shall be carried out in accordance with current or

applicable standards.

6.1.3 Welding symbols are used to convey the necessary welding information (weld size, type, etc.)

6.1.4 All welds are continuous, unless otherwise indicated by note on the drawing or by a skip-weld

symbol. Symbols govern any abrupt change in the outline of the joint or to the extent of

dimension lines.

6.1.5 Welding shall be done in the flat position where practical.

6.1.6 For the vertical position, the direction of welding shall be upward.

6.2 WELD PREPARATIONS

6.2.1 Surfaces to be welded shall be relatively smooth without any gouging and shall be free of dirt,

grease, scale, slag, or any foreign material.

6.2.2 Tack welds shall be made by the procedure used for the final weld or by an otherwise qualified

procedure. Cracked or defective tack welds shall be removed prior to final welding. Both ends

6-1

of sound tack welds shall be tapered by chipping, grinding, or burring to assure complete fusion

with the subsequent weld.

6.2.3 All visible defects such as cracks, unfused areas, overlap, high spots, poor head contour,

undercut, or porosity, shall be corrected before depositing the next bead. The area shall be

chipped out, ground or otherwise removed to sound metal before re-welding. Slag and spatter

shall be removed before depositing the next bead. Arc craters in completed welds shall be filled

to provide a uniform cross section for the entire weld length.

6.3 ELECTRODE STORAGE

6.3.1 Flux covered electrodes shall be kept in their sealed shipping containers until ready for use.

After opening the container, all electrodes shall be kept in a holding oven maintained at a

temperature sufficient to prevent moisture absorption.

6.3.2 In no case shall electrodes be exposed to the atmosphere for more than four (4) hours prior to

use. Unused electrodes must be returned to storage ovens.

6.3.3 The minimum temperature of parts to be welded shall be 50 degrees Fahrenheit.

6.4 GROOVED WELDS

6.4.1 The size of a groove weld is the depth of the groove. The weld depth shall be 100% of the plate

6-2

thickness unless a definite depth is specified on the weld symbol.

6.4.2 For a weld depth of 100% of the plate thickness on single groove welds without backing strips

and on double groove welds, the back side shall be chipped, ground, machined, or gouged to

sound metal and welded after depositing at least two weld layers on the front side.

6.5 CONTROL OF STAMPS AND SIGNATURES

6.5.1 It shall be the responsibility of Engineering to maintain a file of Welder Certifications and

Welder Identification Stamps.

6.5.2 Each Certification shall show the following information:

(A) Welder’s name

(B) Identification symbol

(C) Welding process

(D) Type and thickness of base metal

(E) Type and size filler metal

(F) Welding position that the operator is qualified in

6.5.3 It shall be the responsibility of the Quality Control Manager to maintain a log of Inspector's

Signatures, and under no circumstances will anyone other than a member of the Inspection

Department sign any records indicating conformance.

6-3

SECTION SEVEN

CLEANING AND PAINTING

7.1 RESPONSIBILITIES

7.1.1 It shall be the responsibility of the Quality Control Manager and the Quality Control Inspector(s)

to insure that the correct processes and procedures, as outlined in the customer’s contract in

regards to cleaning and painting, are followed to all applicable standards.

7.1.2 Unless otherwise specified Reddy Buffaloes Pump Standard for Cleaning and Painting shall be

followed. Color of paint shall be in accordance to its use, i.e. Fire pumps shall be painted red,

and Navy pumps shall be painted machinery grey, and industrial pumps shall be painted to

customer’s requirement.


Section 2.3 Painting Procedure.

7-1

SECTION EIGHT

HANDLING & STORAGE

8.1 PRECAUTIONS

8.1.1 Raw materials shall be segregated from finished pumps. No special preservation or packaging is

required on raw materials unless specially mandated by the vendor supplier.

8.1.2 Care should be taken to keep raw materials stored in a dry ambient temperature. Ferrous parts

shall be stored under shelter to prevent excessive corrosion. All areas of storage shall be secure

and shall be in low traffic zones to prevent accidental damage.

8.2 PRESERVATION AND PACKAGING

8.2.1 Finished pumps shall be cleaned and painted per painting procedures. All exposed ferrous

surfaces shall be painted

8.2.2 Finished pumps shall be packaged in accordance to customer’s requirement. The customer’s

requirement shall be noted in the Contract Review and Planning Record if applicable. The two

basic methods of packaging are noted below:

8.2.3 Palletization - This method shall be used on all domestic shipments and export containerized

shipments and consist of lagging down the pump on a preformed pallet. The pallet shall be

either shrink plastic wrapped or cardboard boxed

8.2.4 Export Box – A wooden box shall be constructed to encompass the pump unit envelope. The

box shall be constructed of 2x4 wood with sufficient rigidity to support the static weight of both

the pump and box. The box size shall be minimized to allow ease of handling and transportation.

8-1

SECTION NINE

FIRE PUMPS

9.1 MANUFACTURE AND TESTING

9.1.1 All the fire pumps shall be manufactured to the same standards as applicable to other pumps,

except that no changes to design or materials are to be done without obtaining written permission

from Underwriters Laboratory (UL) and Factory Mutual (FM).

9.1.2 All the pumps are to be hydrostatically tested as specified by the Approval Agency in their

standard. If any doubt exists, the Quality Control Manager shall issue a written, signed notice of

the test pressure to be used. That notice shall become a permanent part of each fire pump’s

serialized file, along with the actual hydrostatic test result. A detailed copy of the hydrotest plan

is noted in the hydrostatic test procedure.

9.1.3 Each pump has to be tested to achieve the performance as specified by the customer. All the

instruments and gauges shall be calibrated at regular intervals. A record must be kept with direct

traceability to the N.B.S. A detailed copy of the performance test plan is noted in the

performance test procedure.

9.1.4 Each pump’s test data shall be processed and performance curves plotted. If the test data agrees

with the customer’s requirements and also meets the Approval Authority Specifications, the

nameplates shall be prepared. A sample copy of the test data is attached in Figure 9-1 and the

performance curve is shown in Figure 9-2.

9-1

9.1.5 A photocopy of the common Underwriters Laboratory / Factory Mutual nameplate shall illustrate

the configuration and test of all fire pump nameplates. The nameplate used on a given pump

shall only carry the mark of the listed pump model and rating. The Quality Control Manager

shall issue a written, signed instruction for each fire pump nameplate, clearly indicating which

agency mark(s) are to be used. That notice shall become a permanent part of each fire pump’s

individual serialized file. The pump serial number shall also be metal stamped into the upper

surface of the discharge flange perimeter (this is normally the thicker of the flanges). The serial

number stamping letters shall be 1/4” high or larger.

9.1.6 All the fire pumps, engines and motors shall be painted only with red paint after initially priming

the pump.

9.1.7 All the fire pump accessories also shall be painted with the same color as the main pump.

9.1.8 All the test data and performance curves and other notices specified above shall be kept in

permanent serialized files. A separate record shall be maintained for each fire pump serial

number assigned.

9.1.9 Impeller pattern cards shall be kept updated, with the job serial number, duty conditions,

impeller diameter, customer name, and motor or engine horsepower.

9.1.10 Nobody, including the Quality Control Manager, has any authority to substitute materials, parts,

or ship pumps which do not meet Approval Authority conditions without first contacting the

General Manager of the Plant.


Section 3.3 Performance Test and Section 3.4 Hydrostatic Test.

9-2

SECTION TEN

INTERNAL QUALITY AUDIT SYSTEM

10.1 SCOPE

10.1.1 The purpose of this section is to document the policy for the control of internal quality audits.

10.1.2 The Quality Control Manager is responsible for establishing and maintaining procedures which

control internal quality audits in accordance with the requirements of this Quality Control

Manual.

10.2 INTERNAL AUDITS

10.2.1 A comprehensive system of planned and documented internal quality audits is conducted in

accordance with documented procedures.

10.2.2 Audits are performed to verify that quality activities comply with planned arrangements and to

determine the effectiveness of the quality system.

10.3 AUDITORS

10.3.1 Auditors shall be independent of the area/function being audited.

10.4 REPORTING

10.4.1 Results of the audits are documented and brought to the attention of the personnel having

responsibility for the area audited.

10.4.2 Supervisors responsible for the area audited take timely corrective action on deficiencies.

10-1

SECTION ELEVEN

TRAINING OF PERSONNEL

11.1 SCOPE

11.1.1 The purpose of this section is to establish and document the policy for the control of employee

training, to ensure a competent workforce.

11.1.2 It is the responsibility of each Department Manager to ensure the control of training in

compliance with this section.

11.1.3 Human Resources is responsible for coordinating and maintaining training requirements

11.2 TRAINING

11.2.1 Supervisors will determine training needs for all job functions affecting product quality.

11.2.2 The Quality Control Manager will identify the quality training needs for each job function.

11.2.3 On the job training will be delivered by the Supervisor within each department.

11.2.4 New employees will receive indoctrination and on the job training as required for the position.

11.2.5 Any special training requirements beyond those delivered on the job shall be documented and

maintained in Human Resources. Human Resources shall evaluate training materials and

trainers qualifications prior to approving training.

11.2.6 Employees will be qualified to perform specific tasks based on education, training, and/or

experience.

11-1