aircraft systems & manufacturing, inc

AIRCRAFT SYSTEMS & MANUFACTURING, INC.

104 Golden Oaks Drive, Georgetown, TX 78628

Quality System Manual

Revision D

11 Mar 2016

This manual establishes and describes the

Quality Control/Assurance system used by Aircraft Systems & Manufacturing, Inc.

in support of Production Approval PQ0601SW

Required Physical Manual Distribution

1 of 5 Original-Document Control (Vault)

2 of 5 FAA

3 of 5 President

4 of 5 Director Quality

5 of 5 Production Manager

_________________________

Approved by FAA

This page deliberately left blank

Aircraft Systems & Manufacturing Quality Control Manual

Title: Introduction Issue Date: 27 Jun 2013

Page: i Revision: A

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

- TABLE OF CONTENTS i

- INTRODUCTION iii

- MANUAL CONTROL & REVISIONS iv

- RECORD OF REVISIONS v

- LIST OF EFFECTIVE PAGES vi

I HOUSING AND FACILITIES

II COMPANY ORGANIZATION

III OPERATIONS & PROCEDURES 3.1 Design Data Control 1

3.2 Document Control 4

3.3 Supplier Control 5

3.4 Manufacturing Process Control 7

3.5 Inspection and Testing 8

3.6 Inspection, Measuring and Test Equipment Control 11

3.7 Inspection and Test Status 12

3.8 Nonconforming Product and Article Control 12

3.9 Corrective and Preventive Actions 15

3.10 Handling and Storage 16

3.11 Control of Quality Records 17

3.12 Internal Audits 18

3.13 In-Service Feedback 19

3.14 Quality Escapes 20

3.15 Other Quality Procedures 22


Title: Introduction Issue Date: 27 Jun 2013

Page: ii Revision: A

Table of Contents (cont’d)

IV QUALITY CONTROL FORMS

4.1 QC Forms Index 24

4.1.1 Equipment Calibration Record 25

4.1.2 Vendor Survey Forms 26

4.1.3 Vendor Qualification Tracking 31

4.1.4 PO Receipt 32

4.1.5 Sales Order 33

4.1.6 Work Order 34

4.1.7 Purchase Order 35

4.1.8 MRB Record 36

4.1.9 Stamp Log 37

4.1.10 Stamp Impressions Sample 38

4.1.11 Harness Inspection Checklist 39

4.1.12 Kit Final QC Checklist 40

4.1.13 Manual Review Record 41

APPENDICES

Appendix A – MOU between ASW-190 and ASM 42


Title: Introduction Issue Date: 21 Apr 2014

Page: iii Revision: B

INTRODUCTION

This Quality Control Manual (QC Manual) is prepared in accordance with the current

Federal Aviation Regulations, 14 CFR Part 21.307 for PMA Production Approval Holders

(PAH), and the policies of Aircraft Systems & Manufacturing, Inc., also known as ASM.

This manual complies with 14 CFR 21.308 and explains the structure, operations and

administrative requirements of ASM’s PAH in detail. It gives examples of quality forms used

and their method of execution.

Manufacturing of products by ASM’s PAH will be performed in accordance with current

Federal Aviation Regulations (FARs), approved manufacturer's data, drawings,

specifications, ASM’s Quality System Manual and bulletins, and other technical data

approved by the administrator for the particular product or part.

In all circumstances, parts will be manufactured that conform to approved data, are airworthy

and safe for installation and use.

ASM’s Manufacturing Operations and Quality Control are conducted in a separate building a

short distance from the company headquarters. The HQ building houses Administration,

Engineering, Document Control, Archives and Purchasing. Information and requirements

flow in both directions digitally, telephonically and in person, as required.

Documents required for the operation of ASM’s PAH will be kept in the technical library

and maintained in a current status at all times by Document Control.

Management, production and inspectors in the PAH will have a current copy of this manual

in their respective work areas. All personnel will be provided training by the Director of

Quality on the directly applicable portions of this manual and must thoroughly understand

its contents. A record of this training will be kept in individual personnel files.

This manual is approved by the FAA, and compliance with all procedures herein is

mandatory.

The aviation industry is wide ranging, complex and dynamic. It is not possible to cover every

possible situation within either the regulations or a manual. Deviations from the manual must

be authorized in writing by ASM and the FAA.

THIS REVISION OF ASM’S QS MANUAL SUPERCEDES AND REPLACES ALL

PREVIOUS REVISIONS.


Title: Introduction Issue Date: 21 Apr 2014

Page: iv Revision: B

MANUAL CONTROL & REVISIONS

PROCEDURES

1.Each manual will have a control number and an assignment entry on the manual cover

page. A master list containing the manual number, location and revision status will be

maintained by document control.

1.1 The approved original paper manual with physical signatures will be stored in ASM’s

vault in the fireproof safe.

2.The manual will be provided in paper form (copy) to all applicable work areas. A current

on-line (electronic) edition, will be maintained on ASM’s internal secure web-site for

reference by all authorized users.

3.The Director Quality will have those revisions he finds necessary produced in a final form

and transmitted by electronic means (e-mail) to the FAA Manufacturing Inspection District

Office (MIDO) in San Antonio, TX for review and approval, prior to implementation.

4.All proposed changes to the manual will be coordinated with and approved by the FAA

prior to implementation. The Director Quality will be the focal point of applicable FAA

communications. Generally, approved changes are effective immediately unless otherwise

specified.

5.The QC manual is organized for revisioning purposes by a List of Effective Pages. Upon

approval by the FAA, sufficient copies will be made and distributed to provide revision

pages for each physical manual holder.

6.Upon receipt of a revision, each manual holder will be responsible for inserting the revised

pages into its manual, record the revision on the manual’s record of revision page.

7.The Director Quality will audit manuals annually for accurate revisioning, and continued

applicability, and will annotate the inspections on the Manual Review Record (see Section

IV)


Title: Introduction Issue Date: 11 Mar 2016

Page: v Revision: D

RECORD OF REVISIONS

Retain this record in the manual. Upon receipt of revisions, insert revised pages in the

manual, remove superseded pages, and enter the revision number, revision date, insertion

date and initials of person incorporating the revision, in the appropriate block on the Record

of Revisions.

Revision

No. Revision

Date

Insertion

Date By:

Audit

By:

Initial

Release 04/16/2011

A 27 Jun 2013

B 21 Apr 2014

C 23 Oct 2015

D 11 Mar 2016


Title: Introduction Issue Date: 11 Mar 2016

Page: vi Revision: D

LIST OF EFFECTIVE PAGES

SECTION - - TABLE OF CONTENTS & FRONT MATTER PAGE Cover i ii iii iv v vi REVISION D A A B C D B

DATE 03/11/2016 06/27/2013 06/27/2013 04/21/2014 10/23/2015 03/11/2016 04/21/2014

SECTION I - HOUSING AND FACILITIES

SECTION II - COMPANY ORGANIZATION PAGE REVISION

DATE

SECTION III – OPERATIONS AND PROCEDURES PAGE 1 2 3 4 5 6 6A 7 REVISION A A A B B A A B

DATE 06/27/2013 06/27/2013 06/27/2013 03/11/2016 03/11/2016 06/27/2013 03/11/2016 03/11/2016

PAGE 8 9 10 11 12 13 14 15 REVISION A A A A A A A A

DATE 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013


DATE 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013

SECTION IV – QUALITY CONTROL FORMS PAGE 24 25 26 27 28 REVISION A A A A A

DATE 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013


DATE 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013

PAGE 37 38 39 40 41 42 43 REVISION A A A A A A A

DATE 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013 06/27/2013

PAGE 1 REVISION IR

DATE 03/11/2016

Section I: Housing and Facilities


Title: Housing & Facilities Issue Date: 11 Mar 2016

Page: 1 Revision: IR

1.1 LOCATION

1.1.1 Corporate Headquarters

Aircraft Systems & Manufacturing, Inc., a Texas corporation, is located at:

Aircraft Systems & Manufacturing, Inc.

104 Golden Oaks Drive

Georgetown, Texas, USA 78628

512-869-2737 (office)

www.asminc.net

[email protected] (email)

Functions integrated at the headquarters building include corporate offices,

administration, engineering and design, document control, purchasing and quality

management. All mail service for the company is directed to this location.

1.1.2 Manufacturing

Manufacturing is a satellite facility in close proximity of the headquarters, located

at:

105 Halmar Cove

St 170

Georgetown, Texas, USA 78628

512-943-8432 (office)

Functions integrated at the manufacturing facility include receiving and incoming

inspection, stores, assembly and fabrication, test and inspection, and shipping.

Quality records are stored digitally on distributed servers. This address is used for

shipping and deliveries only, no mail service.

http://www.asminc.net/

mailto:[email protected]

Section II: Company Organization

Section III: Operations & Procedures


Title: Operations & Procedures Issue Date: 27 Jun 2013

Page: 1 Revision: A

3.1 DESIGN DATA CONTROL

3.1.1 Design Data

Design data is generated and/or aggregated by ASM’s Engineering staff. Finished

data is managed by Document Control, see paragraph 3.2. The data packages are

coordinated with, reviewed by and ultimately approved by the FAA, in accordance

with current rules, policies and procedures. Any data element, whether a report,

list, diagram, etc., is generically referred to as a “drawing”. Each data package is

unique in format and content, however the following data elements, relevant to

manufacturing and quality, are common and consistent within each data package:

3.1.1.1 Top Drawing List or TDL (also referred to as “Master” drawing list).

List of all drawings, documents and data pertinent to the project

May include other subordinate lists, such as a Fabricated Parts List, Kit

Contents List, etc. Each project varies depending on the complexity of the

project. Certain documents may be embedded within others, or may not be

applicable, or may be titled differently or formatted differently than past

projects. This is determined by engineering, as required.

Drawings/data are listed by drawing number, drawing title, revision level

and date of revision. FAA approval of the Top Drawing List confers

approval of all subordinate drawings listed thereon. Coordination of data

submittal to the FAA and approvals thereof is per Memorandum of

Understanding (MOU) between ASM and ASW-190, dated April 7, 2005.

3.1.1.2 Fabricated Parts List or FPL

List of all drawings relevant to manufacturing of parts (as opposed to

“buy” parts such as standard and/or TSOA parts.

Includes all fabrication drawings for parts and assemblies, special process

drawings, and specification control drawings for parts manufactured to a

certain design which are not considered “standard” or TSOA parts.

Drawings/data are listed by drawing number, drawing title, revision level

and date of revision.



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3.1.1.3 Kit Contents List or KCL

List of sub-kits/sub-assemblies which, when aggregated, form a complete

STC PMA installation kit by part number.

Generally, but not always, ASM applies for PMA of the complete STC

installation kit part number, rather than individual or sub-component parts.

Revision status of the kit part number is defined by the revision status of

the TDL.

3.1.2 Revision Control

All drawings listed under the Top Drawing List, and the TDL itself, are controlled

by revision and date. There are uncountable reasons to revise data. This procedure

does not define the necessity for revisions, only the processes necessary to control

revisions.

3.1.2.1 Generally, any change in any subordinate drawing in a data package causes

that changed drawing to be revised, and any other affected drawings to be

revised concurrently. At a minimum, the Top Drawing List must be revised to

account for any change in revision status of a subordinate drawing.

3.1.2.2 An Engineering Change Order (ECO) is the normal vehicle for defining

changes to a drawing. The ECO form is generated from a sequential list and

log maintained by Engineering, so that each ECO is unique for each drawing,

and accompanies the drawing for its life cycle. In rare circumstances the

required change is easily described on the drawing’s revision table, obviating

the need for an ECO.

3.1.2.3 Revision bars, revision clouds, or change flags are the preferred method of

indicating a change in the body of a drawing and constitute a good practice,

however, are not required.



Page: 3 Revision: A

3.1.3 Approval

All drawings must be approved before manufacturing may commence.

3.1.3.1 Engineering Approval or Release. This usage of the term “approved” in

engineering drawing title blocks DOES NOT imply FAA approval of the

drawing. This usage indicates that the drawing is completely finished through

ASM’s design, drafting, checking and configuration management, and is in a

state where it can be reviewed and evaluated by FAA personnel for

compliance with regulations.

Engineering Approval or Release is indicated on drawings by the engineer’s or

other company authority’s initials or signatures and dates in appropriate blocks

on the body of the drawing and ECO, if applicable. Engineering Approved or

Released drawings may be used for planning, purchasing, R&D and

prototyping purposes only.

“FAA APPROVED” or “FAA DER APPROVED”. Indicates that the

drawing(s) have been reviewed and evaluated by appropriate FAA personnel,

the design/drawings comply with applicable regulations, and may proceed to

manufacturing.

FAA Approval may be in the form of an FAA Form 8110-3 from a qualified

FAA DER, or in the form of an FAA stamp on the drawing with the FAA

project engineer’s initials.

Revised data is submitted periodically to the applicable ACO on a schedule

and in a form determined by the ACO, or per MOU dated Apr 7, 2005.

Revisions of Instructions for Continued Airworthiness (ICA) are coordinated

with the ACO and applicable AEG.


Title: Operations & Procedures Issue Date: 11 Mar 2016

Page: 4 Revision: B

3.1.4 Distribution

Design data is distributed to authorized users according to need. Method of

distribution is also according to need.

3.1.4.1 FAA personnel are authorized unlimited access to all design data at any time.

They have access to all paper and electronic records on demand.

3.1.4.2 Manufacturing personnel are provided approved design data as necessary to

accomplish specific tasks in hardcopy or electronic format.

3.1.4.3 Customers (end users), when licensed, are authorized all pertinent design,

installation, operational, and maintenance data. Proprietary data may be

released to customers on a case-by-case basis. Data may be provided in

hardcopy or electronic format.

3.1.4.4 Certain data may be used for educational or marketing purposes. Data used for

these applications is not considered “FAA Approved”, regardless of original

approval status.

3.1.4.5 Revised data is made available to authorized users as required. Document

control is responsible for providing current, approved design data to suppliers

(fabricators) and ASM’s manufacturing personnel for building and inspection

of parts.

3.2 DOCUMENT CONTROL Doc Control manages storage, distribution and change process of all data.

Data may be in paper (hardcopy) or electronic format or both.

3.2.1 Design Documents and Data

Design data is maintained in secure storage systems, both physical for

hardcopy and in distributed databases for electronic data. Data includes

engineering drawings, diagrams, reports, test results and supporting data,

among others. Hardcopy is under lock and key or restricted access. Electronic

storage is password protected with multiple backups.

3.2.1.1 All current engineering data is stored in hardcopy format in the vault.

Hardcopy revisions of data (historical data) prior to 1 Jan, 2011 are stored in

ASM’s archives and scanned to digital format as time allows.

3.2.1.2 Data revisions post 1 Jan, 2011 are stored in distributed databases in native

format or scanned to common format. Hardcopy prints are provided to all

authorized users on demand.



Page: 5 Revision: B

3.2.1.3 All design data is retained indefinitely.

3.2.2 Quality System Documents and Data

Quality system documents and data include this QC manual, forms, checklists,

reports, purchase orders, work orders, material certs and other records applicable

to the manufacturing (including acquisition of raw materials), inspecting, testing

and delivery of parts produced under the PAH’s authority.

3.2.2.1 The QC Manual is FAA approved by revision level. Proposed changes must

be reviewed and approved by the FAA prior to implementation. The

introductory paragraphs of this manual describe revision and control

procedures for the QC Manual.

3.2.2.2 Purchasing, traceability and material certification documents are scanned and

filed in a searchable database as they are received, and printed out as required.

The database is username and password protected.

3.2.2.3 Work orders, inspection checklists, Acceptance Test Procedures (ATP)

reports, copies of airworthiness certificates, certificates of compliance (C of

C’s) and shipping documents accompany each lot (typically a discrete

installation kit) as it progresses through the line. During final inspection, all

data is reviewed, collated and packaged for filing. Each QC data package is

dated and filed by project number in office type file cabinets until scanned for

digital archives.

3.3 SUPPLIER CONTROL

3.3.1 Purchasing Department

ASM’s Purchasing Department is responsible for all aspects of purchasing (with

the exception of invoicing and payment), receiving, stocking, kitting and

exercising surveillance and qualification of suppliers of materials.

3.3.2 Fabricators

ASM contracts with specialist fabricators to manufacture sheet metal and

machined parts. Those parts are manufactured to ASM supplied engineering

drawings. Fabricators, due to the specialized nature and inherent complexity of

metalworking, require a high level of oversight. To the greatest extent practical,

fabricators must be qualified by on-site inspection, and must provide references

and samples of materials before a qualification determination is made.



Page: 6 Revision: A

3.3.3 Stocking Distributors

Distributors of “standard” and common aviation parts provide centralized

distribution of parts from many different manufacturers, or may combine

manufacturing and distribution of certain parts.

3.3.4 OEMs

OEMs manufacture discrete units, such as LRUs, antennae, indicators, etc, usually

under TSOA or PMA.

3.3.5 Vendor Surveys

All vendors are required to be initially qualified and to maintain qualification. All

vendors are subject to on-site surveillance by ASM quality personnel, either for

initial qualification or for maintenance of qualification.

3.3.5.1 Candidate suppliers must normally fill out and return a general ASM vendor

survey. Many large national vendors refuse on the grounds of too many

customers with too many surveys. Alternative qualification may be supported

by review of certifications, (ISO, ASI, etc), evaluation of the vendors quality

manual, distributor’s franchise, criticality of the parts, and vendor status with

other OEMs. If alternately qualified, copies of documents evaluated are

maintained with the vendor’s file.

3.3.5.2 To the greatest extent possible, ASM quality personnel should conduct an on-

site physical survey of the vendor’s plant to verify qualifications. Generally, if

located within the state, all vendors should be site surveyed prior to or within

a year of qualification.

3.3.5.3 A vendor’s sub-tier suppliers must also be qualified. The level of sub-tier

inspection and surveillance required is based on the criticality of the operation.

Finishing operations (paint, non-critical plating, etc), may be evaluated by

samples and surveilled during routine receiving inspections. Sub-tier suppliers

who provide tempering, heat treatment, welding, critical plating or exotic

processes must be qualified to the same extent and by the same methods as a

fabricator.

3.3.5.4 OEM vendors of TSOA / PMA parts are assumed pre-qualified by virtue of

existing FAA approvals, however parts and services provided receive the same

level of inspection/qualification to ensure that OEM parts conform to their

approved design and are in a condition for safe operation.



Page: 6A Revision: A

3.3.5.5 Foreign vendors (non-US, overseas) require special qualifications efforts.

3.3.5.5.1 ASM will only qualify foreign vendors of non-safety, non-critical parts, and

only when such parts are not manufactured or distributed by qualified U. S.

vendors.

3.3.5.5.2 Vendors in Canada and the European Union who are subject to EASA rules,

will be qualified in the same manner as US based vendors. On-site evaluation,

while desirable, may not be possible due to funding constraints. This will not

be a disqualifying factor, so long as all other requirements are met.

3.3.5.5.3 Other foreign vendors (OFV) of non-safety, non-critical parts, must not have

US State Department and/or Commerce Department restrictions/sanctions.

3.3.5.5.4 OFV must submit an ASM Vendor Audit, in English, see 4.1.2.

3.3.5.5.5 OFV must submit a company quality manual, in English

3.3.5.5.6 OFV must submit copies of traceable, international certifications such as

ISO9001 and/or AS9100, if available. Such certifications are not required,

however, they provide strong evidence of a stable, reliable company with an

established quality system.

3.3.5.5.7 OFV must submit design documents for parts, in English, so that ASM can

verify conformity of parts. Acceptance Test Procedures for some assemblies

may be required, and special equipment, if required, must be provided by the

OFV.

3.3.5.5.8 If all requirements are met, then ASM will schedule an on-site vendor audit to

validate the OFV quality system. Audit criteria will include being provided

visible, credible evidence of compliance with items listed on the ASM Vendor

Audit Form.

3.3.5.5.9 If all requirements are met, then ASM will qualify the OFV as a provider of

parts. The OFV will be subject to re-audit, with reasonable notice, at any time

if there are significant instances of non-conformities.

3.3.5.5.10 All OFV parts must be accompanied by Certificates of Compliance. In

addition, Acceptance Test Reports for some assemblies may be required.

3.3.5.5.11 OFV can be disqualified at any time, for any reason.



Page: 7 Revision: B

3.3.6 Maintenance of Qualification

Generally, if the supplier remains qualified with ASM for a significant period of

time, adequate surveillance is assured through normal and routine receiving

inspections. At QC personnel’s discretion, or if there is indication of cause, the

vendor may be required to re-qualify.

All vendors are continuously rated by QC personnel based on discrepancies found

during receiving inspection, responsiveness to inquiries, and on time delivery. A

simple percentage ratio of acceptable parts delivered to rejections is recorded for

each delivery. A 10% rejection rate or higher may be cause for requalification,

suspension or termination of qualifications. Due to criticality or cost, a much

lower rejection rate may also be cause for further actions. Each situation must be

examined on its own merits. It is possible for a vendor to have a 100% quality

rating but become disqualified for other reasons.

3.3.7 Reporting of Vendor Supplied Non-Conformities

All vendors must report to the PAH any product or article released that is

subsequently found not to conform to PAH requirements.

3.3.8 Vendor Disqualification

A vendor may be disqualified at any time, for any reason, or for no reason.

3.4 MANUFACTURING PROCESS CONTROL

3.4.1 Manufacturing Processes

ASM’s standard manufacturing processes fall within OEM’s (Boeing,

McDonnell-Douglas, Airbus, etc) Standard Wiring Practices guidance, AC43-13,

or best commercial practices. Uncommon, special or exotic manufacturing

processes are either referenced in approved manufacturing drawings by Mil-Spec

number (chromium conversion, anodizing and priming metal surfaces), or are

defined by ASM Specifications and approved by the FAA.

3.4.1.1 Mil-Spec processes, such as conversion coatings, anodizing and priming are

accomplished by qualified fabrication vendors, and attested to by C of C’s

accompanying the delivered part.

3.4.1.2 ASM Specifications are a refinement or clarification of standard practices

adapted to ASM’s specific requirements. ASM specifications necessary for a

specific product are listed in Top Drawing List, Fabricated Parts Listing of the

data package, and are reviewed and approved by the FAA. Changes to

manufacturing processes are treated as changes of design data.

3.4.1.3 In addition to the drawings provided to manufacturing technicians, work

orders also list the ASM Specifications to be used for those products.



Page: 8 Revision: A

3.4.1.4 Proposed changes are forwarded to ASM Engineering for evaluation as a

change to design data and are processed in the same way.

3.4.1.5 ASM does not authorize unapproved, preliminary, experimental or

investigatory changes on production articles in-process.

3.4.2 Deliverable Software

ASM does not design, alter, modify or install deliverable software.

3.4.3 Non Deliverable Design Software

ASM uses commercial Computer Aided Design (CAD) software, authoring

software, and database programs for design and administrative purposes only, to

produce paper or paper equivalent drawings. In the event of prolonged power

outages, ASM Engineering will revert to prior generation revision design tools

(stubby pencil, #2, and yellow paper). No versioning or revision control of design

tools is required.

3.5 INSPECTION AND TESTING

3.5.1 Deliverable Products Inspection Procedures

ASM’s deliverable products are primarily PMA installation kits for avionics

upgrades, or sub-components of those installation kits. Typical kits consist of pre-

assembled wiring harnesses, nuts, screws and fastening hardware for electrical

components, circuit breakers and brackets.

3.5.1.1 Most of the sub-component parts of an ASM PMA installation kit go directly

from incoming receiving inspection to stores without further

assembly/modification. See Receiving Inspection, para 3.5.2 following.

3.5.1.2 Wire harness or component manufacturing requires in-process inspection steps

as listed on the work orders. Parts and assemblies are inspected as required,

and if satisfactory, the inspection step on the work order is signed off (or

stamped) by the inspector.

3.5.1.3 If the part or assembly does not pass inspection, it is reworked on the bench to

correct any defects and retested or reinspected.

3.5.1.4 Following final assembly, completed harnesses/components are forwarded to

QC along with associated work orders. QC verifies that in-process inspections

have been recorded on the work order, then provides a General Visual

Inspection (GVI) of the completed part to the approved manufacturing

drawing.



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3.5.1.5 Following the GVI, QC performs 100% electrical continuity test of all

terminated wiring, diode and resistor testing (if applicable), using approved

diagrams and test procedures (if applicable).

3.5.1.6 QC records the results of all testing and inspections on a QC checklist,

recording the rev level of all applicable drawings, serial number if applicable,

pass/fail annotation on all GVI details, and description of any GVI or

electrical discrepancies. If any discrepancies are detected, the part is returned

to the shop floor for rework

3.5.1.7 Parts that test 100% are routed to stores, along with the appropriate work

orders, check lists and test results as applicable.

3.5.1.8 Parts from stores are aggregated and organized as sub-kits with work orders

for each. When completed, QC inspects the completed kit using approved

drawings and the kit final checklist.

3.5.1.9 Following final QC, the completed kit is packaged and routed to stores.

3.5.2 Receiving Inspection Procedures

3.5.2.1 Purchase Orders are used to acquire all raw materials used in production of

approved parts. Purchase Orders are generated by the purchasing department.

Material requirements referenced on drawings and/or engineering

specifications, special tests or requirements will be furnished to the

Purchasing Department by Engineering for inclusion on the Purchase

Order.

Suppliers from whom materials and supplies are purchased will be

furnished with any applicable engineering drawings, engineering

specifications or special information in addition to the Purchase Orders,

as required.

Certification of material and/or processes must be supplied by the vendors.

3.5.2.2 Receiving inspectors will ensure that material orders to be inspected have:

a shipping list reflecting quantities shipped and engineering references by

revision level (if required), and,

Certificate(s) of Conformance signed and dated by the original

manufacturer and any distributors.



Page: 10 Revision: A

Note: MilSpec and standard parts are generally ordered by part number

alone. If not specified in approved drawings, revision level of

MilSpec and standard parts is not applicable.

Note: Fabricated parts are defined by drawing number and revision level.

Conformance to revision is required.

3.5.2.3 Receiving inspectors will inspect 100% of fabricated parts to approved design

/ fabrication drawings.

Verify each dimension shown on the drawing, as modified by notes and

tolerances, and,

Conduct electrical operations tests as applicable for electrical parts. Lamp

assemblies and certain switches may be tested on the bench with simple

apparatus. LRU’s and antennae are normally beyond ASM’s means of

electrical/functional testing.

Note: Inspectors must verify calibration of applicable measuring tools

prior to inspection.

3.5.2.4 MilSpec or standard parts in lots will be sample inspected by 10 items or 10%,

whichever is smaller, for nominal size, thread gauge, length, color, general

appearance, etc., as required.

Check for nominal characteristics to the greatest extent possible using

available measuring instruments.

If a sample lot passes inspection, and there are no other indications of non-

conformance, then all items in that lot pass.

If any of the sample items fail, then 100% of the remaining items must be

inspected, or the entire lot must be rejected.

3.5.2.5 Unless otherwise specified by approved design drawings, neither non

destructive inspection (NDI) nor sophisticated qualitative/quantitative testing

is required.




3.5.2.6 Prepare labels, tags, bags, as required with part number, P.O. number, rev

level (if required), lot number (if required) and route conforming parts to

stores.

3.5.2.7 Certain existing parts in stores may have been accepted under previous

revisions/versions of QC inspection manuals and may have different tags.

Older standard parts may continue to be used until exhausted without further

showing. Older non-standard parts may continue to be used, but should be

evaluated for applicability prior to use.

3.5.2.8 Sign off or stamp acceptance of parts on “Received Goods by Purchase Order”

form. Scan all accompanying documents (packing slip, certs, etc) and

electronically file in QC database. Forward paper copies to accounting.

3.6 INSPECTION, MEASURING AND TEST EQUIPMENT

CONTROL

3.6.1 Calibrated equipment

ASM uses a variety of precision tools for fabrication and inspection, some of

which are calibrated periodically, some of which cannot be calibrated, and some

of which must be calibrated per use with other calibrated tools.

3.6.1.1 All precision tools or equipment which must be calibrated is controlled with a

“Calibrated Tools Master” or log, which records the part number, serial

number, calibration date, and period of required calibration.

3.6.1.2 Equipment requiring calibration must be calibrated using methods and

standards acceptable to the FAA, such as, National Institute of Standards and

Technology (NIST). Equipment calibrated must have a calibration certificate

on file which identifies the equipment by part number and serial number, date

of cal, and specify the periodicity of cal.

3.6.1.3 All calibrable tools must be “in cal” to be used for testing or production of

parts. Tools need not be “in cal” if not in use, however once identified, must

be red tagged and stored in quarantine. “Out of cal” tools cannot be used again

until properly calibrated and certified. Calibrable tools/equipment must have a

sticker or tag affixed which shows the cal date, re-cal date, part number &

serial number of the tool.

3.6.1.4 Certain tools, such as some wire crimpers, may be calibrated in house by using

manufacturer’s instructions and certified, calibrated tooling to accomplish the

calibration. A current ASM Calibration certificate must be on file for those

tools, and a cal sticker or tag affixed.




3.6.1.5 Certain tools, such as adjustable power supplies, must be calibrated per use

using calibrated test equipment. Those tools must have a sticker or tag affixed

showing “Calibrate Before Using” or similar.

3.6.1.6 Certain tools, such as scales, may be calibrable, but are used for reference

only. Such tools must have a label or sticker affixed showing “Reference

Only” or similar, and cannot be used for manufacturing or inspection until

calibrated and certified.

3.6.2 Calibrated equipment control

Calibrated tools used for manufacturing may go “out of cal” or become damaged

between periodic calibrations. To reduce impact, severity, and improve

traceability, the use of calibrated tools will be monitored as follows:

3.6.2.1 All calibrable tools used in the course of an assembly must be inspected prior

to use. If possible, calibrable tools are quick checked with go-no go gauges

prior to use, daily. “Out of cal” or damaged tools must be red tagged and

quarantined immediately.

3.6.2.2 Calibrated tools used to manufacture parts must be recorded by serial number

on the work order used to produce those parts.

3.6.2.3 Where applicable for Acceptance Test Reports, calibrated tools used to inspect

products must be recorded by serial number on the report.

3.6.2.4 Unless otherwise specified by approved drawings, it is not necessary to record

the tooling used to test or inspect incoming raw materials (receiving

inspection).

3.7 INSPECTION AND TEST STATUS Inspection and test records are generated for receiving, in-process, Acceptance

Test and final inspections as specified in Section 3.5 above.

3.8 NONCONFORMING PRODUCT AND ARTICLE CONTROL All articles and products manufactured by ASM under the PAH authority must

conform to approved data and be in a condition for safe operation. At any stage of

manufacture, nonconforming parts may be identified. In all cases of

nonconformity, review, evaluation and disposition must be accomplished and

results recorded.

3.8.1 Material Review Board

ASM has a standing Material Review Board (MRB) to review, evaluate and

disposition nonconforming materials and processes. The board consists of a




minimum of three qualified individuals; a design engineer, a manufacturing

specialist and a QC representative. Additional members may be empanelled as

required.

3.8.1.1 A qualified PAH engineer is required to evaluate all data pertinent to the

nonconforming part. If the part is to be used without alteration or modified to

be used, then drawings and or data must be prepared detailing the

nonconformity, use, or alteration.

3.8.1.2 It is ASM policy that all design data (minor change) must be approved by a

DER. Major changes will be coordinated with the FAA.

3.8.1.3 A design engineer is required to evaluate, analyze and prepare supplemental

drawings and or data to use or modify the part for use.

3.8.1.4 A QC representative is required to insure that parts intended for use or

modification are in fact used or modified in accordance with approved data.

3.8.1.5 Qualified manufacturing technicians and or logistics personnel may advise the

board as required.

3.8.2 Procedures

Any inspector, technician, engineer or interested other may stop the production

line at any time to resolve a nonconforming part question.

3.8.2.1 Return to Vendor

Any receiving inspector may identify nonconforming incoming parts during

the receiving inspection. Nonconforming raw parts identified at this stage may

be Returned to Vendor (RTV) with no MRB action required. Parts are RTV’d

with a note describing the non-conformity. The vendor must then correct the

part or provide the correct part.

3.8.2.2 Rarely, parts may arrive which are useable or can be made useable with little

effort, despite the nonconformity. This may be the case with cosmetic

blemishes, non-critical tolerance errors, or finishes. If the part(s) are RTV’d

then no further action is required.

3.8.2.3 “Use as Is” (raw parts)

If there is consideration of use or alteration of the part to be made useable,

then the MRB must convene.

3.8.2.4 Engineering must determine what impact, if any, is presented by the

nonconformity. He must evaluate based on structural considerations,




mechanical fit and function, reliability and operational effect. At all times,

safety must be the primary concern.

3.8.2.5 Engineering may reject the part and direct RTV, in which case, no further

MRB action is necessary.

3.8.2.6 Engineering may determine that there is no impact caused by use of the part

“as is”. For use “as is” the engineer must present a numbered report describing

the part, the non-conformity, and substantiate the degree of impact of the non-

conformity, if any. Sketches, drawings and any other pertinent data are

included with the report.

3.8.2.7 Rework (raw parts)

Engineering may determine that reworking the part may bring it back into

conformity or into a useable state. The engineer must consider all of the other

potential impact with “use as is”, plus the capability and economic impact of

reworking the part, at all times keeping safety as the paramount requirement.

If Engineering determines that rework is acceptable, then the engineer must

present a numbered report describing the part, the non-conformity, details of

rework to be accomplished and substantiation of degree of impact. Sketches,

drawings and any other pertinent data are included with the report.

3.8.2.8 The report is numbered with the corresponding ASM project number and

becomes a part of the current design data. Reports are maintained, distributed

and archived as engineering documents, ie, indefinitely.

3.8.2.9 Disposition

Engineering will submit the report(s) to a qualified DER (see para 3.8.1.2), for

review, evaluation of compliance with applicable regulations and approval of

the data. If the data is approved, as evidenced by an FAA Form 8110-3

approving the data, then the part can be used for manufacturing or reworked to

return it to a conforming state. Reworked parts must be re-inspected to the

approved data before re-entering the production line.

3.8.2.10 If the data is not approved, then the part is RTV’d or scrapped.

3.8.2.11 In-process nonconformities.

In process non-conformities are not evaluated by MRB, they are returned by

QC to production for rework to a conforming state without further action. If

unable to be reworked to a conforming state, then the assembly must be

scrapped.

3.8.2.12 Nonconforming parts discovered during receiving inspection, in stores or prior

to entering the production line must be segregated at all times until disposition




is made. Nonconforming assemblies discovered in-process remain on the line

until they conform or until scrapped. If there is some delay in determination,

all nonconforming parts are segregated and quarantined until disposition is

determined.

3.8.2.13 Scrap

If the disposition is scrap, then the nonconforming part is immediately

removed from production, stores, or the line and destroyed; OR red tagged,

quarantined and held for destruction. In rare cases the part or assembly may be

retained for training use, in which case it is red tagged “For Training Use

Only”, and marked with X’s in prominent display. Parts used for training are

stored in quarantine.

3.8.2.14 Destruction

There are many acceptable methods of destroying parts to be scrapped,

including simple disposal in a properly regulated landfill. Destruction may be

assured, if required, by application of one or whacks with a hammer (ball

peen, carpenter’s or sledge). If no suitable hammer is available, a balanced

hard soled shoe may prove effective.

3.9 CORRECTIVE AND PREVENTIVE ACTIONS Most, if not all, nonconformities or noncompliances are caused by human error.

Procedures for hiring qualified personnel, maintaining proficiency, providing

adequate environmental, health, morale and welfare conditions are beyond the

scope of this manual.

Procedures for detecting and correcting nonconformities and noncompliances are

addressed in Sections 3.8, Nonconforming Product and Article Control and 3.5,

Inspection and Testing, above. Those procedures are effective to control

occasional, minor nonconformities and noncompliances. No further action, other

than spot correction and continued surveillance, is required

In rare circumstances, continuous, uncorrected and inappropriate behavior results

in nonconformities and or noncompliances. Remedies must be worked out with

Human Resources personnel to ensure appropriate and legal behavior

modification strategies are attempted. Such remedies may include remedial

training, reassignment or termination.

More commonly, suppliers sometimes provide parts which do not conform or

comply. Spot corrective action procedures are provided in Section 3.3 above,

Supplier Control, and 3.8, Nonconforming Product and Article Control, above. In

the event that procedural remedies are not effective, then the supplier must be

disqualified for cause.




3.9.1 Procedures

The President of ASM will be briefed on significant nonconformities as they

occur. Issues relating to safety or which have significant business impact

(financial, time, personnel, relationships), will be addressed as follows:

3.9.1.1 The President will direct any qualified member of ASM’s staff to perform an

analysis of the significant nonconformity.

3.9.1.2 The staff member will prepare a report, in a form and presentation directed by

the President, specific details of which may include:

The detailed nature of the nonconformity, including who, what, where,

when, why, and how.

The extent of the nonconformities impact.

A recommendation from the staff of any corrective actions.

An evaluation of the effectiveness of the corrective actions.

Proposals for long term monitoring and trend data collection.

Periodic follow up reviews of data

3.9.1.3 The President will evaluate the report and determine appropriate corrective

action. HR issues will be resolved through appropriate labor relations and/or

legal means. Those reports will be filed and maintained by HR in accordance

with applicable federal and state laws.

3.9.1.4 Reports of noncomformities resulting from supplier error, engineering,

technical, or training issues will be maintained as QC documents for not less

than 5 years.

3.10 HANDLING AND STORAGE

ASM maintains a store of raw materials, completed subassemblies and finished

parts. All parts must be segregated, organized, secured and issued to maintain the

integrity and preservation of the parts.

3.10.1 Procedures

All materials enter the stores system through a single point of entry (Receiving)

and are issued from a single point (Stores) according to strict procedures.




3.10.1.1 ASM stores is located under cover, in a temperature controlled, dry and well

lighted environment.

3.10.1.2 Conforming parts which have passed incoming (receiving) inspection, are

identified by part number, p/o number, location code and lot code (if

applicable), and tagged or packaged in clear poly bags with tag affixed.

3.10.1.3 Parts are routed to designated storage areas and shelved or binned as

appropriate.

3.10.1.4 Items having a shelf life are prominently tagged with the expiration date, are

routed to the shelf life storage area, and binned in order that oldest materials

are used first.

3.10.1.5 Shelf life items in stores are inspected monthly for expiration. Expired items

are scrapped and inventory records adjusted.

3.10.1.6 Stores inventory control is maintained by periodic cycle count and annual

inventory count. A periodic listing of bin samples (cycle) is generated by

database software and physically counted by stores personnel. This statistical

sampling method maintains a high degree of inventory integrity without

requiring complete inventory counts.

3.10.1.7 Materials are issued by kitting order associated with work orders. As work

orders are generated by the database, kitting orders and pick lists are

concurrently generated. Kitting orders define sub-assemblies. Pick lists are

presented to stores personnel for issue of parts necessary to build sub-

assemblies.

3.10.1.8 Entry to stores is limited to authorized personnel.

3.10.1.9 Nonconforming parts, training parts and “out of cal” tools are stored in a

locked, marked quarantine vault with access limited to authorized personnel

only.

3.11 CONTROL OF QUALITY RECORDS

Quality records consist of this manual, inspection forms, checklists, work records,

quality reports and purchasing, shipping & receiving records. All quality records

are retained for a minimum of 5 years from the date of approval, acceptance or

generation as appropriate. ASM does not manufacture critical components as

defined by Part 45.15(c).

3.11.1 Procedures




3.11.1.1 Purchasing and receiving records are collected after acceptance of the parts

and stored in archival storage on ASM’s second floor.

3.11.1.2 Work orders, inspection checklists, completed forms, test reports, and

shipping records are collected and attached to the parts if in stores. After

shipment, all records are combined with the shipping record and stored in

archival storage in the shipping department.

3.11.1.3 The original of this manual and any generated QC reports, correspondence,

etc., are stored in the records vault.

3.11.1.4 Purchasing and receiving records are stored indefinitely, as raw parts may

remain in stores for periods exceeding the minimum record retention rules.

3.11.1.5 The original manual and subsequent revisions are retained indefinitely. QC

reports and correspondence (exceeding 5 years old) are reviewed annually for

determination of retention or destruction.

3.11.1.6 Shipping records are purged annually (exceeding 5 years old) and destroyed.

3.12 INTERNAL AUDITS

Internal audits are used to ensure compliance with regulations and to provide

ASM management with a “snapshot in time” of the organization’s quality health,

efficiency, and compliance. Audits may be specific and localized to evaluate a

particular situation, or may be applied across the organization.

3.12.1 Procedures

3.12.1.1 An annual, organizational audit is required each calendar year.

3.12.1.2 The President may direct an additional full or limited audit at any time.

3.12.1.3 Auditors will use the Standardized Audit Criteria from current FAA Order

8120.23, applicable system elements, for the annual audit.

3.12.1.4 Copies of system elements will be used by auditors as checklists. Notes will

be entered in available space, with additional sheets added as required. Non-

applicable system elements will be N/A’d. Copies of substantiating documents

will be made and attached as required.

3.12.1.5 The President will define criteria for on-demand audits.

3.12.1.6 Auditors will be appointed by the President from qualified personnel.




3.12.1.7 From the checklists and substantiating documents, the auditor(s) will present a

controlled (dated) narrative summary report to the President, management and

appropriate personnel. Checklists and substantiating documents will be

attached to the report as appendices. Audit records and reports will be retained

as quality records.

3.12.1.8 The President will use the audit reports to direct and manage corrective

actions and system improvements as an ongoing quality system improvement

tool.

3.13 IN-SERVICE FEEDBACK

ASM has a long history and tradition of providing superior customer service and

support. This is accomplished ensuring that all possible lines of communication

are kept open between end users, mechanics, pilots, QC and ASM personnel.

3.13.1 Procedures

3.13.1.1 ASM’s website, www.asminc.net, provides full contact information, mailing

address, e-mail listings and phone numbers of ASM points of contact (POCs).

3.13.1.2 All ASM installation kits are shipped with an appropriate approved data

package. The last page of all doc packages is the customer feedback

questionnaire & survey.

3.13.1.3 All customer feedback is evaluated by the President, QC and Engineering. For

suggestions, proposals for improvements and complaints, the President directs

actions as required.

3.13.1.4 Malfunctions and/or defects will be reported to the FAA within 72 hours using

FAA Form 8010-4, Malfunction Defect Report.

3.13.1.5 Unsafe features, unairworthy conditions, and unsafe characteristics

reported, that result in or could result in occurrences listed in FAR Part

21.3(c), will be reported to the FAA within 24 hours as detailed in the

regulation.

3.13.1.6 ASM will provide all documents, personnel, and assistance required to assist

with any investigation and resolution of unsafe or unairworthy factors.

3.13.1.7 ASM will evaluate all feedback for determinations of design changes and

changes to Instructions for Continued Airworthiness.

http://www.asminc.net/




3.13.1.8 Minor changes will be coordinated with the FAA in accordance with MOU

dated April 7, 2005.

3.13.1.9 Major changes will be coordinated with the FAA and processed as directed by

FAA personnel.

3.14 QUALITY ESCAPES

The quality system exists to prevent nonconforming material from “escaping”,

that is, from leaving the factory and being installed in aircraft. However, it is

possible for an escape to occur. If and when an escape occurs, the following

procedures must be implemented to control, recall or correct any nonconforming

condition:

3.14.1 Procedures

3.14.1.1 Upon discovery, consult with Engineering and appropriately qualified DERs

to determine if there is an unsafe condition.

3.14.1.2 IF AN UNSAFE CONDITION EXISTS, notify the FAA per paragraph

3.13.1.5 above. ASM will provide all documents, personnel, and assistance

required to assist with any investigation and resolution of unsafe or

unairworthy factors.

In addition, if not otherwise directed by the FAA:

Immediately recover and quarantine all identified nonconforming parts

remaining in the factory in-process or in stores, including all applicable

work orders, inspection results, manufacturer’s certs and other

documentation applicable. Make available to investigators.

From the project control records in Doc Control, prepare a list of all

owner/operators/customers for the applicable project, including serial

numbers of affected aircraft and registrations. Provide that list to the FAA

and to the contacted owner/operator/customers.

Notify all owner/operators of the condition by the most expeditious means

possible, normally by telephone contact. Provide the name and contact of

ASM’s technical representative. Provide a list of names and contact

information of those contacted, and a list of those unable to contact, to the

FAA.

Notification of an unsafe condition will result in “What must I do?”

questions from operators. ASM is unable to advise or speculate on




operational matters such as maintenance, repair, operational limitations,

dispatch and grounding of aircraft. Refer all such questions to the FAA.

Follow up as directed by FAA personnel.

3.14.1.3 If an unsafe condition does NOT exist, then Engineering and appropriately

qualified DERS must determine the impact of the nonconforming condition

and respond appropriately.

3.14.1.4 If the condition MAY result in a malfunction, then do the following:

Notify the FAA and advise of the condition. Make all design data and

records available to the FAA, and comply with any direction provided.

If not otherwise directed by the FAA:


remaining in the factory, in-process or in stores, including all applicable

work orders, inspection results, manufacturer’s certs, work orders and

other documentation applicable. Make available to investigators.

Concurrently notify all owner/operators of the condition by the most

expeditious means possible, normally by telephone contact.

Follow up as directed by the FAA.

3.14.1.5 If the CONDITION IS SAFE and NOT subject to malfunction, then proceed

as follows:

If the condition is a result of drawing or documentation errors, then correct

the documentation by means of the normal revisioning process, FAA

approval, and distribution of the revised documents, as per paragraph 3.1

above.

If nonconforming parts are not installed in aircraft, then recall shipped

nonconforming parts and replace with conforming parts. Coordinate with

owner/operator’s QC staff.

If nonconforming parts are installed in aircraft, advise the owner/operator

of the condition by means of a Service Information Letter (SIL), and

provide conforming parts for replacement at the next maintenance interval.

Coordinate with the owner/operator’s QC staff.




Advise the FAA and provide copies of the SIL. Perform all additional

actions directed by the FAA.


remaining in the factory, in-process or in stores. Destroy or quarantine as

required. MRB action may be implemented.

File a copy of the SIL(s) with the ASM project design data files.

Insure that nonconforming parts are recalled, returned, and destroyed.

3.14.1.6 Review procedures and practices to determine the cause of the nonconformity,

the escape, and implement corrective actions to prevent recurrence. Report as

required, see paragraph 3.9.1. SILs are design data and are retained

indefinitely.

3.15 OTHER QUALITY PROCEDURES

Paragraphs 3.1 through 3.14 above address specific elements of Part 21.137(a)

thru (n). The following procedures are local and specific to ASM’s quality system.

3.15.1 Stamp Use and Control

3.15.1.1 ASM’s QC personnel use stamps to indicate approval and/or acceptance of

various steps, materials, documentation, etc.

3.15.1.2 Qualified QC personnel are issued controlled stamps by the Director Quality.

3.15.1.3 Stamps are retained and controlled by the individual, and used within the

individual’s qualifications.

3.15.1.4 Un-issued stamps are quarantined under lock and key.

3.15.1.5 Lost stamps are struck from the control roster and retired for minimum 6

months. Transitioning personnel will surrender their stamp upon

discontinuation of their authority to inspect. Lost and/or transitioned stamps

will be quarantined for a minimum of 6 months before re-issue to qualified

personnel.

3.15.1.6 Initials and date in ink may be used by all qualified QC personnel in all

circumstances where a stamp could be used.




3.15.2 Kitting and Shipping

3.15.2.1 Kitting for manufacturing consists of pulling parts from stores according to a

kit or pick list, generated concurrently with work orders. Pick lists are working

papers that are destroyed after use.

3.15.2.2 Kitting for shipment involves organizing, inspecting and packaging parts for

shipment. Kitting for shipment is accomplished by work order, with

appropriate work steps and in-process inspections annotated thereon.

Certification, after final inspection, is indicated by Certificate of

Compliance. A domestic Airworthiness Certificate, FAA Form 8130-3, is

prepared if requested and indicated on the applicable sales order.

Items to be exported must be presented to the FAA or designees, as

appropriate.

Packaging is by best commercial method, unless otherwise specified in the

sales order.

IV. QUALITY CONTROL FORMS


Title: Quality Control Forms Issue Date: 27 Jun 2013


4.1 QC FORMS INDEX Forms used in the ASM, Inc. Quality Control program are developed and revised

as needed. The format of forms may change due to software or configuration

differences.

4.1.1 Equipment Calibration Record

4.1.2 Vendor Survey Form

4.1.3 Vendor Qualification Tracking

4.1.4 PO Receipt

4.1.5 Sales Order

4.1.6 Work Order

4.1.7 Purchase Order

4.1.8 MRB Record

4.1.9 Stamp Log

4.1.10 Stamp Impressions Sample

4.1.11 Harness Inspection Checklist

4.1.12 Kit Final QC Checklist

4.1.13 Manual Audit Log