Quality Manual
Innovative Design Inc.
Doc. # 004a
Quality is the job of everyone here at Innovative Design Inc. We have a great track record with our current customers and understand that growing our business depends largely on maintaining this record. All our employees realize that quality begins with them, and everything they manufacture is a direct reflection on Innovative Design Inc.
Quality Responsibilities
A. Plant Manager’s responsibilities
1. Review the quality system annually.
2. Save discrepancy emails in a Q.C. folder on comcast email system.
3. Report discrepancies to the customer’s Q.C.
department
4. Maintain the quality procedures for employees
and supervisors.
5. Review all corrective actions quarterly with the
president to ensure any problems are fixed.
B. Supervisor’s responsibilities
1. Verify that a discrepancy condition exists.
2. Report discrepancies via email to the Plant
Manager.
3. Instruct employee how to fill out the tag and
place the affected part in the appropriate area
outside Q.C.
C. Employee’s responsibilities
1. Verify the print is signed and dated and the print
revision matches the one on the job router.
2. Use blueprints and provided inspection
equipment to complete inspections on parts
at the intervals specified on the inspection sheets.
3. Fill out the inspection sheets.
4. Notify a supervisor of any discrepancy.
5. Tag the affected part according to supervisor’s
suggestion of a written description of deficiency and
place affected part outside Q.C.
6. Do not use or move a tagged part unless a
supervisor initials the tag to verify it is useable.
Quality Authorities
A. Plant Manager’s authorities
1. Decide if part can be reworked.
2. Decide if part can be shipped.
B. Supervisor’s authorities
1. If part conforms to a customers standard
deviation, part may be shipped at supervisor’s discretion.
There still must be an email of discrepancy to the plant
manager and a tag placed on the affected part.
C. Employee’s authorities
1. Certain normal discrepancy deviations may
be written inside the job router packet. If
an employee comes across a discrepancy which
is contained inside the job router packet, they
are to follow the procedure for handling said
discrepancy.
Quality System
A. There will be different procedures for each
customer based on their requirements. All of
which are available in the job router packets.
Contract Review
A. Contract review worksheets will be provided to
to a supervisor which will contain any special
customer requirements. The supervisor will fill out
the worksheet and return to the plant manager.
Worksheets provide a series of check off’s for
the supervisor, which includes: machine
capability, appropriate tooling, appropriate
inspection equipment, and a deficiency section
which will be used to identify things needed to
perform the job appropriately. Sheet also has a
spot to determine if it is a new job or it is a
revision of an existing job.
B. Upon order acceptance a new inspection sheet will
be generated with the important dimensions to be
inspected and the allowable tolerances. A blueprint
will accompany it with all the important areas
highlighted. The above along with any special
instructions will be included in the job router
packet.
Design Control
A. Design changes on our products and our customers
requires a review by our engineer and our plant
manager.
B. Analysis software is run on all critical areas to
ensure product reliability on our new product and
may be performed on our customers products if
asked for.
C. A design review team will meet to discuss our new
designs. Members will express any concerns and
their inputs will be shared and noted along with
the safe and functional characteristics of the
design. The plant manager will document the
meeting. Members are to include the engineer,
plant manager, 1 supervisor, and if applicable 1
machine operator.
Document Control
A. All blueprints, inspection reports, and procedure
lists will be included in the job router packets. All
materials will also be reinserted into the job
router packets and returned to the job router
station when the job is finished. The only
permitted exception is for repeat production jobs,
which may be stored at the respective machines
where the jobs are run.
B. All obsolete documents will be replaced with
revisions as soon as they are available. The
obsolete documents will then be placed in the
obsolete document file with a hand written date
representing the day it was pulled on the first
document.
C. All new and changed documents will be reviewed
and signed and dated by the engineer and the plant
manager before placing into the job router
packets.
D. A document master list will be kept on the plant
manager’s computer reflecting all revisions of
documents. Any customer documents that are
not in a digitized format will be scanned and
saved.
Purchasing
A. All purchase orders must uniquely and adequately
describe the products ordered.
Customer Supplied Product
A. All customer-supplied items are to be logged by
the plant manager. All such items will be
properly cared for and returned to the customer
when asked. These items to include: product,
fixtures, tooling, gauges, calibration devices,
inspection equipment, and any other customer
supplied device.
Product Identification and Traceability
A. When a customer specifies, all parts supplied by
us will have identification as per their
requirements. This can be done with ink
marker or by stamping.
B. When a customer specifies we will include
traceability that may include any or all of the
following: machine #, date, time, operator,
identification #, or serial #.
Process Control
A. Job router packets will provide key process
notes on any special methods used to complete
the key processes. An updated copy of which
will be maintained in the customers file.
B. All machines in the shop have a biannual
preventative maintenance for alignment, fluid
levels, and filters.
Inspection and Testing
A. All incoming material will be inspected as per
1. Our specs
2. Customer’s specs
3. Raw material “follow procedures on doc002a”
B. No incoming material will be used until it is
Inspected.
C. If incoming material is non-conforming an
employee is to notify his supervisor. The
supervisor is to notify the plant manager. The
plant manager will notify the vendor vie email or
fax with a non-conforming statement.
D. All non-conforming material is tagged “Do Not
Use” and set aside.
E. As far as finished outgoing parts,
1. Frequent production runs, the shipping memo
itself is proof of good parts. Any nonconformity
will be noted on them and anything not noted
represents good parts.
2. For all other parts the supplied inspection sheets
will serve as documentation of good parts.
Inspection Measuring and Testing
A. All inspection, measuring, and test equipment
will be calibrated bi annually. Any inspection
equipment that is not calibrated will be labeled
for reference only. Any inspection equipment
that is labeled for reference only is not to be used
for any dimensional tolerances. It may however
be used for fractional dimensions. Calibration is
to include personal equipment and the only
exception will be for tape measures, squares and
steel rules. These will be gathered all at once and
visually inspected to be straight and not
deformed. Everything except the exceptions will
be labeled as calibrated and given a gauge
number.
Inspection and Test Status
A. Any non-conforming part must be tagged with
the deficiency legibly written on it as soon as
the discrepancy is noticed.
Control of non-conforming product
A. Any part with a tag on it may not leave the plant
without a supervisor’s initials on the tag
verifying the product is o.k. to ship.
Corrective and Preventative Action
A. All customer complaints will be documented in
writing and shown to the supervisors by the
plant manager. The supervisors will then hold a
meeting with the employees running the job on
how to fix the non-conformity.
B. All employees will be on the lookout for
potential non-conformities of a job including the
work of other employees.
C. All supervisors will monitor the work of employees
to ensure past non-conformities do not happen again.
Handling, Storage, Packaging, Preservation, and Delivery
A. Customer’s product is to be stored in a safe
clean place, out of the way of normal forklift
travel or other hazards. If applicable apply rust
preventative.
B. When moving product from one area to another
be sure to move the load securely and be aware
of any potential hazards in your path.
C. When product is completed, carefully package
product. Pay special attention to never scratch or
mar any surfaces. Apply rust preventative if
applicable. Place product in a safe secure place
within the designated shipping area.
Quality Records
A. When writing on inspection forms ensure to
have clean hands and pay close attention to
writing legibly. If your entry looks sloppy, get a
new form and re-enter the information for a nice
clean look.
B. Always place completed inspection forms back
in the job router packets.
Internal Quality Audits
A. The entire quality system will be audited 1 time
per year by the plant manager
B. Audit findings will be placed in the back of the
Q.C. manual.
C. All deficiencies will be handled ASAP.
D. Audit sheets include a section to verify past problems were fixed.
Training
A. There will be training on all changes for
employees and supervisors upon
implementation.
B. There is a sign in sheet for all attendees to sign
with a written description of what was covered.
C. New employees and supervisors will be trained
on the current procedures.
Servicing
A. When servicing a product or piece of equipment
for a customer. The written receipt the employee
hands the customer notes what was performed
and anything the employee notices that may
need future attention.
