Quality System 

 Explain the quality system in place, i.e. manual, policy.

A quality policy statement, and corresponding quality manual are developed describing how the quality policy is carried out at Bygd Precision. The manual provides documented descriptions of the order processing and manufacturing operations, and the quality system checks in place from order entry to shipment of the order.

How is auditing used?

Two types of audits at Bygd Precision include auditing all customer prints for accuracy to the order and product and product audits of all orders prior to customer shipment. System audits are not formally scheduled due to the fact that Bygd Precision is small enough to monitor and assess the system, make changes, and take corrective actions very quickly on a daily basis without a formal audit schedule.  As the company grows, a formal audit system would be developed to address the needs of a larger company.

Purchasing

How are suppliers selected and approved?

Bygd Precision uses only a limited number of suppliers and has developed a close working relationship with those suppliers over a long period of time. The small number does not warrant developing a formal selection and approval system. If a new supplier is used, they are given a probationary period where their performance is monitored.  Any problems that arise during this period must be corrected. If a supplier is having trouble performing up to expectations and cannot correct the problems, another source may be explored.

Describe the system of contract review.

When purchase orders are received, they are reviewed for accuracy, including description, quantity and delivery date. They are compared to previous orders if possible, and reviewed for changes.  If any confliction information is discovered, the customer is contacted to clarity the situation.  If Bygd Precision cannot meet the customer’s order expectations, they are also notified and all attempts are made to determine a solution that will work for the customer.

Document Control

Describe the system of document control. (Prints, specifications, work instructions)

All orders from the customer are entered into the shop management software, called JobBoss.  The necessary documentation including shop travelers, service purchase orders, material purchase orders, inventory reports and work instructions and procedures are produced. The associated prints are matched with this documentation and it follows the order through the shop until it is filed after shipment.  Any prints or specifications received are always compared to the current order revision. Instructions and other documentation are stored on computer and can only be changed by authorized personnel. When changes are made, all old documentation is marked obsolete.

How does the system ensure that production configurations are not changed without customer approval?

Products are only manufactured to the current revision of the customer print. No changes can be made to the print or product without customer approval. Any new prints received from the customer are reviewed for changes. The customer is contacted whenever conflicting information is discovered, or a specification is in question.

How are quality records maintained?

All quality and inspection records for each order are maintained and kept on file with all the customer’s orders. The length of retention varies depending on the customer’s requirements and can be determined when new orders are placed.

Material Handling

What systems are in place for identification and trace-ability? (Part numbers, lot tracking inventory control)

All raw material is separated by the type and given a supplier identification marking. Each customer order is given a job number and the material used for that order is identified on the shop traveler. This is done for trace-ability and lot tracking purposes.  The shop management software (JobBoss) maintains current records of all raw material and work in progress material inventory. Shop travelers and prints are kept with each order of parts to identify work in progress.

How is deterioration of stored product prevented?

Several methods are used or can be used as required or specified by the customer including, chemical blackening, oil coating, adding protective sheaths, as well as indoor storage of all inventory.

Process Control

How do employees know how to do their jobs? (Access to written procedures and prints?

Employees are trained for their jobs and work under close direction of the supervisor for a period of time until the supervisor is comfortable that they have attained the skills necessary to do the job.  For specific job orders, shop travelers that follow every job contain all the information and specifications, including prints needed to complete the job. All other procedures are contained in the manual and the company handbook, both readily available when needed.

Describe preventative maintenance activities.

Preventative maintenance activities are specified for each machine and a logbook of activities is maintained that specifies when maintenance needs to be performed, when it was performed, and when it needs to be performed again.  Problems are noted and action is taken when necessary to prevent machine downtime.

What controls are in place to ensure safety?

An OSHA compliant safety program that includes lock out tag out procedures, forklift safety, chemical handling and eye protection is in place and is reviewed regularly to ensure both OSHA compliance and accident prevention.

Explain how SPC is used in processes.

Each order is inspected to ensure compliance and product perfection. Analysis and corrective actions are currently used for investigation of out of tolerance characteristics and a continual process of improvement is implemented.  A formal SPC program has not been developed, but should a customer request or require SPC process monitoring or studies, a procedure would be developed and training would be given to meet the customers requirements.

Inspection and Testing (sampling plans, test results records)

Describe receiving inspection procedures.

Material is visually inspected and measured to ensure compliance to the purchase order and tooling is measured to ensure compliance to print specifications. The suppliers are notified of any nonconformance and material or tooling is returned if defective. Material safety sheets, which contain material components, serve as material certifications that are maintained on file for trace-ability.  Documentation is maintained concerning certification of any outside services.  

Describe in-process inspection procedures.

Each operator inspects parts to print specifications while running orders. Critical dimensions are identified on the print and monitored. Records of the inspections can be recorded at the customer’s request and shipped with the order. Operators are responsible for the quality of their work.

Describe final inspection procedures.

Each order is subjected to a final inspection. Checked parts are marked and the results of the final inspections are documented.  These documents are then shipped with the order to the customer. At the customer’s request, specific sampling plans and inspection procedures can be implemented to meet customer requirements.

Calibration system

Explain the calibration system. (Standards, intervals, environment controls, out of tolerance procedures, equipment)

An inventory of all measuring tools and equipment is maintained and color-coded calibration labels are used to identify when items were last calibrated. Each operator has an individual number that is associated with specific assigned set of measuring equipment they are responsible for maintaining.  Equipment may be calibrated to a MIST traceable standard if requested. 

Control of nonconforming product

What systems are in place to ensure control of nonconforming product?

(Segregation, identification, disposition procedures)

Nonconforming product is marked as nonconforming and segregated for review and disposition. Disposition is usually made at the same time the problem is found.  Scrap material is placed in containers identified for scrap material.  A corrective action request is issued if deemed necessary at the time of review. Scrap or reworked material is noted on the job travelers and the order status is updated on the production control system.

Corrective and Preventative Action

Describe the procedures in place for corrective action. (Implementation, verification methods)

Customer corrective action requests are requests are responded to as necessary and changes implemented based on the root cause of analysis.  Internal corrective actions are addressed immediately as they happen and a corrective action form describing the problem and action taken is kept on file.  Changes made as a result of corrective actions are reviewed and verified by the president.

Training

Describe the employee orientation program.

The president reviews the handbook, quality policy and manual, and OSHA safety procedures with them. Additional training is provided by the department head or supervisor in, measuring equipment use, blueprint orientation, machine operation, safety, shop floor layout, and material locations.

How are employees trained in their job functions?

Employees are trained and certified in machine use or job function by the department head. A probationary period is used where the new employee works closely with the department head in training on the job.  Function, performance, and progress are monitored until the department head feels they are ready to perform the job requirements.

Customer Service

Describe the methods of handling customer complaints.

Customer complaints are immediately directed to the president. The president will perform a timely clarification and investigation of the situation and respond to the customer as soon as an appropriate corrective action and response is determined. If necessary, a formal corrective action request will be issued and a formal investigation into the cause and corrective measures will take place to resolve and correct the problem.

How do you know your customer is satisfied?

Current customers frequently give verbal confirmation of satisfaction and many repeat orders are taken. Close personal contact with customers is also maintained, along with frequent visits to meet customers and ensure good communication and satisfaction.