SampleQualityDocuments APQP

WestleyEngineeringLimited 120PritchettStreet Birmingham B64EH Telephone01213331925 Facsimile01213331926 www.westleyengineering.co.uk

Contents

Index BVQIBSENISO9001:2000andTS16949Certificates QualityProceduresManualIndex(page1) QualityProceduresManualIndex(page2) QualityPolicyStatement ListofInspectionEquipment

AQPDocumentationOverview QD020CommitmenttoProductConformity(quotationstage) QD021TeamFeasibilityCommitment QD006AQPTimingPlan

SampleManufacturingDocuments ControlPlan OperatorCarePoint

WestleyEngineeringLimited

Contents

Sample Quality Documents

Index

Westley Engineering Limited

Contents

ISO9001:2000 CertificateofApproval

TS16949 CertificateofApproval

WestleyEngineeringLimited

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Business Operating Procedures Index -----------------------------------------------------------------------------------------------------Sheet1of2 Issuedate:February04 IssueLevel: 2

-----------------------------------------------------------------------------------------------------Quality Management System 4.01 4.02 4.03 4.04 4.05 4.06 4.07 4.08 Internal BMS Documents Customer Drawings Customer Specifications Company Drawings Process Instructions National/International Standards Forms Quality Records 4

Management Responsibility 5.01 Management Process Resource Management 6.01 Human Resources Product Realization 7.01 7.02 7.03 7.04 7.05 7.06 7.07 7.08 7.09 7.10 7.11 7.12 7.13 7.14 7.15 7.16 Customer Enquiries Customer Orders. New Product Introduction Advanced Product Quality Planning Product/Process Changes Production Control Product Manufacture Tool Design & Manufacture Control of Production & Release Product Preservation Calibration Control Evaluation of Suppliers Purchasing Receiving Inspection Planned Maintenance Tooling Management

Business Operating Procedures Index -----------------------------------------------------------------------------------------------------Sheet2of2 Issuedate:February04 IssueLevel: 2

-----------------------------------------------------------------------------------------------------Measurement, Analysis and Improvements 8.01 8.02 8.03 8.04 8.05 8.06 8.07 8.08 8.09 Customer Satisfaction Internal System Audits Nonconformance Control Customer Returns Concession Requests Corrective Action Preventive Action Continual Improvement Statistical Process Control 8

QualityPolicyManual
---------------------------------------------------------------------------------------------------------------Issuedate:Sep08 Issue Level: 7Revision: 6Issued by: P.Richards -QualityManager

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QUALITY POLICY STATEMENT

Westley Engineering Ltd. is committed to a continual quality improvement programme. The objective of the programme is to design, develop, and supply products that satisfy our customers needs first-time, on-time, every-time, at good value to them and profitability to the company. This objective can only be achieved by creating and encouraging quality awareness in all employees and ensuring that all understand the importance of, and work in accordance with, the documented Quality Management System. The policy is implemented through our Quality Management System which operates in accordance with the requirements of BS EN ISO 9001:2000 and ISO/TS 16949 together with any Customer quality standards. The Quality Management System has sound fundamental principles laid down over the years but is a live document and is therefore being continually improved with the aim of satisfying the requirements of our Quality Objectives.. . . . . . . . G.A.Dunne P.J. Richards N.Portman T. Smelt A. Hudson D.Gascoyne D.Hill
Managing Director Quality Manager Company Secretary / Accountant Production Manger Machine Shop Manger Senior Technical Engineer Engineering Support Manger

InspectionEquipment
QualityOffice MitutoyoCMM-Euro-M544 MitutoyoProjector-PJ-3000 MitutoyoDigitalHardnessTester-AVK-C2 RockwellHardnessTester TrimosDigitalHeightGaugewith36x24GraniteSurfacePlate ElcometerCoatingThicknessGauge VisionEngineeringMicroscope Mettler(Salter)DigitalScales CADARcomputerisedSPCsystem PCwithMicrosoftOffice Handheldmeasuringequipmentasnecessary Toolroom BatyShadowmasterProjector

Sample Quality Documents

AQP Documentation Overview

Westley Engineering Limited

Contents

QD020

Commitment to Product Conformity (Quotation Stage)

In pursuit of mutual interest in satisfying our customers quality needs, and our commitment to product conformity.

This Form relates to Drawing Number:

Issue Number:

1 Drawings and associated specifications are complete unambiguous and fully understood? 2 We can continuously conform to the requirements of the drawing and prescribed specifications in every respect? 3 We require assistance from yourselves in order to determine our ability to provide total conformance? 4 We have suggestions for modifying the drawing/specification which would be to our mutual benefit in either conformance or cost? 5 We will comply with all packing instructions? 6 We are prepared to use SPC methods to control agreed critical features? 7 We can if necessary, provide: i) An F.M.E.A. ii) Control Plan & Process Flow Diagram. iii) Evidence of Capability I.S.I.R. & Statistical Studies. 8 We require further explanation of points and notes attached. All points and notes must be discussed to our mutual satisfaction before we can proceed with any other order for this part number.

Yes/No

Yes/No

Yes/No

Yes/No Yes/No Yes/No

Yes/No Yes/No Yes/No

Yes/No

Signature: Name: Date:

Westley Engineering Limited

Contents

QD021
Customer:

Team Feasibility Commitment

Part number: Issue Level:

Feasibility Considerations:
The Advanced Quality Planning Team has considered the following questions, not intended to be all-inclusive in performing a feasibility evaluation. Drawings and/or specifications (Internal or External) have been used as a basis for analysing the ability to meet all specified requirements. All 'no' answers are supported with attached comments identifying our concerns and/or proposed changes to enable us to meet the specified requirements. 1
1.1 1.2

1.3 1.4 1.5

General Is product adequately defined to enable feasibility evaluation? Can product be manufactured to tolerances specified on the drawing? Can product be manufactured with Cpk's that meet requirements? Is there adequate capacity to produce product? Does the design allow the use of efficient material handling techniques? Can the product be manufactured without incurring any unusual: Costs for capital equipment? Costs for tooling? Alternative manufacturing methods? Is Statistical Process Contol required on product? Is Statistical Process Control presently used on similar products? Where Statistical Process Control is used on similar products: Are processes in control and stable? Are Cpk's greater than 1.33?

Yes/No Yes/No Yes/No Yes/No Yes/No

2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2

Yes/No Yes/No Yes/No Yes/No Yes/No

Yes/No Yes/No

Conclusion:
Feasible Feasible Not Feasible Product can be produced as specified with no revisions. Changes recommended (see attached sheet). Major revisions required to produce product within the specified requirements.

Sign-off by AQP Team:

Team Member/Title/Date: Team Member/Title/Date: Team Member/Title/Date: Team Member/Title/Date: Team Member/Title/Date: Team Member/Title/Date: Only if project is feasible and quotations are agreed shall the AQP Checklist be completed.

Westley Engineering Limited

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QD006 AQP Timing Plan

Page 1 of 1 Project leader: Description:
Bar Chart Summary

Date:

Customer: Issued by:

Part number:

Task

Responsible

Completion Signature

Date

Receive Customer Order

Receive Customer Drawing Register and Issue Drawing

Create Inspection File

Team Feasibility

AQP Checklist

Tooling

Tooling Schedule Timing Plan (QD070)

Order Material

Material Delivery Date

Quality

Process FMEA Review

Control Plan and Process Flow Diagram

Gauge Requirements

Inspection Audit Sheets

Statistical/Capabiltiy Study

PPAP (Dim/Material)

Update Trojan System

Tool Tryouts

10

Sample Submission

Contents

11

Week

Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Date

26

27

28

29

P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A

Westley Engineering Limited

Sample Quality Documents

Sample Manufacturing Documents

Westley Engineering Limited

Contents

QD001 Control plan

Distribution: Prototype Page 1 of 1 Prepared by: Issued/approved by:
S/C Specification or tolerance Size Frequency Evaluation method Sample Control method Measurement method

Goods inwards Pre-launch Control plan issue level: Control plan issue date:
Action on defects

Quality office Production

Despatch

Part number:

Description:

Drawing issue level:

Drawing issue date:

Customer:

Process Step number Feature

Flowchart

Operation (tool location)

Product characteristic

No.

Contents

Key: S/C Significant Characteristic

Operation

Move

Inspection

Storage

Westley Engineering Limited

Operator care point

precision pressings and tooling

westley engineering

Ensure free movement of gear wheel

Part number: Part description: Operation: Operation description:

68324322 Wheel assembly 1 Assembly

Operator instructions Every component to be checked for free movement of wheel by the operator after assembly

Clearance on 3 legs 0.4/0.6mm

0.4/0.6mm

Contents

If in doubt stop and ask

These instructions to be used on the following operations: Op.1 assembly